Different Shapes of Tea Bags and Their Formation Process

Discover the unique shapes of tea bags and the formation processes to make these bags. Learn how each design enhances brewing and caters to diverse consumer preferences.

Contents

Introduction

Tea bags are a cornerstone of the modern tea industry, providing a convenient way for consumers to enjoy their favorite beverage without needing a tea maker or tea steeper. Several shapes of tea bags – double chamber, square/rectangular, round, and pyramid – brings its own unique aesthetic appeal and functionality during brewing. These differences influence the production and shaping processes. In this article, we will explore the distinct characteristics and manufacturing methods for various types of filter bags.

1. Double chamber tea bags

Double chamber tea bags are among the most popular and widely used shapes of tea bags in the tea industry. This bag consists of two compartments, allowing tea leaves to spread out evenly and increase their movement. It also provides ample space to enhance water circulation around tea leaves, ensuring better infusion. Double chamber bags are typically made of thin, biodegradable filter paper. They are often equipped with a string and tag for convenience, making them both practical and environmentally friendly.

The creation of double chamber tea bags requires complex precision engineering. It transforms flat filter paper into designed functional bags that are meticulously sealed to ensure the tea is secured within.

Shapes Of Tea Bags (1) — Double chamber tea bag

Folding and filling the chamber

The process begins with a continuous roll of filter paper being fed into the machine. The paper is folded along its length to form a compartment, and the tea is inserted. It is then heat-sealed to become a strip of filter bags with tea inside. Special rollers apply pressure to create paper folds at specific points, forming the structure of the compartments, while rolling evenly helps the tea spread evenly in the compartment.

Shaping and sealing

In this step, the cutting device precisely trims the strip of the tea bag strip to a predetermined length, ensuring it is sufficient to fold into two chambers. Then, a horizontal bar is inserted into the middle of the cut filter bag, and folded in half to create two compartments. This double chamber bag is transferred to the next part to fix the top of the bag, fixing the tea inside. The machine staples or knots a string to the top of the bag, and a tag is affixed at the end of the string for easy handling.

2. Square/Rectangular tea bags

Square or rectangular tea bags, also known as single-chamber tea bags, are the most traditional format and are still highly popular due to their simplicity and practicality. These flat bags are sealed on three or four sides and are often made without strings or tags, making them cost-effective and easy to stack.

Shapes Of Tea Bags (2) — Rectangular tea bag

The process of forming square/rectangular tea bags is similar to that of double-chamber tea bags, with a key difference in the sequence of steps. In the production of double-chamber tea bags, the cutting step occurs before sealing. However, for square/rectangular tea bags, the filter paper is first sealed on all four sides to enclose the tea completely. Only after this is the sealed sheet cut into individual bags, ensuring a clean and uniform finish.

Shaping and filling the bag

Flat filter paper is drawn from a roll and laid out smoothly. Using an accurate volume or weight dosing system, the tea leaves are evenly distributed on the filter paper. To form the tea bags, the machine folds the paper along its center, securely enclosing the tea. The folded strip then passes through rollers that ensure the edges are perfectly aligned, preparing it for the final sealing step.

Sealing and cutting

The filter paper is heat-sealed on three or four sides at a temperature of 180-220°C, ensuring a secure enclosure. Simultaneously, it is cut to a predetermined length to maintain uniformity in each bag. If a thread and tag are required, they are attached before the heat-sealing process. This ensures a firm attachment and a tight seal to protect the tea inside.

3. Round tea bags

Round tea bags are a modern innovation designed to fit perfectly into mugs and teapots. Their circular shape ensures even better brewing, as water can flow around the bag without obstruction. Moreover, round tea bags are often regarded as a premium alternative to square tea bags and appeal to consumers seeking a more aesthetically pleasing option.

The process of forming round filter bags differs slightly from that of other types. For round filter bags, the paper is cut into a circular shape and heat-sealed along the edges to create a tight seal, ensuring the tea leaves are securely enclosed. Additionally, round filter bags typically do not include tags, making the production process simpler.

Preparing material and filling tea leaves

First, the filter paper from a roll is fed into the machine continuously, it is then shaped into a tube to hold the tea. The machine accurately measures the tea leaves based on a predetermined quantity and automatically dispenses them one portion at a time into the forming tea bags. After that, a precise interval is maintained between each portion, allowing the machine to separate the tube into individual tea bags seamlessly.

Shaping and sealing

Once the tea is dispensed, a heat sealer bonds the two layers of filter paper to form a sealed circular bag, leaving enough space inside for the tea to expand during brewing. After sealing, a cutting machine precisely trims the paper into small, round bags, matching the sealed dimensions. This ensures the filter bag is fully enclosed, effectively preserving the tea inside.

4. Pyramid tea bags – Among premium shapes of tea bags

Pyramid tea bags are tetrahedron-shaped bags that are made from nylon or biodegradable mesh, allowing visibility of the tea leaves. These three-dimensional bags are designed to provide ample space for whole tea leaves and larger herbal ingredients to expand fully during brewing. In addition, their unique, transparent design also allows consumers to see the quality of the tea inside, enhancing the premium feel.

Pyramid filter bags stand out with their unique and sophisticated shape, making their forming process more intricate and refined compared to other filter bags. Ultrasonic sealing technology is employed to seamlessly bond the edges of the filter bag, ensuring a secure seal while maintaining an elegant and luxurious appearance. This advanced method guarantees both functionality and aesthetic appeal, highlighting the premium quality of pyramid filter bags.

Shaping the filter material and filling tea leaves

The pyramid tea bag packing machine starts by feeding a roll of mesh packaging material into the system. The forming unit then shapes the mesh into the distinctive pyramid structure. This process begins with creating a tube-like form, sealing it along its length, and securing the bottom to create a triangular base. After the pyramid shape is formed, the machine’s filling system dispenses a precise amount of tea leaves into each bag. Using a volumetric method, the machine ensures accurate and consistent tea quantity across all bags.

Sealing and cutting

After filling, the machine’s sealing system seals the tea bag along a line perpendicular to the previous seal, finalizing the distinctive pyramid shape. Once sealed, the bags are cut and separated into individual units from the material tube. Ultrasonic cutting technology is employed for this step, ensuring clean and precise cuts. This technology also maintains the integrity and aesthetic appeal of each pyramid tea bag. After cut, the tea bags can be further processed by attaching strings and tags or packaging them in protective outer envelopes.

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Conclusion

The design and shapes of tea bags significantly impact consumer experience, brewing performance, and brand perception. Advanced machinery and precision techniques ensure that each type of tea bag – whether double chamber, square, round, or pyramid – is produced efficiently and to the highest standards. By understanding the unique attributes and formation processes of these tea bags, tea brands can better align their products with current market trends and consumer desires, enhancing their brand’s appeal and reputation.

About Future Generation Co., Ltd

Future Generation Company Limited is one of the largest beverage suppliers in Vietnam, with 26 years of experience in production and export. FGC is equipped with modern machines such as Hotfill PET and TetraPak, ensuring high-capacity production. FGC strives to achieve our mission to become Vietnam’s leading healthy beverage company. Our factories also meet international standards such as ISO, HACCP, etc. In addition, we constantly innovate our machinery system, strengthen production capacity, and increase productivity.

FGC also provides Private Label Services. With this service, we can help customers research and formulate beverages, design product label packaging, and create their own brands. This is an ideal solution for small and medium enterprises. Moreover, FGC provides free samples for customers to test before bulk orders. We also ensure delivery as fast as possible.