Product specifications The tea comes from the steamed green tea leaves mixed with brown rice and red beans with a added tinge of dried chrysanthemum flowers. Cereal tea color is green yellow due to the mixing of green tea leaves with roasted brown rice and red beans. Thus the tea has a strong roasted aroma and flavor. That might not sound that appetizing to you, but don't knock it till you've tried it. Product specification: Japanese sencha (green tea leaves) mixed with cereal: pulse ratio The light toasted aroma and flavor of the roasted brown rice is a nice variation to plain green tea High nutritive value- The antioxidants in green tea are believed to reduce the risk of cancer and cardiovascular disease Each carton box contains 20 individually aluminum sealed tea ba gs

PRODUCT TYPE- Cereal tea, blended tea STYLE- In tea bags PROCESSING TYPE- Steamed SPECIALITIES- Health beverage, Organic tea SMELL- High aroma, green tea mixed with cereal: pulse SHELF LIFE- Up-to 12 months WEIGHT (g)- 2g per tea bag GRADE- (F)-fanning PACKAGING- 1.Aluminum sealed packet size- 7.6* 6.5cm (4.5g) 2.Carton size- 8* 10.6* 6.6cm (48g)

Green tea leaves processing Raw material storage (Warehouse and silos) Weighing To weigh the ingredient before going to the process of sorting Sorting Adequate uniformity and selection for trade requirement Shaping and cutting Create a distinctive look- pointed shape Grading Fanning (F) Grading Fanning (F) Filling into tea bags (2g of green tea leaves and cereal: pulse) Packaging (into aluminium sealed packets) (Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet) Packaging (into aluminium sealed packets) (Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet) Packaging (into carton boxes) (20 aluminium sealed packets placed into labelled carton boxes) Packaging (into carton boxes) (20 aluminium sealed packets placed into labelled carton boxes)

Brown rice processing Raw material storage (Warehouse and silos) Washing and draining In clean water Weighing To weigh the ingredient before going to the process of roasting Roasting Roasting temperature 200  c for 30mins Cooling Cooling process for 5mins Milling Mill sitting- 7 Sieving Sieve setting- 1mm Filling into tea bags (2g of green tea leaves and cereal: pulse) Packaging (into aluminium sealed packets) (Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet) Packaging (into aluminium sealed packets) (Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet) Packaging (into carton boxes) (20 aluminium sealed packets placed into labelled carton boxes) Packaging (into carton boxes) (20 aluminium sealed packets placed into labelled carton boxes)

Red beans processing Raw material storage (Warehouse and silos) Washing and draining In clean water Weighing To weigh the ingredient before going to the process of roasting Blanching Boiling temperature 100  c for 5mins Cooling Cooling process for 5mins Roasting Roasting temperature 200  c for 30mins Cooling Cooling process for 5mins Milling Mill sitting- 9 Milling Mill sitting- 9 Sieving Sieve setting- 1mm Sieving Sieve setting- 1mm Filling into tea bags (2g of green tea leaves and cereal: pulse) Packaging (into aluminium sealed packets) (Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet) Packaging (into aluminium sealed packets) (Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet) Packaging (into carton boxes) (20 aluminium sealed packets placed into labelled carton boxes) Packaging (into carton boxes) (20 aluminium sealed packets placed into labelled carton boxes)

Chrysanthemum (dried flowers) processing Raw material storage (Warehouse and silos) Sorting Adequate uniformity and selection for trade requirement Weighing To weigh the ingredient before going to the process of filling Weighing To weigh the ingredient before going to the process of filling Packaging (into aluminium sealed packets) (Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet) Packaging (into aluminium sealed packets) (Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet) Packaging (into carton boxes) (20 aluminium sealed packets placed into labelled carton boxes) Packaging (into carton boxes) (20 aluminium sealed packets placed into labelled carton boxes)

Equipment Flowchart Raw material (Brown rice) Water spray nozzle To clean and wash the raw material Cabinet oven Roasting temperature 200  c for 30mins Weighing conveyor To weigh the ingredient before going to the process of roasting Air blower Cooling process for 5mins Hammer Mill Mill sitting- 7 Raw material storage (Red Bean) Water spray nozzle To clean and wash the raw material Weighing conveyor To weigh the ingredient before going to the process of roasting Blanching tank Boiling temperature 100  c for 5min Air blower Cooling process for 2mins Cabinet oven Roasting temperature 200  c for 30mins Air blower Cooling process for 5mins Hammer Mill Mill sitting- 7 Sieving machine Sieve setting- 1mm Sieving machine Sieve setting- 1mm Raw material storage (Green tea) Weighing To weigh the ingredient before going to the process of sorting Sorting machine To obtain consistent size of green tea leaves Shaping and cutting machine Obtain pointed shape Grading separator Fanning (F) Grading separator Fanning (F) Raw material storage (Flower) Sorting machine To obtain consistent size of dried flower Weighing balance To weigh the ingredient before going to the process of filling Weighing balance To weigh the ingredient before going to the process of filling Packaging Machine

Equipment Description Brown rice & Red Bean production line equipment The weight of initial load of raw material is 75 kg. In order to produce 10,000 tea bags. Water spray nozzle washing: brown rice is washed using a water spray nozzle to inject higher pressures of water to remove the unwanted particles Weighing conveyor: The clean brown rice has been conveyed to the tray and ready to be roasted in the cabinet oven Cabinet oven The maximum load of the product is 180 kg. The roasting condition for brown rice is 200  c for 30 mins.

Equipment Description Brown rice & Red Bean production line equipment Air blower air blower is used to cool the product instead of air-drying (used in the laboratory scale) to minimize the time consumption. Hammer milling Capacity range is suitable for up to 200kg/hr. The grounded brown rice has to be sieved by using sieving machine. Sieving machine: The brown rice has been sieved with 1mm sieving diameter, after which the material is conveyed to the filling plant.

Equipment Description Brown Rice & Red Bean production line equipment Blanching tank: The red bean has been boiled under the heating conditions and then goes to roasting process at 200  C for 5 minutes.

Equipment Description Green Tea Production Line Equipment Tea sorting machine: The tea size ranges from a speck of dust to a leaf size 4cm long and 1cm wide. These fractions are to be brought to a desired size to attain uniformity and requirements conforming to the trade. Shaping and Cutting: Range of green tea shaping and cutting equipments vary depending on the requirement. They mainly aid in the extraction process of the stalks and cellular matter present with tealeaves. Machines: savage tea cutter, cellular tea-cutting machine.

Equipment Description Green Tea Production Line Equipment Grading separator: The separator can provide the grading diameter to fanning size.

Equipment Description Chrysanthemum flower production line equipment Sorting machine: The dried flower size ranges from 1 cm to 2cm in diameter. These fractions are to be brought to a desired size to attain uniformity and requirements conforming to the trade. Weighing balance: Approximately 0.4g of the dried flowers are weighed and placed along with the tea bag to be air tight aluminium sealed.

Equipment Description Packaging Line Equipment Weighing hopper: -The ingredient is weighed in gram unit (tea leaves, cereal: pulses and dried flowers) Tea bag filling machine: -Filling by weight based on the formula specification Aluminium sachet sealing machine: -The aluminium packing prevents the oxidation and maintains the tea, cereal and pulse aroma. Carton box packing - The tea bags are packed into carton boxes.

Task 4: Screening experiment  What is screening experiment for in this task? Determine the factors or parameters are most likely to affect our select responses Correlation between the HOWs and WHATs (significant)  What should we do in designing and selecting of the experiments and responses, respectively? According to Unit 2 works to determine the following factors which could significantly affect the quality

Task 4: Screening experiment  What is screening experiment for in this task? Determine the factors or parameters are most likely to affect our select responses Correlation between the HOWs and WHATs (significant)  What should we do in selecting and designing of the responses and experiments, respectively? According to Unit 2 works to determine the following factors which could significantly affect the quality Used factorial design to identify the experiments (3 factors with 2 levels = 2 3 = 8 different samples per each, 40 assessors, total no. of samples = 8*40=320) The following 8 samples are:

1g tea leaves 1.5g tea leaves Ratio 4:1Ratio 1:1 Ratio 4:1 Ratio 1:1 1mm 1.4mm The samples were prepared as per requirement for the sensory test to determine the significantly affect factors for the quality or consumer acceptability by 9-point scale and using R project (ANOVA) to analysis the results.

However It is failed to generate any significant change in the responses to the WHATs. Moreover, the assessors have rated all the samples quite low and this proves to be a roadblock to the optimisation procedure. The team has to look into the possible causes and repeat this task again at the beginning of the next unit.

Task 7: Legislations The conformance of the production process was examined with regard to national, European and international regulations (basic by the Codex Alimentarius and the FSA).

 There were 4 processes relevant with regard to legislation Storage: Basic food law/commission regulations 2006 pointed that the amount of cereals (i.e. the maximum content of cereal should be 0.05 mg/kg wet weight). Codex Alimentarius (CAC/PCP ) pointed the quality factors (i.e. the moisture content of rice is 15%m/m max). Washing: FSA guideline pointed out to remove the physical, chemical, and microbiological hazards from ingredients to increase the quality and safety. Blanching: FSA and Codex Alimentarius published pre-cooked by Blanching is in order to inactivate the enzyme and change the texture. Packaging: In the most recent study published in 2009, the level of aluminum sealed bags has recently been lowered. The content in the food by less than 1mg/kg and/ or less than 10mg/kg for 85% of foods.

What went wrong?

Temperature Troubles

The consumer & TEA

“ I want milk in my tea ” “ I like black tea ” “ Green Tea is healthy” “I want loads of sugar”

!DEA

THERMOS