How Is Tea Bag Produced In A High-Capacity Automation Production Line?

Discover the advanced automation process behind high-capacity tea bag production. From measuring tea leaves to sealing and packaging, learn how modern machines create tea bags efficiently and consistently.

Contents

Introduction

Tea bag production has come a long way from manual processes to fully automated systems. These automated machines ensure precision, consistency, and speed, which are crucial for meeting the demands of large-scale markets. A high-capacity automation line can produce thousands of tea bags per hour, from the preparation of tea leaves to the final packaging. In this article, we will look at how these machines work together to make the tea bags we enjoy.

1. What is a tea bag?

A tea bag is a small, porous, sealed packet filled with dried tea leaves or herbal blends. It provides an easy way to make tea without needing to filter out the leaves. Tea bags contain small-size tea leaves at a consistent portion size for each cup, eliminating the hassle of measuring loose tea and significantly reducing preparation time. This convenience has made tea bags the preferred option for many consumers, whether they are at home, in the office, or on the go.

Popular shapes of tea bag

Tea bags are available in different forms, such as rectangles, squares, circles, and pyramids, and can be made from filter paper, silk, or biodegradable materials. Tea bags are now widely available in single-chamber and double-chamber varieties, as well as in specialized formats like pyramid and round tea bags. This allows for a more generous expansion of tea leaves for richer flavor extraction.

Single-chamber tea bags: These are the most common tea bags and are filled with tea in a single chamber, which allows the tea to diffuse into the water.
Double-chamber tea bags: These contain tea in two separate chambers within the same bag, allowing better flow of water through the leaves and improved extraction of flavor.
Round tea bags: Round tea bags can ensure full contact with water, maximizing flavor extraction.
Pyramid tea bags: Made from mesh or nylon, these tea bags allow for larger leaves to be packed inside, giving more room for the leaves to expand and release flavor.

Tea bag machine line (1) — Types of tea bags

2. Working process of tea bag machine

A tea bag machine in a high-capacity automation line is a sophisticated system made up of various components. Each part play a critical role in the efficient production of tea bags. These components work in harmony, ensuring that the entire operation runs smoothly and effectively. Its working process involves several coordinated steps that transform bulk tea leaves into individually sealed and packaged tea bags ready for distribution. This intricate process is essential for ensuring that each tea bag meets quality standards and preserves the freshness and flavor of the tea. Let’s explore how this machine works together.

Measuring the weight of tea leaves

The first step in the tea bag production process is measuring the correct amount of tea leaves for each bag. The stainless steel hopper feeds the tea leaves into the measuring cup. These cups accurately portions out the exact weight of tea required for each bag. High-capacity machines use electronic scales and precision measuring devices to ensure the same amount in every bag, preventing over- or under-filling.

The stainless steel hopper serves as the primary storage and feeding system for loose tea leaves. This hopper can handle large quantities of tea, ensuring the machine can operate continuously without frequent refilling. The use of stainless steel ensures the hopper is easy to clean, avoiding any contamination and preserving the quality of the tea. Advanced models include vibration mechanisms to maintain consistent tea flow, level sensors to monitor tea quantity. Additionally, there is also a metal filter to detect and remove any metals in tea.

The measuring cup uses volumetric or weight-based measurement techniques to dispense exact amounts of tea leaves. The measuring cups are typically arranged in a rotary tray which contains several measuring cups, allowing for continuous operation at high speeds. Each cup includes calibration mechanisms and sensors to maintain accuracy throughout the production run.

Explore how much tea in a tea bag?

How much tea is in a tea bag?

Making filter bag and filling the tea bag

The process of forming the filter bag occurs simultaneously with tea measurement. The inner bag-making device draws the filter material from a roll of filter paper or mesh, cutting and folding it to form the appropriate shape. The bag is then partially sealed, leaving one side open to receive the tea leaves. After forming the bag, the machine fills it with the pre-measured portion of tea leaves. The filling process is highly automated to prevent spillage or uneven distribution.

The inner bag-making device is responsible for creating the filter bag that holds the tea leaves. Using rolls of filter paper or mesh, it transforms flat filter paper into shaped pouches. Once the filter bag is packed with tea leaves, the device proceeds to seal and cut the bag. Then the machine will stitch the thread of the bag and label it, the inner bag is finished.

Tea bag machine line (2) — The label and thread-making device

Sealing and tagging

When filling the bag with tea, the next step is to seal it. The sealing method can be either heat sealing or ultrasonic sealing, based on the material in the bag. Heat sealing is the most common method, using temperature and pressure to close the bag securely. In the case of nylon or other synthetic materials, manufacturers use ultrasonic sealing to bond the edges without melting the material.

For tea bags that include a string and label, the label and thread-making device attaches these components during this process. This device includes thread spools, cutting mechanisms, and label-feeding systems. The device precisely measures the thread length and cuts, while getting the label and securely attaches both components to the tea bag. Modern systems include tension control mechanisms to ensure proper thread handling and quality control sensors to verify correct attachment.

Besides, to maintain the speed and precision in this process, the manipulator plays an important role. It is a robotic arm or system that helps move the tea bags between different stages of production. It transfers the tea bags from filling to sealing stations and then to the packaging area, ensuring the bags are filled, sealed, and labeled accurately.

Tea bag machine line (3) — Operators use the control panel to monitor the production process

Packaging and boxing

After sealing and tagging the tea bags, a conveyor will transfer them to the packaging area. If individual wrapping is required, the envelope-making device wraps each tea bag in a protective envelope and then discharges them from the machine. Otherwise, the tea bags are sorted, stacked for bulk packaging, and moved out to be packed in boxes. This conveyor brings a set number of finished tea bags at a time, so the workers can easily pack them into boxes without having to count each one again. This makes everything quicker and easier.

At this step, an envelope making device can be used if an extra layer of protection is needed or for personal use. It is an optional component used in production lines. The device wraps each tea bag in a protective envelope (for individual use) to preserve the freshness of the tea and prevent contamination. The envelope-making device contains materials feeding systems, folding mechanisms, and sealing tools. It coordinates the cutting, folding, and sealing of envelope material (often aluminum foil film and kraft paper). Whereas, it still maintains proper alignment and registration marks.

Besides the devices used directly in the tea bag production process, there is a device that helps control the overall process. It is the control panel. The control panel serves as the central hub for the operation of the entire tea bag machine. Operators use the control panel to monitor the production process, make adjustments to speed or settings, and ensure the system is running smoothly. Modern machines come with digital touch screens that offer real-time feedback and data on production rates, machine status, and quality control.

Tea bag machine line (4) — A tea bag machine line at FGC’s factory

Conclusion

High-capacity automation has changed the way tea bags are produced, allowing manufacturers to produce consistent, high-quality tea bags at a rapid pace. By utilizing advanced technology such as precise weighing systems, robotic manipulators, and automated sealing devices, these machines are capable of managing large volumes of production. As a result, tea companies, like FGC, can meet the increasing global demand while ensuring consistency in product quality.

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.