Abstract: The present invention provides a method of processing to enhance the stability and increase the shelf life of made tea. After procuring the tea from tea gardens and tea estates with the defined characteristic parameters the tea is stored in cold storage. Processed by sorting grading and filtering out the impurities in the dehumidified environment. Based on projections and order flow the raw materials are treated blended vaccumized and nitrogen flushed in a dehumidified environment and sent for order fulfilment. For packing the graded and stored tea is packed in teabags. The teabags are put in laminated pouches followed by which the pouch with teabag is subjected to gas flushing. The pouches comprising teabags are heat sealed. This innovation is a combination of storage method and packaging technique.
We Claim:
1. A method for storage and packaging of blended/non-blended tea by providing a non-reactive environment for tea bags to preserve freshness, maintain quality, enhance stability and to increase a shelf life of tea by maintaining a stability of bio-chemical components, the method comprising the steps of:
procuring tea from one or more tea gardens through a mapping of tea plantation, and wherein the tea is procured at a plurality of flush timings to obtain tea with varying liquor characteristics;
identifying a batch sample from the procured tea and confirming a matching of the batch sample with a previously shortlisted tea sample based on a plurality of predetermined quality specifications, and wherein the procured tea is rejected when the batch sample does not match with the shortlisted tea sample;
storing the procured tea in a cold storage for retaining a quality, composition, flavour and colour of the procured tea;
processing the procured tea using sorting and grading techniques, and wherein the tea is subjected to a quality check before and after processing the procured tea to meet the plurality of predetermined quality specifications, and wherein the tea is reprocessed when the processed tea does not meet the plurality of predetermined quality specifications;
packaging the processed tea in tea bags, wherein the tea bags are gas flushed to remove existing gases and residual gases in the tea bag environment to avoid oxidative deterioration, and wherein the tea bag is gas flushed using inert gases for inhibiting growth of aerobic micro-organisms, and wherein the tea bags are nitrogen gas flushed; and
individually packaging each tea bags in pouch, and wherein the pouches are gas flushed and heat sealed during packaging for enhancing the stability and increasing the shelf life of tea, and wherein each tea bag is gas flushed separately.
2. The method according to claim 1, wherein the plurality of predetermined quality specifications comprise physical, chemical and microbial quality specifications that the tea and tea bags/pouches need to meet at various stages of tea processing.
3. The method according to claim 2, wherein the plurality of physical quality specifications comprise non-contamination of tea from living insects, moulds, dead insects, insect fragments and rodent as visible to naked eye, flavour of tea free from any off odour, taint and mustiness, sensory evaluation of the tea greater than 7 points on a scale of 10 points, porosity of tea bag material, tensile strength of a tea bag tag, thickness of pouch material and intactness of sealing.
4. The method according to claim 3, wherein one or more sensory parameters considered during sensory evaluation of tea comprise dry leaf bloom, dry leaf aroma intensity, wet leaf colour, wet leaf aroma intensity, liquor colour, liquor aroma intensity, liquor astringency, liquor strength, liquor flavor, liquor bitterness, and liquor after taste.
5. The method according to claim 2, wherein the plurality of chemical quality specifications comprise a moisture content of tea between 2% to 5 %, a water soluble ash of tea in the range of 4% to 8 %, an acid insoluble ash of tea less than 1 % and a water extract of tea more than 32 %.
6. The method according to claim 2, wherein the plurality of microbial quality specifications comprise an absence of pathogenic micro¬organisms in the tea and a total plate count of tea below 100000 cfu/g.
7. The method according to claim 1, wherein the gases used for flushing the tea bags and pouches are nitrogen, carbon dioxide, argon and a mixture of inert gases, and wherein the gas pressure during gas flushing of tea bags
is maintained at about 1 bar and temperature of gas while applying gas to the tea bags is maintained below 5 °C.
8. The method according to claim 1, further comprises procuring non-tea ingredients (flavoring agents), through the process of sampling, subjecting the non-tea ingredients to a quality check and storing the non-tea ingredients in a cold storage.
9. The method according to claim 1, further comprises developing a blended tea by blending stored tea and non-tea ingredients, and wherein the blended tea is packaged in tea bags by gas flushing.
10. The method according to claim 1, further comprising developing blended tea by blending tea leaves procured from one or more tea estates.
11. The method according to claim 1, further comprising developing blended tea by blending tea leaves procured from one or more tea estates and one or more non-tea ingredients, and wherein the one or more non-tea ingredients are flavoring agents.
12. The method according to claim 1, wherein a packaging material used for making tea bags and pouches comprise biaxial oriented polypropylene (BOPP), metalized polyester (MET-PET) and polyethylene (PE).
13. The method according to claim 1, wherein the packaged tea is gas flushed and delivered to a consumer with a freshness similar to a freshness of tea on the day of manufacture.
14. A computer implemented method comprising instructions stored on a non-transitory computer readable storage medium and executed on a computing system provided with a hardware processor and memory, for storage and packaging of blended/non-blended tea by providing a non-reactive environment for tea bags to preserve freshness, maintain quality,
enhance stability and to increase a shelf life of tea by maintaining a stability of bio-chemical components, the method comprising the steps of:
procuring tea from one or more tea gardens through a mapping of tea plantation with a user computing device, and wherein the tea is procured at a plurality of flush timings to obtain tea with varying liquor characteristics;
identifying a batch sample from the procured tea and confirming a matching of the batch sample with a previously shortlisted tea sample based on a plurality of predetermined quality specifications with the user computing system, and wherein the procured tea is rejected when the batch sample does not match with the shortlisted tea sample;
storing the procured tea in a cold storage for retaining a quality, composition, flavour and colour of the procured tea;
processing the procured tea using sorting and grading techniques, in a processing station and wherein the tea is subjected to a quality check before and after processing the procured tea to meet the plurality of predetermined quality specifications, and wherein the tea is reprocessed when the processed tea does not meet the plurality of predetermined quality specifications;
packaging the processed tea in tea bags in the processing station, wherein the tea bags are gas flushed to remove existing gases and residual gases in the tea bag environment to avoid oxidative deterioration, and wherein the tea bag is gas flushed using inert gases for inhibiting growth of aerobic micro-organisms, and wherein the tea bags are nitrogen gas flushed; and
packaging the tea bags in pouches in the processing station, and wherein the pouches are gas flushed and heat sealed during packaging for enhancing the stability and increasing the shelf life of tea, and wherein each tea bag is gas flushed separately.
15. The method according to claim 14, wherein the plurality of predetermined quality specifications comprise physical, chemical and microbial quality specifications that the tea and tea bags/pouches need to meet at various stages of tea processing.
16. The method according to claim 15, wherein the plurality of physical quality specifications comprise non-contamination of tea from living insects, moulds, dead insects, insect fragments and rodent as visible to naked eye, flavour of tea free from any off odour, taint and mustiness, sensory evaluation of the tea greater than 7 points on a scale of 10 points, porosity of tea bag material, tensile strength of a tea bag tag, thickness of pouch material and intactness of sealing.
17. The method according to claim 15, wherein one or more sensory parameters considered during sensory evaluation of tea comprise dry leaf bloom, dry leaf aroma intensity, wet leaf colour, wet leaf aroma intensity, liquor colour, liquor aroma intensity, liquor astringency, liquor strength, liquor flavor, liquor bitterness, and liquor after taste.
18. The method according to claim 15, wherein the plurality of chemical quality specifications comprise a moisture content of tea between 2% to 5 %, a water soluble ash of tea in the range of 4% to 8 %, an acid insoluble ash of tea less than 1 % and a water extract of tea more than 32 %.
19. The method according to claim 15, wherein the plurality of microbial quality specifications comprise an absence of pathogenic micro¬organisms in the tea and a total plate count of tea below 100000 cfu/g.
20. The method according to claim 14, wherein the gases used for flushing the tea bags and pouches are nitrogen, carbon dioxide, argon and a mixture of inert gases, and wherein the gas pressure during gas flushing
of tea bags is maintained at about 1 bar and temperature of gas while applying gas to the tea bags is maintained below 5°C.
21. The method according to claim 14, further comprises procuring non-tea ingredients (flavoring agents), through the process of sampling, subjecting the non-tea ingredients to a quality check and storing the non-tea ingredients in a cold storage.
22. The method according to claim 14, further comprises developing a blended tea by blending stored tea and non-tea ingredients, and wherein the blended tea is packaged in tea bags by gas flushing.
23. The method according to claim 14, further comprising developing blended tea by blending tea leaves procured from one or more tea estates.
24. The method according to claim 14, further comprising developing blended tea by blending tea leaves procured from one or more tea estates and one or more non-tea ingredients, and wherein the one or more non-tea ingredients are flavoring agents.
25. The method according to claim 14, wherein a packaging material used for making tea bags and pouches comprise biaxial oriented polypropylene (BOPP), metalized polyester (MET-PET) and polyethylene (PE).
| # | Name | Date |
|---|---|---|
| 1 | 201947002619-FER.pdf | 2021-10-17 |
| 1 | 201947002619.pdf | 2019-01-22 |
| 2 | 201947002619-STATEMENT OF UNDERTAKING (FORM 3) [22-01-2019(online)].pdf | 2019-01-22 |
| 2 | 201947002619-FORM 13 [30-09-2020(online)].pdf | 2020-09-30 |
| 3 | 201947002619-REQUEST FOR EXAMINATION (FORM-18) [22-01-2019(online)].pdf | 2019-01-22 |
| 3 | 201947002619-FORM-26 [30-09-2020(online)].pdf | 2020-09-30 |
| 4 | 201947002619-RELEVANT DOCUMENTS [30-09-2020(online)].pdf | 2020-09-30 |
| 4 | 201947002619-PROOF OF RIGHT [22-01-2019(online)].pdf | 2019-01-22 |
| 5 | Correspondence by Agent_Form1And POA_30-01-2019.pdf | 2019-01-30 |
| 5 | 201947002619-POWER OF AUTHORITY [22-01-2019(online)].pdf | 2019-01-22 |
| 6 | Abstract_201947002619.jpg | 2019-01-24 |
| 6 | 201947002619-FORM 18 [22-01-2019(online)].pdf | 2019-01-22 |
| 7 | 201947002619-FORM 1 [22-01-2019(online)].pdf | 2019-01-22 |
| 7 | 201947002619-COMPLETE SPECIFICATION [22-01-2019(online)].pdf | 2019-01-22 |
| 8 | 201947002619-DRAWINGS [22-01-2019(online)].pdf | 2019-01-22 |
| 8 | 201947002619-DECLARATION OF INVENTORSHIP (FORM 5) [22-01-2019(online)].pdf | 2019-01-22 |
| 9 | 201947002619-DRAWINGS [22-01-2019(online)].pdf | 2019-01-22 |
| 9 | 201947002619-DECLARATION OF INVENTORSHIP (FORM 5) [22-01-2019(online)].pdf | 2019-01-22 |
| 10 | 201947002619-COMPLETE SPECIFICATION [22-01-2019(online)].pdf | 2019-01-22 |
| 10 | 201947002619-FORM 1 [22-01-2019(online)].pdf | 2019-01-22 |
| 11 | Abstract_201947002619.jpg | 2019-01-24 |
| 11 | 201947002619-FORM 18 [22-01-2019(online)].pdf | 2019-01-22 |
| 12 | Correspondence by Agent_Form1And POA_30-01-2019.pdf | 2019-01-30 |
| 12 | 201947002619-POWER OF AUTHORITY [22-01-2019(online)].pdf | 2019-01-22 |
| 13 | 201947002619-RELEVANT DOCUMENTS [30-09-2020(online)].pdf | 2020-09-30 |
| 13 | 201947002619-PROOF OF RIGHT [22-01-2019(online)].pdf | 2019-01-22 |
| 14 | 201947002619-REQUEST FOR EXAMINATION (FORM-18) [22-01-2019(online)].pdf | 2019-01-22 |
| 14 | 201947002619-FORM-26 [30-09-2020(online)].pdf | 2020-09-30 |
| 15 | 201947002619-STATEMENT OF UNDERTAKING (FORM 3) [22-01-2019(online)].pdf | 2019-01-22 |
| 15 | 201947002619-FORM 13 [30-09-2020(online)].pdf | 2020-09-30 |
| 16 | 201947002619.pdf | 2019-01-22 |
| 16 | 201947002619-FER.pdf | 2021-10-17 |
| 1 | packagingteaE_30-11-2020.pdf |