Detailed Project Report on tea blending and packaging unit

TEA BLENDING AND PACKAGING UNIT
[CODE NO.3728]  

Tea is one of the most popular beverages and is consumed by nearly half of the world population. India was the first country to cultivate the tea as far back as 2737 B.C. Tea is made from the young leaves & unopened buds of the plant 'Camelia Binerisies'. This plant is grown in tropical and subtropical regions.  It is considered to be native of Assam and upper Indo- China.

This is the reason why packaging of tea has grown multidimensional in last few years. India is self-sufficient in manufacturing automatic weighing & packing machines today & such machines are being even exported to various   neighboring countries.  The Indian machine manufacturers are mostly in  large scale sectors & a few in small & medium scale too. Simple packing machine to Duplex tea packers are all equally competent for  the purpose  &  are manufactured by leading  tea  processing  machine manufactures  of  India.  Automatic tea packing machine is the latest advancement in the field, which makes packing  faster  & secured. Small packs in 50, 100, 250, 500 grms & 1 kg packets are usually prepared in paper board packets where as packing of large quantities are usually done in tin containers for retail selling. Tea chets of plywood are preferred for shipment of processed tea in substantially large quantities. Since tea  industry  is  an evergreen  industry hence the packing of tea continues round  the year  irrespective  of  reason  or weather. That is why it  is considered to be a very stable industry & the men working in  the line  are employed on permanent basis & are quite experienced  in the job.   This industry can be set up in small scale as well as large scale  unit, but it remains basically a  labour  intensive industry with a very attractive profitability. The machines used are available indigenously in a very wide range of performances & qualities.  Some leading manufacturers of these machines produce machines of quantities comparable to any grid machine in the world.
As far as raw materials & other consumables are concerned, everything is available indigenously & at reasonable rates too. Since this industry creates a limited pollution of air & can be controlled effectively by the use of dust collector type of arrangements. There is not much difficulty in getting clearances from various government offices before setting up the plant.  In this way this industry seems to be much suitable for India.

This industry could be set up in any part of the country where normal utilities could be made available.

COST ESTIMATION

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%                


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 – A:

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)