TEA MACHINERY

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WITHERING TROUGHS are generally installed in the first floor of the factory. Green leaf is spread over a wire mesh (No.4/16 16gauge) which is fitted on plenum chamber. Height of the plenum chamber is 0.6-.76 m (2-2.5 feet) and leaf is loaded over the mesh to.20-.23 m (8-9″) height or 8-9 kg/sq. m. (2.5-3 kg/sq. ft.) of the withering trough. Size of the withering trough is 30.5 m (100′) long 1.8 m (6′) wider or 22.9 m (75′) long and 1.8 m (6′) wide. Better withering can be achieved with smaller trough 22.9 X 1.8 m (75′ x 6′). The trough should be fitted with a suitable fan to deliver the required quantity of air as per the size of the trough. To achieve proper withering the fan has to deliver 45 CFM air for every one square foot of trough area. For artificial withering hot air from the drier room is bulked with outside air and used. Fans are arranged in such a way that they can draw hot air from the drier and cool air from the atmosphere

GREEN LEAF SIFTER is designed to remove extraneous matter such as stones, metal pieces etc to avoid damage to CTC rollers. The green leaf sifter consists of a reciprocating tray powered with an electric motor. The reciprocating tray is fitted with a mesh through which leaves are passed and unwanted materials removed. Powerful magnets are fitted in the sifter which removes iron/steel particles from the green leaf.

GREEN LEAF SHREDDER is a pre-conditioning machine. The machine shreds the leaves into small pieces before sending it to the rotorvane. Besides, the green leaf shredder helps to increase the rotorvane capacity and in efficient mixing of RC material to the withered leaf especially in the CTC type of processing. The machine consists of a cylinder in which the main shaft having knives (blades) rotate at a speed of 2500 RPM.

ORTHODOX ROLLER: A conventional roller for orthodox rolling consists of three parts- the table, the hood and the pressure cap. Rotation of the machine is achieved through three crankshafts attached to the table. The level gear mechanism transmits power to one of the crankshafts at a time, while the other two rotate freely on their bearings and play an auxiliary role. The pressure cap applies pressure to the leaf mass during rolling, imparting the proper twisting and brushing action. It is the pressure applied during orthodox rolling that causes the extraction of sap and imparts twist to the leaf. In some kinds of rolling tables, both vertical and lateral pressures may be applied. Vertical pressure is applied with the help of pressure caps, whereas lateral pressure is applied by a cone fitted in the middle of the table. This cone also causes greater circulation of leaf than that provided by battens alone

ROTORVANE consists of a cylindrical drum of a diameter of 200 cm (8″), 380 cm (15″) or 460 cm (18″), depending on the capacity. Inside the circumference of the drum, the resistors are fitted at appropriate distances. The main shaft which rotates inside the drum, has vanes at equal intervals. There is a worm arrangement in the main shaft which facilitates forward motion of the leaves into the drum. The leaves are crushed in between the vanes and resistors and discharged through the diaphragm. The RPM of rotorvane ranges from 30 to 35.

CTC-ROLLERS consist of a main shaft on which the segments are fixed by heat treatment on a mandrel form. The diameter of the roller is generally 200 cm (8″) and the latest senova rollers are of 330 cm (13″) diameter. Depending on the capacity of the rollers, their length varies from 600 (24″) to 910 cm (36″). Generally two rollers are fixed horizontally and parallel to each other and both rotate in opposite directions. The ratio of speed between the low speed and high speed rollers is 1:10 depending on the requirement of leaf or dust grade.

FERMENTATION DRUM: The fermenting drum is a simple cylindrical drum with conical feeding and discharge ends. The standard drum is 4.8 – 6.1 m (16-20 feet) long and has a diameter of 1.5 m (5 feet) at the cylindrical portion. The total length of the conical segment is four feet. The capacity of the drum will be 5.2 kg of rolled dhool for every square meter area of the drum.

CONTINUOUS FERMENTING MACHINE helps to eliminate microbial contamination in tea. Micro organisms occur as contaminants during tea processing due to the presence of a layer of fermented juice on the processing machines and other equipments. The CFMs consist of a tray made up of conveyor racks with three to four tier systems like “quality” drier arrangements. The fermented dhools travel in a thin layer on the conveyor rack. Above or below the tray, UV lamps are fitted which are used to kill the external bacteria and triggers the activity of polyphenol oxidase, thereby hastening the biochemical reaction. Bright infusions are obtained in the continuous fermenting machine. This machine is generally used for NRC tea manufacture. In RC tea manufacture googhie sifter is used before CFM for granulation of tea.

ECP DRIER: The Endless Chain Pressure type driers consist of two or three individual tray circuits. When the leaf is fed into the feeding circuit, the spreader spreads the leaf uniformly on the tray. As soon as the leaf completes the run on top circuit, the tray carrying leaf are automatically tilted at the end of the circuit and the leaf falls on the mid circuit where direction of tray movement is opposite to that of top circuit. Thus the leaf is subjected to gradual high temperature from top to bottom circuit and drying is completed when the leaf reaches the bottom circuit. The total drying time is 20-22 minutes. The output of the drier is 200-250 kg made tea with the feeding moisture level of 55%. The inlet and exhaust temperatures may be maintained at 100°C and 55°C, respectively.

FLUID BED DRIER onsists of drying chamber, plenum chamber, air flow damper and dust collectors. The drying chamber is separated by a perforated grid plate through which high pressure hot air from the plenum chamber gets into the drying chamber for fluidisation. The plenum chamber is divided into four zones which have individual air control valves. These valves control the quantity of air to the individual zone and the direction of hot air entering the control dampers. At the top of the drying chamber two centrifugal exhaust fans are fitted with cyclone, one for refiring and the other for dust extraction. When the fermented dhool is fed into the drying chamber in the first zone it gets fluidised. With the help of pressurised hot air, water is removed by evaporation. The inlet and exhaust temperatures for FBD may be maintained at 250°F to 260°F and 150-160°F for achieving better quality.

VIBRO FLUID BED DRIER works on the principle of ‘vibrating fluidized bed’. It works on pneumatic and mechanical power. The fermented teas are fed through a feed system into the drying chamber. Hot air from the heater is passed from underneath to the drying chamber through the perforated tray carrying wet teas. The tea leaf is effectively fluidised by a combination of air pressure and mechanical vibration.

COMBINATION DRIER Tempest drier is a combination of conventional and fluid bed drier. In the tempest drier on top of the drying chamber i.e., above the fluidisation zone there is a tray moving inside which carries the fermented leaf from the drum where surface moisture is removed by exhaust temperature. Since a certain percentage of moisture is removed from the leaf before entering into the fluidisation zone, the output of the drier is higher than conventional FBD.

FIBRE EXTRACTOR This works on the principles of static electricity. There are 4 to 6 PVC rollers arranged in a row. The PVC rollers brushes against thick pads of felt which imparts a static electricity to developed on the PVC rollers. When tea is fed in to fibre extractor after firing, frictional force takes place between fibre and the rollers. As a result static electricity is produced. The PVC rollers act as positive charge (+) and fibre acts as a negative charge (-), thereby both attract each other and fibre is collected from the PVC rolle.

SORTER is a simple machine which is used to grade the bulk tea from the fibre extractor into different grades according to their size. Generally the sorter is fitted with meshes of different size.

News & Events

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  • Dr. C.S. Venkata Ram Memorial Annual Tea Colloquium-2015

    Dr. C.S. Venkata Ram Memorial Annual Tea Colloquium will be held on July 10, 2015 at Seminar Hall, UPASI Tea Research Foundation, Tea Research Institute, Valparai. The maximum time for presentation is ten minutes followed by discussion. Prizes will be awarded for the best three…

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  • Residue analysis in other crops

    31-05-2013

    The Pesticide Residue Division is equipped with state-of-art instruments viz., Gas Chromatograph, High Performance Liquid Chromatograph, GCMS, Atomic Absorption Spectrophotometer, etc., Our lab is GLP certified by National GLP Compliance Monitoring Authority, Govt. of India for the execution of Pesticide Residue Studies. We are accredited…

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  • Vacancy 2017

    09/06/2016 @ 4:55 pm

    Date of Publish: 12.01.2017 UPASI TEA RESEARCH FOUNDATION TEA RESEARCH INSTITUTE NIRAR DAM P.O. VALPARAI – 642 127   THE POST OF RESEARCH FELLOWS ENTOMOLOGY Project title:  CABI project “Sustainable Tea Production”             Designation of Posts Fellowship Consolidated (Rs.) Relevant Qualifications   Research Fellows (2)…

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  • Monthly circular – April 2014

    07/04/2014

       Monthly Circular April -2014  WEATHER Weather data recorded in March 2014 at the TRF observatory are given below, along with the corresponding figures for March 2013. Year Total Rainfall mm Mean Sunshine hr/day Mean Temperature ° C Mean Relative Humidity % at Mean Evaporation…

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  • Quotations & Tenders

    DETAILS OF VEHICLES FOR SALE Sl. No. Make Regn. No. Place Year of Mfg. 1 Suzuki Max 100 R TN 41 F 7245 Valparai 1999 2 Suzuki Max 100 R TN 41 F 7246 Valparai 1999 3 Suzuki Max 100 R TN 41 F 7250…

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Articles

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  • Publications

    09.05.2012

    Ajaikumar, S., Siby Mathew, R. Raj Kumar and P. Mohan Kumar (2014). Mechanical harvesting in tea: A case study of Pasuparai estate. Journal of Plantation Crops. 42(2): 201-214. Ajay, D. and Baby, U.I. 2010. Induction of systemic resistance to Exobasidium vexans in tea through SAR…

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  • Latest

    12/12/12

    The principal landmark in the history of tea research in south India, was the establishment of a Tea Experimental Station in Gudalur in 1926. During the last seven and half decades, this research organisation. Now known as the UPASI Tea Research Foundation (UPASI TRF), had…

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  • Publications and Library

    01/02/05

    Annual Report is the one among the major publications of UPASI TRF. Annual report of each year is released by September of the following year. Other publications include Research Highlights and half yearly Newsletters. The Bulletin of UPASI TRF is an occasional publication. The Handbook…

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Conferences Seminars

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  • PLACROSYM XXI

    DATE:  10-12 December 2014

    PLACE:  Kozhikode

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  • Research Extension Meeting

    DATE:  06-08 May 2013

    PLACE:  Valparai

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  • JOINT AREA SCIENTIFIC SYMPOSIA (JASS)

    DATE:  

    PLACE:  

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  • INTERNATIONAL TEA CONVENTION

    DATE:  

    PLACE:  

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  • TGLIA

    DATE:   2013

    PLACE:  

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  • Dr.C.S. Venkata Ram Annual Tea Colloquium

    DATE:  1 August 2013

    PLACE:  VALPARAI

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  • INTERACTIVE SESSIONS / WORKSHOPS

    DATE:  28/04/2012

    PLACE:  VALPARAI

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  • PLATINUM JUBILEE SYMPOSIUM

    DATE:  2001

    PLACE:  Chennai

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  • PLANTATION CROPS SYMPOSIUM 2014

    DATE:  2014

    PLACE:  

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  • UPASI ANNUAL CONFERENCE

    DATE:  September 2013

    PLACE:  Coonoor

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Research Activities

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  • Pesticide Residue

    Of late, considering the constant usage of pesticides and to monitor the residues in the final produce, a well equipped test facility was established at UPASI TRI in 1994. The pesticide residue laboratory is accredited by National Accreditation Board for testing and calibration Laboratories (NABL)…

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  • Botany

    The Tea Research Institute at Valparai has seven divisions namely Botany, Soil Chemistry, Entomology, Pesticide Residue, Plant Pathology & Microbiology, Plant Physiology & Biotechnology and Tea Technology. Botany Research activities of Botany Division include plant improvement, cultivation practices and weed research. Plant improvement programme was…

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  • Soil Chemistry

    Chemistry Division is involved in research pertaining to soil-plant nutrients of tea besides extending analytical service to the industry. The research activities include investigations on physico-chemical properties of soil, soil-plant interactions, response of tea to major, secondary and micronutrients and their interactions. The research work…

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  • Entomology

    Entomology Division involve in basic and applied aspects of insect pests, particularly, biology, ecology and evolving control measures. The division evolved and recommended physical, chemical and biological method of tea pests control. In the past, extensive studies on bioecology, crop loss due to major pests…

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  • Pathology & Microbiology

    In the division of Plant Pathology & Microbiology, research is carried out on diseases of tea and biofertilizers. Among the tea diseases, blister blight is the most important leaf disease caused by the pathogen, Exobasidium vexans affecting the tender harvestable shoots of tea resulting in…

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  • Physiology & Biotechnology

    Plant Physiology Division was established in 1980 which has been primarily concentrated on crop productivity. The division strives for excellence in applied research in tea productivity and bush health besides biotechnological studies. The research undertaken extends over a wide range of research programmes having collaborative…

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  • Tea Technology

    Besides offering the analytical services and involving in inter laboratory ring test to validate the test methods, Tea Technology Division is concerned about quality of final produce in accordance with PFA Act requirements, storage studies, value added products and manufacturing aspects. The laboratory has been…

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