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Blending materials
The tea leaf raw materials are poured into a storage
tank after checking that they do not contain foreign
matter using such things as an air shower and a
powerful magnet. The temperature of storage is
regulated, and heat-sensitive tea leaf raw materials
are stored in refrigerated storage at 5C or less.
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Extraction
The extraction facility was designed by our company
to facilitate ideal extraction of the tea
components. A computerized system sets the optimal
extraction conditions in accordance with such things
as the origin of the tea leaves and season in order
to produce high quality extracts.
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Separation from tea ground
Even the smallest piece of tea ground is removed
from the extract (tea water); this results in clear
tea water. The removed tea grounds are collected
into a special tank and recycled as fertilizer.
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Concentration
Extracts are concentrated in order to efficiently
convert them into powders. A special method, called
membrane concentration, is used to concentrate
extracts.
* What is membrane concentration?
Membrane concentration is a method that removes
moisture by utilizing an RO membrane, which allows
only liquid to pass through, and by application of
pressure. Deterioration of flavor is minimized
because this process does not use heat.
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Sterilization and drying
After sterilization using a plate heater, the
extracts are converted into powder using the spray
dry method, which instantaneously dries the extracts
by spraying them into heated air. Spray drying is
our core technology, and all the facilities within
our plant were developed by us, from design to
construction. The spray dryer is a huge facility 34
m high and has an area of 470 m
2
, including building components. Products converted
into powder using the spray dryer are automatically
packed into bags and carried onto the next process
(mixing and wrapping) by a robot and an unmanned
carrier device.
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Mixing and wrapping
Products converted into powders are mixed to
homogenize them and are automatically wrapped and
sealed after passing through screening and magnetic
devices to ensure that they do not contain foreign
matter. The wrapped products are then carried into
automatic storage after passing through another
check for foreign matter. Operation of machinery,
inventory management, and management of such things
as loading and unloading in the automated storage
warehouse are all conducted by computers.
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