Detailed Project Report (DPR) on tea blending and packaging unit

Detailed Project Report (DPR) on tea blending and packaging unit
Code #3728
Original
India
Countries
Translation provided by Google AI

Industry Overview

Tea is one of the world's most widely consumed beverages and is cultivated in tropical and subtropical regions. India has a long history of tea cultivation, with Assam and upper Indo-China identified in the report as important areas associated with its origin. The tea industry supports a substantial packaging segment covering small retail packs, larger containers, and bulk shipment packaging.

Tea packaging has become increasingly diversified, with automatic weighing and packing machines enabling faster and more secure packing operations. Indian manufacturers supply a wide range of equipment, from simple packing machines to duplex tea packers, for different scales and requirements. Retail tea is commonly packed in 50, 100, 250, 500 gram and 1 kg packs, while larger quantities may be packed in tin containers and plywood tea chests for shipment.

The report describes tea packing as a stable, year-round activity with indigenous availability of machinery, raw materials and consumables. The industry can be established on both small and large scales and remains relatively labour intensive. Pollution from the operation is described as limited and controllable through dust-collection arrangements. The unit can be established in locations where normal utilities are available.

Cost Estimation

Particulars Details
Plant Capacity 6 Ton/Day
Land & Building (1500 sq.mt.) Rs. 2.55 Cr
Plant & Machinery Rs. 1.04 Cr
Working Capital for 1 Month Rs. 4.09 Cr
Total Capital Investment Rs. 7.80 Cr
Rate of Return 44%
Break Even Point 35%

Content Index

  • INTRODUCTION
  • DESCRIPTION OF TEA
  • BLACK TEA
  • CTC PRODUCTION
  • QUALITY / DURATION OF STORAGE
  • PROPERTIES
  • COMPOSITION OF FRESH TEA LEAF
  • COMPOSITION OF FRESH TEA LEAF (TEA FLUSH)
  • FLAVANOLS
  • OTHER POLYPHENOLS
  • CAFFEINE AND OTHER XANTHINES
  • THEANINE (5-N-ETHYLGLUTAMINE
  • CAROTENOIDS
  • CHLOROPHYLL
  • VOLATILES
  • LIPIDS
  • PHYSICAL
  • CHEMICAL COMPOSITION OF GREEN LEAF
  • USES & APPLICATIONS
  • B.I.S SPECIFICATIONS FOR TEA
  • SCOPE
  • TERMINOLOGY
  • REQUIREMENTS
  • REQUIREMENTS FOR TEA
  • PACKING MARKING
  • SAMPLING
  • TESTS
  • PREPARATION OF GROUND SAMPLE FOR ANALYSIS
  • DETERMINATION OF TOTAL ASH
  • DETERMINATION OF WATER SOLUBLE ASH
  • DETERMINATION OF ACID INSOLUBLE ASH
  • DETERMINATION OF ALKALINITY OF WATER SOLUBLE ASH
  • TERMINATION OF WATER EXTRACT
  • DETERMINATION OF CRUDE FIBRE
  • GRADES OF TEA
  • GRADES OF TEA ARE CLASSIFIED BY
  • CHANGING TRENDS IN TEA PACKAGING
  • OVERVIEW OF TEA INDUSTRY (INDIA & GLOBAL)
  • EXPORT OF TEA FROM INDIA
  • IMPORT OF TEA IN INDIA
  • TOP FIVE TEA PRODUCING COUNTRIES
  • TEA BLENDING
  • PROJECTED DEMAND OF TEA IN GLOBAL MARKET
  • MARKET POTENTIAL OF TEA INDUSTRY
  • PRODUCTION COST
  • PRESENT BLENDER AND PACKAGING UNIT
  • METHOD OF TEA PACKAGING
  • SORTING AND GRADING OF TEA
  • PRECAUTION TO BE TAKEN WHILE SORTING
  • GRADES OF TEA
  • ORTHODOX WHOLE LEAF GRADES
  • ORTHODOX BROKEN GRADES
  • ORTHODOX FANNING
  • CTC GRADES
  • CTC BROKEN
  • FANNINGS
  • CTC DUST
  • LEGGCUT GRADES
  • LEGGCUT FANNINGS
  • LEGGCUT DUST
  • PERCENTAGE OF VARIOUS GRADES
  • STALK EXTRACTION
  • GREYING OF TEA
  • BLOOM
  • GREYNESS
  • SORTING PROCEDURE
  • SORTING OF LEGGCUT TEA
  • SORTING AND PACKAGING STAGES
  • PROCESS FLOW DIAGRAM
  • CTC FIBER EXTRACTOR AND COMBINATIONS
  • TABLE SHOWS THE SIZES OF THE SORTING TRAYS.
  • PACKAGING
  • BEST METHODS OF TEA PACKAGING
  • FLAVOURED AND SCENTED TEAS
  • FLOWERS
  • HERBS
  • OTHER FLAVOURANTS
  • TEA MANUFACTURING PROCESS
  • PLUCKING
  • WITHERING
  • ROLLING
  • FERMENTATION
  • DRYING
  • GRADING (SIFTING)
  • PACKING / DESPATCHING
  • PLANT LAYOUT
  • SUPPLIERS OF RAW MATERIALS
  • SUPPLIERS OF PLANT AND MACHINERY

Appendix

  • 01. PLANT ECONOMICS
  • 02. LAND & BUILDING
  • 03. PLANT AND MACHINERY
  • 04. OTHER FIXED ASSESTS
  • 05. FIXED CAPITAL
  • 06. RAW MATERIAL
  • 07. SALARY AND WAGES
  • 08. UTILITIES AND OVERHEADS
  • 09. TOTAL WORKING CAPITAL
  • 10. TOTAL CAPITAL INVESTMENT
  • 11. COST OF PRODUCTION
  • 12. TURN OVER/ANNUM
  • 13. BREAK EVEN POINT
  • 14. RESOURCES FOR FINANCE
  • 15. INSTALMENT PAYABLE IN 5 YEARS
  • 16. DEPRECIATION CHART FOR 5 YEARS
  • 17. PROFIT ANALYSIS FOR 5 YEARS
  • 18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Frequently Asked Questions

A tea processing and packaging project involves activities such as handling tea, sorting and grading, processing according to the selected tea type, blending where required, packaging, and dispatching. The report covers both tea manufacturing processes and packaging operations, including plucking, withering, rolling, fermentation, drying, grading and packing. The project also addresses plant layout, raw materials, machinery, quality considerations and supplier requirements.

The report covers several tea grading categories, including orthodox whole leaf grades, orthodox broken grades, orthodox fanning, CTC grades, CTC broken, fannings, CTC dust and Leggcut grades. It also includes sections on Leggcut fannings, Leggcut dust and the percentage of various grades. Sorting and grading are important for separating tea according to characteristics and preparing appropriate products for packaging and marketing.

The report identifies plucking, withering, rolling, fermentation, drying, grading or sifting, and packing or despatching as the main stages of tea manufacturing. The exact processing sequence and operating conditions depend on the type of tea being produced. The report also discusses CTC production, sorting procedures, stalk extraction, packaging stages and process flow arrangements as part of the broader tea-processing operation.

Tea can be packed in different formats depending on quantity, product requirements and distribution needs. The report describes retail packs in sizes including 50, 100, 250 and 500 grams and 1 kg, while larger quantities may be packed in tin containers. Plywood tea chests are also discussed for shipment of processed tea in substantially large quantities. The report additionally covers automatic weighing and packing machines and methods of tea packaging.

The report includes a dedicated section on B.I.S specifications for tea covering scope, terminology, requirements, packing and marking, sampling and tests. Listed analytical procedures include determination of total ash, water-soluble ash, acid-insoluble ash, alkalinity of water-soluble ash, water extract and crude fibre. These sections provide a framework for addressing tea quality characteristics and analytical requirements within the project documentation.

Planning a tea packaging unit requires consideration of packaging format, product grades, processing and sorting requirements, machinery, raw-material availability, utilities, plant layout, storage and dispatch arrangements. The report also highlights the availability of indigenous machinery and consumables and discusses automatic weighing and packing equipment. Proper dust control, efficient material movement and suitable packaging systems are important operational considerations for establishing an organized tea unit.

Yes, the report states that the tea industry can be established as both a small-scale and a large-scale unit. The appropriate scale depends on factors such as production requirements, machinery selection, available infrastructure, labour requirements, raw-material supply and market arrangements. The report presents a project configuration with a plant capacity of 6 Ton/Day and also discusses machinery and operating considerations relevant to tea processing, sorting and packaging.

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