MASINDE MULIRO UNIVERSITY OF SCIENCE AND TECHNOLOGY

SCHOOL OF ENGINEERING AND BUILT ENGINEERING

COURSE TITLE: INDUSTRIAL ATTACHMENT I

NAME: PAUL KIPRONO CHERUIYOT

REG. NUMBER: MIE/B/01-02342/2017

COURSE CODE: MIE 390

INDUSTRY: LITEIN TEA FACTORY

DURATION:8 WEEKS

UNIVERSITY SUPERVISOR: DR. ROTICH

INDUSTRY BASED SUPERVISOR: ENGINEER ERICK LANGAT

DECLARATION
I Paul Cheruiyot declare that the work produced in this report is from my research and the
information given by the instructors during practical sessions.
Signature.....................
Date..........................

DEDICATION
I dedicate this effort to my parents and our family members, Mr. / Mrs. Marisin family and
learned school supervisor of Masinde Muliro University of Science and Technology who guided
and encouraged me during the preparation of this report and I want to say THANK YOU.
ACKNOWLEDGEMENT
Thanks goes to Almighty GOD for the gift of protection and knowledge which has enable me to
accomplish all the activities.
Am pleased with Litein Tea factory administration and the company at large for granting me this
opportunity to train, it was a very good experience and I managed to learn a lot of things as
pertain my career.
Am so grateful and humbled by the organization supervisor Eng. Erick Langat and other workers
of the organization for the information and knowledge they provided and other individuals who
shared their knowledge with me during this training period.
It would not be appropriate to forget my university supervisor Dr. Paul Rotich for sacrificing his
time to come and supervise me and the knowledge which he shared with me especially in report
writing.
And finally to those who have in any way helped me either financially, academically or
otherwise to make this publication a success.
EXECUTIVE SUMMARY
Industrial training programme provide a student with appreciable skills designed to expose or
equip them with real life working experience.
The programme teaches me on how to interact effectively with other workers and supervisors
under various conditions in the organization. It also exposes me to work methods and techniques
in handling equipments and machines. The programme also provided me with a simultaneous
process of Industrial training and studying and helps me to put theory into practice. I learnt all
the various activities done in every section aiming at production of black tea. I also went through
various quality parameters that are considered in every section.
This report contains and gives a detailed explanation of all the activities carried out at Litein Tea
Factory in Kericho County.
  Table of Contents
CHAPTER 1................................................................................................................................................9
1.1 INTRODUCTION.............................................................................................................................9
1.2 INFORMATION ABOUT THE FACTORY.....................................................................................9
1.3 Vision and mission of Litein tea factory............................................................................................9
1.4 COMPANY LAYOUT.......................................................................................................................10
1.5 COMPANY STRUCTURE................................................................................................................10
............................................................................................................................................................... 11
............................................................................................................................................................... 11
............................................................................................................................................................... 11
............................................................................................................................................................... 11
............................................................................................................................................................... 11
1.6 DUTIES AND RESPONSIBILITIES OF KEY PERSONNELS AT LITEIN TEA FACTORY.....12
1.7 STAFF ESTABLISHMENT OF THE DEPARTMENT IN TERMS OF NUMBER OF
EMPLOYEES AND THEIR RESPONSILITIES..................................................................................14
CHAPTER 2..............................................................................................................................................20
2.1 STUDENT MAIN OBJECTIVE FOR THE ATTACHMENT EXERCISE....................................20
2.2 COMPANY’S OPERATION..........................................................................................................20
The company has various section of operation and their parameters include;....................................20
 Withering...................................................................................................................................20
 CTC and fermenting (CFU).......................................................................................................20
 Dryers........................................................................................................................................20
 Sorting.......................................................................................................................................20
 Packing......................................................................................................................................20
 Quality and control room...........................................................................................................20
...........................................................................................................................................................21
2.3 MACHINERY INDENTIFICATION AND FUNCTION...............................................................21
2.3.1 Chasing lathe machine..............................................................................................................21
2.3.2 Multipurpose lathe machine......................................................................................................22
2.3.5 Inspection bench.......................................................................................................................23
2.4 CTC MANUFACTURING PROCESS FLOW DIAGRAM............................................................23
CHAPTER THREE...................................................................................................................................25
3.1 PROCESSING OF TEA..................................................................................................................25
3.11 BLACK TEA PROCESSING AT LITEIN TEA FACTORY....................................................25
3.12 PROCESSING ROOM..............................................................................................................25
3.3 SORTING........................................................................................................................................33
3.4 PACKING.......................................................................................................................................35
 3.4.1 PARAMETERS IN PACKING................................................................................................36
CHAPTER 4..............................................................................................................................................36
4.1 QUALITY CONTROL....................................................................................................................36
4.2 BOILER SECTION.........................................................................................................................39
4.2.1 THE BOILER OPERATION....................................................................................................39
4.3 WATER TREATMENT OPERATION...........................................................................................43
4.3.1 Litein Tea Factory Water Treatment Flow Diagram.................................................................44
4.4 GARAGE........................................................................................................................................44
CHAPTER 5..............................................................................................................................................46
5.1 ASSIGNED DUTIES IN VARIOUS SECTIONS...........................................................................47
CHAPTER 6..............................................................................................................................................55
6.1 CHALLENGES ENCOUNTERED DURING ATTACHMENT PERIOD......................................55
6.2 RECOMMENDATION OF HOW THE ATTACHMENT PERIOD CAN BE IMPROVED BY
THE UNIVERSITY..............................................................................................................................55
6.3 CONCLUSION...............................................................................................................................55
REFERENCES..........................................................................................................................................56

TABLE OF FIGURES
ACRONYMS

1 TR ..............Thearubigins.
2 TF…………. Theaflavin.
3 CCP………. Critical Control Point.
4 SOP…... Standard Operating Procedure
5 PPE….... Personal Protective Equipment
6 PPO…….. Polyphenols oxidase.
7 CTC……………. Crushing, tearing and curling.
8 HACCP…………Hazard Analysis and Critical control Point.
CHAPTER 1
1.1 INTRODUCTION
Industrial training attachment is an integral part of undergraduate program at Masinde Muliro
University of Science and Technology. It provides students with valuable insights into
professional and industry -oriented side of the field studies in practice. It enables one to develop
an objective of awareness of general workplace behavior and interpersonal skills which are
important objectives of industrial training experience.
The training time allows the students to link the theoretical principles learned in final years in
purpose to reach Bachelor degree. It provides every student an opportunity to apply the skills and
knowledge achieved during the course of study and to acquire new skills in managing
relationship and carry out jobs assigned.

1.2 INFORMATION ABOUT THE FACTORY

Litein is in Kericho County Bureti sub-county and Litein Location. The Factory is situated 32 km
from Kericho town of Kericho off the Kericho–Kisii highway,267 Kilometers West of Nairobi
through Narok–Bomet route and 294 kilometers through Nakuru-Kericho route.
It was founded in 1967 for processing and marketing black tea. It. has a capacity of processing
about 125,000 kilograms of green leaves tea or 2,500 kilograms of black CTC tea. This is the
same as 5kilogram of green tea producing 1kilogram of final black tea. The products of the
organization are certified by KEBS.
It is found 1478 meters above the sea level with an average rainfall of 1482millimetres in a year
and average temperatures of 17.3` in a year. This warm and temperate climate is significant for
the production of high quality tea for the right kind of tea grown in these regions. It has got
volcanic soils which are rich in plant nutrients.
The factory is fed with water from Kipsonoi river. The factory is determined to serve customers
through innovation continuous improvement ,an intense focus on customer needs and dedication
to meet those needs with a sense of urgency. Excellence is not only a value ;it is a discipline and
a means of making the world a better place. The red volcanic soils, conducive weather
patterns ,well distributed rainfall all year round coupled with good manufacturing practices
,combine to form a unique feature contributing to special unique characteristic in Litein teas
which are naturally colourly and creamy with special mellow and flavoury Aroma. It’s satellite is
Chelal Tea Factory and its inception was to reduce congestion.

1.3 Vision and mission of Litein tea factory

Vision: To be a leading producer of high quality tea products in the world.

Mission: To provide efficient and effective services to the small holder tea Farmersin

production, leaf collection and processing of high quality teas for the benefit of stake holders.
 1.4 COMPANY LAYOUT

GATE/ENTRANCE

LEAF RECEPTION/LEAF
COUNT ANALYSIS
SECTION STAFF
OFFICES TEA ROOM

MANAGEMENT/V
ISTORS
WASHROOM
FACTORY
DRESSING ROOM PARKING

FOREMAN
OFFLOADING
OFFICE

STORE KUNI SHED GARAGE

BOILER
KUNI SHED LAUNDRY

PETROL FILLING POINT

 1.5 COMPANY STRUCTURE
BOARD OF DIRECTORS O-LEVEL

FACTORY UNIT MANAGER

FACTORY PRODUCTION CORDINATOR DEGREE FIELD SERVICES

FSA DEGREE
ACCOUNTANT DEGREE CORDINATOR DEGREE
GROUP
PRODUCTION MANAGER ADMINISTRATOR
DEGREE
ASST.FACTORY ACCOUNTANT
DEGREE/DIPLOMA

PRODUCTION ASS.DEGREE PLANT TECHNICIAN

DIPLOMA

MVT
STORE KEEPER SFM
CHIEF CLERK S.F.S DIPLOMA
SFE
DIPLOMA
DIPLOMA
CLERK II TESA
MA DIPL
GOM
CLERK 1
SUPERVISOR G.O.E AUTO
ELLECT
DRIVERS
OFFICE CHARGE HANDS DRIVER
TEA/TREE
MECH

LEAD
SHOP FLOOR FARMER
WORKER
LEAF COLL.CLERKS

B.G FARMERS
COMMITTEE

KEY

(a)..SFM-SENIOR FACTORY M ECHANIC (b)..MVT-MOTOR VEHICLE TECHNICIAN

(c)..FSA-FIELD SYSTEM ADMINISTRATOR (d)..SFS-SENIOR FACTORY SUPERVISOR
(e)..SFE-SENIOR FACTORY ELECTRICIAN (f)..GOE- GRADE ONE ELECTRICIAN
(g)..GOM-GRADE ONE MECHANIC
 1.6 DUTIES AND RESPONSIBILITIES OF KEY PERSONNELLELS AT LITEIN
TEA FACTORY
DESIGNATION RESPONSIBILITY

BOARD OF  Ensuring effective operation and maintenance of food safety management

DIRECTORS system in the company.

 Participation in HACCP management reviews.

 Ensuring availability of resources for HACCP establishment, implementation

and maintenance.

 To ensure sufficient information on issues concerning food safety is available

throughout the food chain in the company.

FACTORY  Ensuring effective establishment, implementation and sustainability of system

MANAGER in the factory.
 Conducting management reviews.
 Establishing factory food safety policies.
 Participate in HACCP reviews meetings and the study.
 Communicating with both external and internal parties on matters relating to
the food safety management system.
 Ensure relevant training pertaining food safety

Management system.

ASSISTANT  To manage a food safety team and organize its work.

FACTORY
MANAGER  To ensure relevant training and education of the food safety team members.

 To ensure that the food safety management system is established,

implemented, maintained and updated.

 To report to the factory management on the effectiveness and suitability of

the food safety management system.

 Training of all staff and employees.

 To ensure effective internal communication.

 Organizing and participating in management review meetings.

 To ensure proper maintenance of CCP station.

FACTORY  To ensure proper operation of CCP station.

ASSISTANTS,
PROCESS  To guide respective machine operators/supervisors on rework.
ASSISTANT
AND FOREMAN  To ensure enforce of all food policies.

 To receive and record complaints /compliments from employees can

 communicate to management.

 To discipline errand employees in all sections.

 Ensure all SOPs are adhering to at all times.

 To carry out non- conformity on critical limits; for CCPs.

 To ensure general factory cleanliness.

 To ensure effective machinery maintenance.

 To ensure proper allocation of competent staff in respective sections.

 To ensure proper collection and disposal of tea wastes.

QUALITY  To ensure compliance of quality in every process step.

ASSURANCE
ASSISTANT  To undertake investigations on customer complaints and report to
management.

 To ensure proper documentation and record keeping.

 To advise management on possible new hazards to the tea and recommend

corrective action.

 To prepare tea samples for lab analysis and act on results.

1.7 STAFF ESTABLISHMENT OF THE DEPARTMENT IN TERMS OF

NUMBER OF EMPLOYEES AND THEIR RESPONSILITIES

The following are some of the staff members at Mechanical department at Litein tea factory:

 Foreman.
 Assistant foreman.
 Withering /discharging supervisors.
 CTC machine operators.
 Dryer machine operators.
 Sorting supervisors/machine operators.
 Packing supervisor.
 Factory plumber.
 General factory employees.

Designation Responsibility
Foreman /Assistant  To ensure proper operation of all CCPs station.
Foreman
 To guide respective machine operators/supervisors on rework.

 To receive and record complaints/compliments from employees and

communicate to management.

 To discipline errand employees in all sections.

 To ensure general factory cleanliness.

 To ensure effective machinery maintenance.

 To ensure proper allocation of competent staff in respective sections

 To ensure proper collection and disposal of tea wastes.

Withering/dischargin  To ensure allocation of the right number of employees in the section.

g supervisors
 To ensure green leaf suppliers conform to the company quality
standards.

 To inspect all employees for personal hygiene conformance and fill

personal hygiene check list.

 To ensure conformance of SOP for the section.

CTC machine  To ensure consistent feed rate of the withered leaf.

operators
 To ensure proper adjustment and setting of bar magnets in every cut.

 To weigh metals picked by magnets every 8 hrs and record on the CCP
monitoring sheet.

 To ensure proper collection of spillages on aluminium trays and their

processing on 1st cut.

 To carry out corrective action and investigation when CCP critical

limits are exceeded.

 To ensure conformance of SOP for the section.

 To communicate to Factory assistant/Process assistant on the non-

conformity.

 To ensure proper operation of machinery.

 To ensure correct usage of PPEs by employees.

 To ascertain areas cleanliness.

  To inspect all employees for personal hygiene checklist.

Dryer machine  To ensure proper operation of dryers.

operators
 To carry out corrective action when CCP critical limits are not attained.

 To ensure conformance of SOP for the section.

 To ensure enforcement of all policies.

 To receive and record food safety complaints/compliments from

employees.

 To ensure proper collection of spillages.

 To inspect all employees for personal hygiene conformance and fill the
personal hygiene checklist.

Sorting  To ensure proper operation of sorting machinery.

supervisors/machine
operators  To make records after every 2hrs on O-PRP metals checklist and
ensure its effectiveness.

 To ensure quality conformance of grades produced.

 To carry out rework for non-conforming products.

 To weigh and record all grades produced as per the mark prior to
binning.

 To ensure cleanliness of all bins.

 To ensure conformance of SOP for the section.

 To inspect all the employees for personal hygiene conformance and fill
the personal hygiene checklist.

Packing supervisor  To ensure consistent feed rate of sorted teas into the packing machine.

 To weigh metals picked by magnets every 4 hrs and recorded in CCP

monitoring sheet.

 Carry out corrective action in liaison with manufacture in charge of

rework when CCP critical limits are exceeded.

 To ensure proper operation of machinery.

 To ensure proper usage of PPEs.

 To ascertain area cleanliness.

  To ensure conformance of SOP for the section.

 To receive and record food safety complaints /compliments from

employees.

 To inspect all paper sacks prior to packing tea.

 To discipline errand employees.

 To ensure correct labeling of paper sacks in respect to invoice number

and mark.

 To draw representative samples for invoice during packing.

 To ensure enforcement of all policies.

 To inspect all the employees for employees for personal hygiene

conformance and fill the personal hygiene checklist.

Factory plumber  To carry out water treatment on daily basis.

 To carry out water treatment test twice daily.

 To ensure proper operation of water machinery.

 To take corrective action when O-PRP Acceptable levels are not

attained.

 To discipline errand employees.

 To carry out treatment on effluent treatment twice a week.

 To ensure enforcement of all applicable policies.

 To receive and record food safety complaints/compliments from

employees.

CHAPTER 2
2.1 STUDENT MAIN OBJECTIVE FOR THE ATTACHMENT EXERCISE

The following are my objectives during my industrial attachment at Litein Tea Factory:

I. To observe real-life practices and implementation of theoretical lessons and principles.

II. To learn about ethics in the industry.
III. To gain experience in organizational skills and professional responsibility.
IV. To be able to efficiently complete given tasks.
V. To foster good relationships with seniors and subordinates.
2.2 COMPANY’S OPERATION

The company has various section of operation and their parameters include;

 Withering
 CTC and fermenting (CFU)
 Dryers
 Sorting
 Packing
 Quality and control room

2.2.1 Processing flow diagram

Fig 1
Figure 1

2.3 MACHINERY INDENTIFICATION AND FUNCTION

2.3.1 Chasing lathe machine
This is a type of lathe machine also but only performs chasing operations on the rollers by
making circumferential grooving on the segmental rollers .An attachment for holding the chaser
(2.1/4” or 1’’) with sliding and centering facility are used for setting the chaser correctly for
pitch matching .CTC rollers in Litein tea factory are of 42’’ and 36’’ majorly and diameter of
up to 14’’ can be filled and grooved .The machine consist of filled all geared headstock with
alloy spindle ,heavy duty bearing for trouble free, smooth heavy duty 4 jaw independent chuck
,special lead screw with centricast phospher bronze nut for free movement of chaser ,micro dial
graduated in 0.001’’.The machine has a forward and reverse drives and gear box drive directly
coupled to motor.

figure
Figure 2

2.3.2 Multipurpose lathe machine

This is majorly used for multipurpose operation for instance facing ,turning ,tapering ,boring
,taper turning and threading .This principle machinery revolves the work piece on its axis ,thus
enabling outcome of symmetrical objects .As a rule ,the work piece is held firmly in place by
either one or two rigid supports called centers that can be moved horizontally to hold materials of
different proportions.
Figure 3

2.3.3 Milling machine

It performs helical grooves on the roller .Suitable for milling 50,55,60,65,70,80,96 and 100
helical grooves for upto 14’’diameter.CTC rollers are fitted with exclusive indexing device to
achieve the a precise division of helical grooves .Mechanical cutter tilt arrangement for accurate
setting of the cutting angle.

Figure 4

2.3.4 Cutting and chasing grinder

Used for re-grinding of milling cutters and chasers .The machine has a fabricated pedestal ,motor
and suitable starter .It can also be used for sharpening of general purpose tools as well .The
milling cutter is mounted on a spindle which rotates on roller bearings .The chaser should be
passed briskly across the wheel to avoid overheating.
2.3.5 Inspection bench.
Design for checking of meshing of CTC rollers, suitable for rollers upto 52’’ size.
Rotor vane
The is processed in a barrel where a rotor with vanes rotates between resistors propelling the
leaf forward and discharges through a cone or end plate. A rotor vane consists of a cylinder that
has a rotating central shaft. Vanes on the shaft propel leaf along the cylinder and distortion
occurs by rubbing and shearing of leaf against projections (resistors) coming out of the cylinder
casing. This process is designed to disrupt the cellular structure of the leaf.
It is extremely important that the resistors, vanes and worm are securely mounted on their
members. The bearing brushes must be well maintained. There are different types of rotor vane
but standard across the black tea factories has 48 resistors and 12 vanes. Optimum rpm of a
rotating shaft is 50.
There should be sufficient pressure to both condition the leaf and maintain adequate through put
to the CTC rollers

2.4 CTC MANUFACTURING PROCESS FLOW DIAGRAM

GREAN LEAF
 WITHERING
OPTIONAL

CUTTING, TEARING
AND CURLING
THROUGH ROTORVANE
AND ROLLERS

Air inlet FERMENTATION BY BIOCHEMICAL Air outlet

OXIDATION OF POLYPHENOL AND ENZYMES
AN EXOTHERMAL REACTION

Hot air at 100-130ºC Exhaust at 55ºC

DRYING

Fibre and refuse removal

SORTING
(2% solid waste).

PACKING

CHAPTER THREE
3.1 PROCESSING OF TEA
3.11 BLACK TEA PROCESSING AT LITEIN TEA FACTORY
Black tea-this tea is produced at Litein tea factory whereby the manufacturing technology
involves the disruption of the cellular integrity of tea shoots; in so doing, the substrates
polyphones and enzymes polyphenol oxidase are mixed. This results in initiation of series of
biochemical and chemical reactions with the uptake of atmospheric oxygen and formation of
pigmented hot-water soluble polyphenolic compounds, characteristic of black tea.

Black tea processing consists of the following units of operation:

 Withering (partial removal of moisture).

 Rolling /disruption (size reduction).

Oxidation /fermentation (biochemical reactions in the presence of oxygen).

 Drying (completion of moisture removal).

 Sorting (fibre removal; grading based on size).

Of these, chemical changes occur primarily during withering, fermentation and drying.

3.12 PROCESSING ROOM

This was the main method that was adopted in Litein tea factory and other black tea factories in
the company. CTC process gave more cuppage i.e number of tea cups per a kilogram of black
tea due to the complete rapture the particle undergoes. The triple action of crush-tear-curl was
done by the teeth on the two rollers moving against each other at different speeds of ratio 10:1.

The simultaneous curling and crushing action depends on surface area available on the teethes
sides. Correct sharpening and setting of rollers was of paramount importance where leaf is hard
and fibre content high, a light cut produced brown fibrous teas with thin liquors. It also caused
undue temperature rise

Sifter

Weighing of withered leaf should be matched to the optimum processing capacity of all
machinery, with drier being most critical. The rotor vane is fed by means of sifter that assists to
even out feed. It also helps to clean leaf of dust and grift before entry to the rotorvane. The auto-
weigher is a new design of sifter, more compact and robust.

Rollers

Rollers are mainly use to cut and curl tea leaves from the rotor vane prior to fermentation. The
processed tea passed through a series of four rollers. The 1st roller had 8 teeth per inch while the
2nd and 3rd had 8 teeth per inch. From the 1st to the last cut rollers were arranged in pairs with
the speed of the rollers in each pair being at the ratio of 8:1.
 The rollers were maintained every Monday with those worn out replaced by the resharpened
rollers. Roller replacement was preceded by thorough setting by the CTC machine operators to
avoid mis-cut of the leaves during processing.

FERMENTATION

Fermentation is the process of converting catechins into theaflavins of other compounds

through a reaction with atmospheric oxygen. (Exothermic reaction).

The process is governed by the following physical and chemical properties of the reactants:

 Concentration (Catechins)- large quantity present at the apical growing portion (tip) of
leaf.
 Temperature – start after CTC at (28-30) and discharge to drier at 20-22
 Catalyst – enzyme polyphenol oxidase.
 Supply of amble air(source of oxygen)
 Standard of cut (extend of leaf maceration)
 Types of machinery used –CTC, LTP etc.
During fermentation process, specific optimum temperature is maintained in every module to
achieve the required tea quality. The temperature range here should be within 23℃-29℃.

In the CFU various attachments are put in place in case of variations in temp or required
moisture content.

Attachments:

i. Humidifier
ii. Propeller fan
iii. Blowing fan
iv. Steam duct
v. Upturner (for turning tea) etc.
Fermentation process does not require any energy unless humidifiers are used.
To obtain a very strong tea with a very dark color in the cup, tea leaves are exposed to a
very long oxidation process.
Carbon dioxide is driven out of the leaf and heat is exchanged. If the temperature of the
dhool is allowed to rise too high, the controlled oxidation will rage out of control and if it
falls too low, oxidation will cease.
The thickness and raking of dhool is to determine the exposure of surface area of the
oxidizing leaf to the air (ideal ambient temperature is 29℃, relative humidity (98%) and
ventilation (98%) and ventilation (15-20 complete changes of air per hour), bacteria must be
prevented from ruining the dhool.
Factors affecting fermentation
a. Leaf standard (Catechins level and types).
b. Wither.
c. Standard of cut (extend of leaf maceration).
d. Types of machinery used (CTC, LTP etc).
e. Ambient temperatures.
f. Fermentation temperatures.
g. Enzymatic activity of polyphenol oxidase.
h. Concentration of oxygen and level of aeration.
Assuming all other factors like leaf standard, cut,wither,concentration of oxygen, aeration levels
are standardized then the biggest single factor that determines the rate and extend of
fermentation is temperature of fermentation.
For fixed fermentation time, use of low temperatures will result in bright, brisk tea liquors while
high temperatures may result in colourly strong but dull tea liquors.
Rough guide for Trinitea fermenters.
In hot ambient condition 23-26℃in the first module and 26-28ºC in the second module but it is
reduced if over fermentation occurs.
In cold ambient condition (day or night) use 25-27ºC in the first module and 27-29ºC in the second
module to 28-30ºC if tea is still greenish at the end of fermentation.
Poor aeration results in oxygen starving and fermentation may not be achieved even at good
temperatures. Dhool moisture content levels (67-69% moisture level is ideal at the end of
fermentation).
The tea are conveyed through the fermentation unit for at least 2hrs-3hrs then conveyed to the
driers.

Importance of fermentation/oxidation

 It enables formation of new compounds at a molecular level. This results in exclusive brown
color and astringent flavor of black tea.
 It plays a vital role in the manufacturing of black tea.

The chemical reactions in oxidations are:

a) The enzymes (polyphenol oxidase and peroxidase) acts with Polyphenols present in the leaves.
This reaction produces Theaflavin. Theaflavin is responsible for the brisk and bright taste of
black tea.
b) Theaflavin then react with more Polyphenols to produce Thearubigins. Thearubigins are
responsible for the distinctive body and color of black tea.
c) Thearubigins react with some of the amino acids and sugars in leaves. This creates the highly
polymerized substances responsible for the unique and distinctive flavor components in black

tea.
Figure 5

DRYER SECTION

After the processed tea is passed through CFU (continuous fermentation unit)and Jumbo
fermenters the tea is first passed through driers prior to sorting.

The main objectives of the drying include;

i. To arrest enzymatic reaction as well as oxidation.

ii. To remove moisture from the leaf particles and to produce a stable product with good
keeping quality.
The major components of the dryer include the following; the dryer, the air heater, heat
exchanger and a fan. The fan is used to introduce the clean hot air at the bottom of the dryer.

In the conventional dryer, the fermented leaf falls over a series of moving perforated trays where
a hot incoming air dries the leaf and the moisture is reduced from around 70% to 3%.

Factors that affect drying:

1) Temperature of inlet & exhaust- the drying of tea involves physical aspects; too
high temperatures at the initial stage may cause case hardening, blistering or
scorching. On the other hand, too low a drying temperature slows down the rate
of drying. Oxidation is allowed to proceed for a longer period resulting in a
“dull” and “soft” product, an effect is known as stewing.
2) Volume of air – volume of air for drying depends on two factors; moisture to be
removed and the temperature selected. If the volume of air is below the normal
requirement, the temperature will have to be increased to produce the same
amount of heat.
3) Thickness of spread- the spread of the tea leaves should be to a reasonable depth
to prevent the air from escaping freely through it. Overloading the drier requires
higher drying temperature and longer period of drying. Generally, finer material
should be spread finer.
4) Period of drying- the time required for drying tea varied with the degree of
wither, temperature, thickness of spread and volume of air. The objectives of
drying can be achieved in shorter residence time by increasing the drying rate. A
fast drying rate carries the risk of case hardening or scorching.
From the major component that were used in drying, air heaters (radiators) both
direct and indirect were used.

The dryer used in drying the tea had an approx. through put of 400-450kg/hr.
however, not all dryers have the same volumetric capacity.

Basic working mechanism of the dryer.

The fermented leaf fed to the dryers were carried away and at the end of the run, the
trays tilt one by one and discharge the leaf to the lower run. The process being
repeated till the leaves exit the dryers to the sorting i.e delivery of the leaves outside
the drying chamber. As the leaves were being carried by the trays, hot air fed at the
bottom pass through the trays and leaves dried.
In the driers automatic temperature measuring instruments were used to monitor temperature in
each section. This helped in keeping the temperatures at standard level hence preventing over
drying/under drying.

The cyclones were used to balance air in the dryers preventing tea from splashing
out.

Auxiliary equipment in the dryers

Cyclones

The cyclones serve the purpose of removing exhaust air from the dryer. Cyclones remove tea
particles and fibre in the exhaust air and deposit these in a bucket held at the bottom of the
cyclone. The bucket is periodically emptied of its contents. These contents are refried and sorted
along with other teas.

Figure 6

Ball breakers

This equipment serves the purpose of feeding the fermented dhool into the dryer. It is positioned
one or two feet above the bed plate and just below the end of the dryer feed conveyor so that the
dhool to be fed into the dryer falls directly onto it.

Lighting

Thorough visual examination of the drying chamber was necessary from time to time and lights
were fitted along one side of the dryer to facilitate this.

Thermometers

Thermometers were positioned in the dryers for proper monitoring of dryer temperature. They
were placed along one side of the dryer.
Optimum dryer temperatures

Feed end – 150℃ to 160℃

Middle section – 80℃to 110℃

Discharge end - 45℃ ¿ 60℃

Manometers

There are two types of manometers used: BTFs, Inclined and U-tube.

Purpose

Used to measure air flow into dryers.

Weirs

These are located at the discharge end of FBD.

They are set at various heights to cause sufficient residence of tea for complete drying to take
place.

Purpose

They govern the run through time of tea particles down the dryer.

They enable the manager his ‘art of cooking’ in drying tea.

They can be lifted or lowered enough to allow the accumulated pellets to travel out of the dryer.

Procedure for dryer operation

Drying of tea involved mainly moisture removal from fermented dhool by

evaporation. During the early stages of drying, the dhool is so wet that continuous
film of water exists over the entire surface. The water removal in the period is mainly
superficial water. During this period, the rate of drying under a given set of air
condition is constant and independent of the moisture content. This period is known
as the constant rate of drying and here the temperature of the dhool approaches the
wet bulb of the air. The magnitude of the constant drying rate depends on the area
exposed to drying medium, the difference in temperature between the airstream and
wet surface of the dhool and the air velocity.

Parts of FBD Dyer

a) Heater system-comprises of heat exchanger/radiator shell and its accessories.

b) Hot air system-comprises of straight or bent hot air inlet duct, flow control
gear, hot air blower, outlet air duct etc hot air is sucked from the heat
exchanger and pressure is built up in the blower for admitting the plenum
chamber.
 c) Feed system-this comprises of a feed Hoppe, ball breaker assembly, drive
motor and discharge hopper. This enables regulated feed to the dyer and
breaking up of lumps in the fermented leaf.
d) Basic equipments and internals-this comprises of plenum and drying chamber
bolted together.Plenum chamber consist of carbon steel fully insulated
chamber having a patented interior design. It has a provision of 3
temperatures drying. Drying chamber consist of discharge Hoppe, side
brackets and mounting brackets. The longitudinal plate is connected together
with tie-rod.

COMPONENTS OF FLUID BED DRYERS.

a) Radiators-steam is passed through it at about 150-PSI.

b) Axial fan-for drawing air from the surrounding atmosphere and forces over
the radiators, heating it and into Plenum chamber.
c) Plenum Chamber-Air tight enclosure below the dryer.
d) Drying Chamber-it is above the plenum chamber and both are separated
peforated steel of metal.
e) Dampers-it leads to the fan and situated in front of the radiator. It is located
about 3 feet below perforated plate.

Function of dampers

1. Regulate air flow into the chamber.

2. Distribute air from the plenum chamber to various section of the drying chamber.

F) Louvers-used to determine the angle at which air enters the drying chamber
depending on the condition of leaf.

G) Discharge conveyor- it feeds the fermented dhool into the dryer.

Moisture content of dhool should be between 67-69% depending on the type of manufacture. The
drying occurs whereby heat flows from the air by virtue of temperature difference between the
two bodies. This heat energy vaporizes moisture present in the tea and the resultant vapor mixes
with air and is carried off leaving dry leaf behind.

The rate of heat transfer is directly proportional to the temperature difference. The high
temperature also enables the air to absorb the evaporated moisture without getting saturated.

Factors that affect drying process

a. Physical properties of tea particle.

b. Particle size.
c. Particle density.

The dryers used in the factory uses air as means of absorbing and exhausting moisture from the
drying dhool.
Purposes of air passing the dryers

a) Transfer of heat to cause evaporation. Volume of air and its temperature are of vital
significance.
b) To evacuate moisture out of the dryer. Volume of air and temperature are important as
they determine its capacity to hold the moisture.
c) To heat the tea particles to cause diffusion. The air temperature and time the particle
remains in contact with the hot air are significant.
d) To cause a forward horizontal motion of a less dense tea particle cause tea out of dryer.

3.3 SORTING
Definition –it is the grading of dryer-mouth teas into even shapes and sizes as dictated by market
requirements.

After drying of the black tea, they were then conveyed to the sorting section. At the sorting, the
tea was first passed through a series of rollers (electrostatic ally charged rollers). The rollers
being electrostatic ally charged removed/ picked all the fibers in the black tea. After passing
through the preorders i.e. after all the fibers and big pellets had been removed, the tea was
conveyed to aviaries screen machine where they were separated into different grades which
included;

Primary grades

 BP – broken pekoe
 BP1 – broken pekoe 1
 PF1 – pekoe fanning’s 1
 PD – pekoe dust
Secondary grades

 BMF
 PF2
The BP grade was reprocessed while the BP1 were taken to a winnower before conveying to the
bins for packing.

The PF1 and PD were conveyed directly to their respective bins for packing. In the sorting
section, the quality of tea was also examined prior to packing among the qualities examined
included;

 the moisture content

 the cut quality
 The extent in which the tea was dried.
In case of higher moisture content in the dried tea, the tea was taken back to the dryers to be
redried where as those not cut to the required standard were taken to the CTC for recutting,.
This ensured that the quality of tea was monitored appropriately before packing.

How to achieve good sortation

  No under-firing as it leads to difficulty in fibre removal.
 Correct standard of cut at CTC to avoid crushing it in the sorting room which removes
the bloom from black tea making it powdery and grayish.
 Right standard of wither which must be of correct moisture.

Sorting machinery

a) Kifaru sorter-fibre and pellets extraction.

b) Fibred stalk extractor-contains sets of revolving polytene rollers on which engineering
felt is firmly held, this creates a static electric charge on the rollers which attract fibers
from the tea to the rollers, this in turn is brushed off by a piece of felt. The clean tea
passes over the conveyor to the vibroscreen.
c) Vibroscreen-this contains a series of meshes that vibrate with a planetary action,
producing five different primary grades.
i. Top mesh-this removes rejects which are crushed.
ii. BP Grade-0.5-1%.
iii. BP 1(Winnowed)-5-8%.
iv. PF 1-30-35%.
v. PD-35-40%.
vi. D 1-2 or less %.

Top grade should be in the range of 90-98%. The percentages of each grade are altered from
time to time according to market changes in order to take advantage of those grades selling
highest at any particular time.

Alteration is made in:

i. Withering (softens or hardens).

ii. CTC (roller configuration).
iii. Sorting (mesh sizes).
d)Winnower -this is a java tunnel with a fan to suck light particles and deposit away from
heavy clean particles which form the snotty BP 1. The balance of this grade is checked
and returned for further crushing and sortation if considered suitable or down grade to
BP 2.
e) Hammer mill-this is a unit to crush pellets of tea mixed with long fibre or larger BMF
particles.
Hammer milling reduces the texture of pellets/fibre to smaller particles easier rework
which contributes to avoid excessive recycling which causes leaf brownness and loss of
bloom.
3.4 PACKING

Figure 7

At the packing lot, an automatic weighing machine is fixed which weighs the predetermined
amount of tea to be packed in every bag as per the customer’s specifications. After packing the
tea, weight of the tea was verified using a digital weighing machine before stacking/piling
together in piles of 20 bags or 10 bags. A flattening machine is stationed in the packing section
which is mainly used in flattening of bags (packed bags)
Blending machine is used for blending the grades.
Eoslift machine is used for lifting sacks of tea and transferring them or relocating them.
Dock leveler machine is used as a bridge between the fork lift (eoslift machine) and lorry while
loading.
Strapping belt is used for strapping paper sacks.
Sewing machine is used for sewing polypropylene bags.
Stenciling machine is used for stenciling.
Weighments of packed tea
Weighing scale machine and packer machine are used during weighing of teas.
Stock check is also done weekly and on monthly basis to access the number of bags sold.
Dispatch of teas
Tea is dispatched to various markets once the full invoices have been filled.
Actual packing of teas
After production, sorting and binning have been done properly, packing is done as the last
process.
3.4.1 PARAMETERS IN PACKING.
I. Blending
II. Sampling
III. Stenciling
IV. Packing
 V. Strapping

CHAPTER 4
4.1 QUALITY CONTROL
Quality assurance-This is an enclosed loop system, which is used to monitor every stage of
production during processing upon specific targets.

Quality assessment and parameters

o Moisture content.
o Density
o Tasting/infusion
o Cuts

Role of quality assurance

 Determine the moisture content of withered leaf.

 Monitoring the cuts during processing.
  Determining the moisture content of dryer mouth teas.
 Determine the moisture content of cyclone teas and BMF.
 Monitoring densities of sorted teas.
 Determining the moisture content of firewood used in boiler.

Determination of the moisture content of withered leaf

Procedure

A handful sample of withered leaf is randomly collected from withering troughs prior to
discharging. The sample is uniformly mixed, crushed and 5g weighed and burnt using a
mettle Toledo meter at a temperature of 130 ºC for a duration of about 30-40 mins,
depending on the wither. The recommended moisture content of withered tea leaf is 70-72 %
while that of dhool fed to the driers is 67-69%.

Monitoring of the CTC cuts during processing

A sample of dhool is collected from the 1st ,2nd ,3rd and 4th cuts sections of CTC. The sample
are pressed to display the quality of particles and presence of fibre. This is done on hourly
basis and aim in making CTC roller adjustment of worn out rollers where applicable.

Determination of the moisture content of the drier mouth teas and infusion of drier mouth
teas

I. Moisture content of DM teas

Collect a sample of dryer mouth teas and weigh 3 g. Burn the sample inside a mettle
meter at a temperature of 120ºC. The target moisture content should be 3 % but the
critical limits are 2.8-3.2%.
II. Moisture content of BMF and Cyclone tea
Collect a sample of cyclone tea and weigh 3g. Burn the sample in a mettle meter. The
target moisture content should be 3% but the critical limits are 2.8-3.2 %. For
packed invoices, collect at least 5 samples of BMF. Burn the sample using a mettle
machine meter. The target moisture content is 3 % but the critical limits are 2.8-3.2
%. If the moisture content is less than 2.8 % the tea will be tasted by a member of
management to determine if the invoice is overfired.
III. Infusion /brewing of made tea for organo-leptic tasting
The following samples of made tea should be collected from sorting room on hourly
basis for brewing and subsequent organo-leptic tasting by QC personnel and MICs.
 BP 1, PF 1 and PD from each line.
 Dryer mouth teas from each line.
 Winnowed teas where applicable.

Brewing and tasting should be done objectively to ensure that only quality products are passed.

How to brew the made tea to get liquor

Weigh 6 g of drier mouth teas and put it in a cup with a perforated on the end and add boiling
water and cover it for 6 mins then drain the liquors onto the bowl. Pour the residue to the lid
and squeeze more liquors out of the residue out of the bowl. The colour of residue on the lid
referred to as ‘infusion’ give an indication of quality of fermentation and also quality of the cut.

The liquors are tasted for briskness, strength, firing quality and other characters contained in
tea.

The dry leaf is also displayed as a measure of sortation of fibers and make.

Measuring densities of sorted teas

Collect samples of primary grades from sorting section i.e. BP1, PF 1, D 1 and PD. Weigh 100
g of each grade and pour it into a measuring cylinder using a free fall system. Good quality teas
should have the following densities.

Determination of moisture content of firewood

Weigh 7 g of saw dust from firewood being fed into the boiler, burn it on the mettle at a
temperature of 125ºC. The target level of moisture content is 13-17 %.

Tea tasting ranking

Grade Bondet mark Sisiba mark

densities densities

BP 1 260-280 270-300

PF 1 240-260 255-280

PD 220-240 235-260

D1 210-230 220-235

Key

Liquors infusion cut sorted leaf

Color (body) 3-bright coppery 3-good cuts 3-blackish

3-good color 2-fairly bright 2-fair cuts 2-fairly blackish

2-fair color 1-dullish 1-poor cuts/flaky 1-brownish

1-light color

Make fibre
3-good make 3-clean

2-fair make 2-fairly clean

1-poor make 1-fibrous

4.2 BOILER SECTION

4.2.1 THE BOILER OPERATION
Definition

A steam boiler in the form of closed vessel, constructed for continuos generation of steam under
pressure through the transference of heat to the liquid (water) which is contained in it. The heat
generated is obtained from combustion of fuel (firewood).

The fuel and combustion

Air and fuel mixture were burned in the combustion chamber. The hot gaseous products of
combustion leave the combustion zone and pass through the tube surface. As the gases flowed a
maximum temperature. The heat lost by the gases was transferred to and by the wear. Feed
water was heated by mixing to the temperature of the water in the boiler, which is that of steam.

The calorific values of firewood used with known moisture content

Moisture content % 0 10 15 20 30 40 50
Gross CV (MJ/Kg) 18.61 16.75 15.82 14.89 13.03 11.16 9.3
Net CV (MJ/Kg) 17.28 15.31 14.30 13.33 11.36 9.39 7.42

Types of boilers

There are basically two types of boilers,

 fire tube boiler

 water tube boiler
the fire tube boiler was used in Litein tea Factory the flow of hot gases was restricted to pass
through the tubes, where they transfer their heat to the surrounding liquid.

In water tube boiler, the hot gases pass over the exterior surface of the tubes, while the water
being heated passes within the tube.

Another distinguishing feature between these two types of boilers is that while fire-tube boilers
are supported by the walls, or the fire box, water-tube boilers are usually suspended from
overhead steel work and columns.

The boilers used were restricted to about 10 to 15 bars (150 – 200 psi) as the working pressure.

The boiler safety control devices

 The boiler was fitted with the following safety control devices;

Sight – glass: indicated the amount of water in the boiler

Mobrey switch: controlled the level and the pumping of new water into the boiler

Fusible plug: this was a low melting point metal plug fitted inside the boiler in the fire
(combustion chamber). If for some reason the boiler run short of water below the level of the
plug, the solder in the plug overheats and melts, an allows water to rush out extinguishing the
fire. Due to the fact that oxidized solder has a higher melting point than straight solder, it was
important that the fusible plugs were changed at least every 3 months.

Safety valve: allows steam pressure to be released after it has reached a pre-set limit. A safety
valve is set to operate 5-10 psi above the operating pressure.

Pressure switches: control the boiler pressure by switching on and off the low fire or high fire of
the oil fired burner to regulate the desired set pressure.

Blow down: an accumulation of sludge and minerals (total dissolved solids TDS) is inevitable in
the bottom of the boiler and its necessary to remove theses by blowing down the boiler.

Steam injector: the electric feed water pumps are controlled by Mobrey switches. In case of
power failure, water has to be feed into the boiler to prevent damage of the boiler by the steam
injector. The principle of operation is that steam is forced through a venture, which draws cold
water through the steam injector and forces it to the boiler.

Steam Distribution.

Steam is transported to where it is needed through piping. When the steam reaches the
radiators, and passes through the radiator tubes, it is condensed back into water by the cooling
effect of the air current through the radiator. The condensate can then be pumped back to the
boiler feed water tank.

The escape of steam through the condensate returns pipe is prevented by using steam trap.

Definition of terms.

Dry saturated steam- steam in the absence of water and without superheat. Its temperature
which is pressure dependent is known as saturation temperature. Practically, the steam
delivered by a boiler is always associated with small quantities of water in the form of tiny
droplets and is known as wet steam. The ratio of dry steam to wet steam in a mixture is called
dryness fraction.

Boiler maintenance

Fireside surface; for efficient heat transfer to the water, the tube surface on the fireside must be
kept clean at all times and free from buildup of combustion product deposit. To ensure this, the
tubes had to be kept clean by brushing every Monday.
Water side surfaces; similarly the waterside surface must be kept clean and free from mud and
mineral deposit. This was achieved by regular blow down once per shift and by water treatment.
In extreme cases, descaling was necessary.

Controls; all boiler controls had to be maintained in working conditions. A failure to observe
this requirement could lead to a disaster.

.
Other essential boiler fittings;

 Safety valve
 Pressure gauge
 Blow down valve
 Fusible plug
 Mobrey
 Water gauge
 Low water alarm
 Boiler feed water pump
 Registration plate

Boiler Steam traps

PURPOSE OF STEAM TRAPS; steam traps are automatic devices which drain condensate,
remove, air and non-condensable gases from the system and stop the passage of live steam
through the drain lines. Accumulation of condensate slightly affects the performance of steam
distribution lines by decreasing the capacity for heat transmission.

Construction of steam traps

The steam traps used in the boiler should conform to federal specification of the boiler.

Traps have the following components;

a) A vessel to collect condensate

b) An opening through which condensate is discharged
c) A valve to close the opening
d) Adequate mechanisms to operate the valve
e) Inlet opening to the vessel for condensate transmission
f) Outlet opening for condensate discharge
Classification of steam traps

i. Mechanical – operates using the difference in density between condensate and steam
ii. Thermostatic – operates using the difference in temperature between steam, condensate
and air.
iii. Thermodynamic – operates using difference in kinetic energy between flowing steam and
condensate.
Traps types
 Mechanical Thermostatic Thermodynamic
Upright bucket Bimetallic Orifice plate
Inverted bucket Thermal expansion Venture nozzle
Float Bellows Piston impulse
Float and thermostatic Disk

 Venture nozzle, float and disk traps were mainly used in Litein tea factory.
 Bucket traps; can be of open top or inverted type. Both use the difference between the
density of steam and condensate for their operation.
 Float and thermostatic traps.This trap also deepens on its operation on the difference in
densities between the steam and condensate. In operation condensate that collects in the
traps body gradually raises thefloatthus opening the discharge valve using a lever
mechanism. After the condensate is discharged, the float drops, closing the valve and
preventing the passage of steam. Air and non-condensate gases are relieved through a
thermostatic vent.

 Orifice plate trap; when a gas or vapor passes through a restriction, it expands to lower
pressure beyond the restriction. Drilling a small whole an orifice trap operates on the
principal of continuously condensate from steam line. This continuous condensate
removal allows trap to use a smaller diameter outlet than other types of steam traps
which operates o an open close sop enclose system.
 Venture nozzle; solacing as short section of smaller inside diameter pipe between two
sections of pipe creates a venture nozzle. The nozzle trap is based on the two phase flow
principle. Steam will pass through the nozzle approximately 25 times faster than
condensate, but the denser condensate impedes the flow of steam. Therefore the steam
must push any condensate through the nozzle first before the steam can pass the nozzle.
 Piston impulse trap; the first thermodynamic operating trap is the piston impulse style.
The piston impulse style valve condensate heats up and approaches steam temperature.
Some flows by the piston opening a round disk on the piston valve and flashes into steam.
The flash steam at pressure between the inlet and discharge is pushing against a
relatively large flange area on top of the disk and pushes the valve down and closed.
 Disk trap; the disk trap consists of only three parts: body, cap and disk. The disk is the
only moving part.

4.3 WATER TREATMENT OPERATION

Water treatment-is a process which aims at rendering water fit for drinking and domestic use.
Principle water contaminants include:

i. Pathogenic bacteria.
ii. Turbidity and suspended solids.
iii. Colour
iv. Taste and odours.
v. Organic compounds.
vi. Dissolved minerals.

Pump is used in pumping water from the dam to the storage tank and from the clean water tank
to the buyers/ consumers. Chemicals used in water treatment plant and the ratios in which they
 are use mixed or used. Chemicals used include: Aluminium sulphate,sodium carbonate and
chlorine.

Aluminium sulphate- is used as a coagulant.

Sodium carbonate-is used as a Ph booster.

Chlorine is used as a disinfectant.

3kgs Aluminium sulphate + 1kg Sodium carbonate + 1kg Chlorine.

4.3.1 Litein Tea Factory Water Treatment Flow Diagram

Main water intake dam

Sedimentation tank

Water filter unit

Underground tank

water pump

Machine Main tank Boiler-steam generation

washing/cleaning
process

Villages

Leaf tea processing

line, fermenting unit.

4.4 GARAGE
1) welding
In Litein tea factory, the main type of welding use was the Shielded Manual Metal Arc Welding.

The shielded manual metal arc welding also known as flux shielded arc welding, is a manual arc
welding process that uses a consumable electrode covered with flux to lay the weld.
 An electric current in the form of ac electric current or dc current from the welding power
supply is used to form an electric arc between the electrode and the melts to be joined. The work
piece and the electrode melt forming a pool of molten metal that cools to form a joint. As the
weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a
shielding gas and providing a layer of slag, both of which protects the weld are from
atmospheric contamination

Operation

SMWA weld area

To strike the electric arc, the electrode is brought into contact with a work piece by a very light
touch with the electrode to the base metal then is pulled back slightly. This initiates the arc and
thus the melting of the workpiece and the consumable electrode case droplets of the electrode to
be passed from the electrode to the weld pool. Striking an arc, which varies widely based upon
electrode and workpiece composition, can be hardest skill for the beginners. The tip of the
electrode needs to be at a lower angle to the work piece which allows the weld pool to flow out
of the arc. As the electrode melts, the flux covering disintegrates, giving off shielding gases that
protects the weld area from oxygen and other atmospheric gases. In addition, the flux provides
molten slag which covers the filler metal as it travels from the electrode to the wed pool.

Traps types

Mechanical Thermostatic Thermodynamic

Upright bucket Bimetallic Orifice plate
Inverted bucket Thermal expansion Venture nozzle
Float Bellows Piston impulse
Float and thermostatic Disk
 Venture nozzle, float and disk traps were mainly used in Litein tea factory.
 Bucket traps; can be of open top or inverted type. Both use the difference between the
density of steam and condensate for their operation.
 Float and thermostatic traps. This trap also deepens on its operation on the difference in
densities between the steam and condensate. In operation condensate that collects in the
traps body gradually raises thefloatthus opening the discharge valve using a lever
mechanism. After the condensate is discharged, the float drops, closing the valve and
preventing the passage of steam. Air and non-condensate gases are relieved through a
thermostatic vent.

 Orifice plate trap; when a gas or vapor passes through a restriction, it expands to lower
pressure beyond the restriction. Drilling a small whole an orifice trap operates on the
principal of continuously condensate from steam line. This continuous condensate
removal allows trap to use a smaller diameter outlet than other types of steam traps
which operates o an open close sop enclose system.
 Venture nozzle; solacing as short section of smaller inside diameter pipe between two
sections of pipe creates a venture nozzle. The nozzle trap is based on the two phase flow
principle. Steam will pass through the nozzle approximately 25 times faster than
 condensate, but the denser condensate impedes the flow of steam. Therefore the steam
must push any condensate through the nozzle first before the steam can pass the nozzle.
 Piston impulse trap; the first thermodynamic operating trap is the piston impulse style.
The piston impulse style valve condensate heats up and approaches steam temperature.
Some flows by the piston opening a round disk on the piston valve and flashes into steam.
The flash steam at pressure between the inlet and discharge is pushing against a
relatively large flange area on top of the disk and pushes the valve down and closed.

 Disk trap; the disk trap consists of only three parts: body, cap and disk. The disk is the
only moving part.

CHAPTER 5
5.1 ASSIGNED DUTIES IN VARIOUS SECTIONS
Weighbridge section

Lorries (empty and loaded) are weighed and records kept at this section. The values are
obtained in kilograms to get the net weight (weight of the loaded lorry-weight of empty lorry).
This was done to know if there are significant differences between the values obtained in the
field and in the factory. The records kept include:

I. Estates where tea came from.

II. Supplier for out growers.
III. Transporter.
IV. Drivers name.
V. Vehicle number plate.
VI. No. of bags supplied.

These records are printed to produce a hard copy so that it assists in reference if needed later.

Estimates are also done in this section.

Leaf count analysis and leaf reception

These are some of the items that I learnt in leaf count analysis section:

I. How to measure the temperature of the tea leaves in sacks by use of the thermometer.
The temperature range should be between 20ºC-30ºC.High temperature causes scorching
of leaves hence affecting its quality.
II. How measure 100g of tea leaves by use of a weighing indicator.
III. How to sort tea leaves into soft leaf, soft loose leaf, long leaf, course leaf and foreign
matter .The results obtained are compared to the company’s target.
IV. How to calculate primary grade and secondary grades by using the formula.

SL+SLL+50%LL=PG (primary Grade).

CL+FM+50%LL=SG (Secondary grade).

Key

SL-Soft leaf

SLL-Soft loose leaf

LL-Loose leaf

CL-Course leaf

FM-Foreign matter.

The measurements used are in form of grams. This is the leaf analysis table which I used.

SL SLL LL PG
 CL FM LL SG

These are some of the values which I obtained in form of table.

Hand plucked teas

SL SLL LL PG CL FM SG

56 11 26 80 7 0 20

42 20 23 74 15 0 26

Shared plucked teas

SL SLL LL PG CL FM SG

40 22 23 73 16 0 27

38 24 22 73 16 0 27

Mechanical tea harvesting

SL SLL LL PG CL FM SG

24 51 3 77 18 0 19

17 48 32 72 11 0 27

If the values obtained are more off from the factory target, then the tea is rejected.

Methods used in plucking tea

1. Hand plucking.
2. Share plucking.
3. Mechanical tea harvesting.

Tea varieties received includes 15/10, sc 15/28, normal or seedling etc.

Once leaf count analysis has been done and confirmed that they met the standards then they are
offloaded in offloading bay (Company leaf and Out growers leaf).

Withering

These are the activities which I did in the withering section:

a. Quality assessment of the tea leaves by doing second leaf count analysis.
b. Determination of desired moisture content of tea leaves (70-72%).
c. Identification of parts/troughs where sacks of tea leaves should be offloaded into.
 d. How records are kept such as:
i. Estate name
ii. Date received
iii. Field no.
iv. Time in
v. Types /variety of tea leaves.
vi. Value of primary grade.
vii. Value of secondary grade.
viii. Kilograms loaded to the troughs or that the trough can hold.
e. Identification of methods used in withering process.
f. Identification of type of withering involved in the factory.
g. How moisture content and heat is monitored and how it is regulated by use of fans and
steam.
h. How withered leaves are loaded to verity chains to take them to the discharging section.
i. How to operate fans in aim of moisture removal and temperature control.

I was able to determine the moisture content of withered tea leaves by fluffing them and placing
them in a container. It then took them to the quality control room and measured 5 g of tea leaves
using a weighing indicator. I cut them into smaller sizes and placed them in a Mettle Toledo
machine and set the temperature to 130ºC. Once the Mettle Toledo machine had stopped, I
recorded the moisture content in form of a table shown below.

Moisture content

Withered leaf 1 73.87

Withered leaf 2 72.81

Withered leaf 3 77.46

Withered leaf 4 68.37

The company’s target is 70-72%.

Once that limit is achieved, the leaves are well withered and they are ready to be discharged for
processing.

Discharging

These are some of the activities that I did at discharging section:

a) How sacks of withered leaves are collected in troughs and loaded to verity chains.
b) How sacks of withered leaves are offloaded from the verity chains.
c) How withered leaves are fed to the sifter.
d) Roles of sifter which includes: reduction of moisture content, elimimination of extraneous
matter like sand, small stones or metals that may have got picked up accidentally in the
field.
 e) How weigh feeder calculates the discharging rate/feeding rate.

Figure 8

f) How records are kept in the section.

Processing room
These are the activities which I accomplished when I was in the processing
room:
a) Identification of various steps in fermentation process.

Leaf conditioning Leaf maceration Crushing

tearing and curling (CTC).
B) Identification of chemical reaction during fermentation process.
c) Identification of factors contributing to fermentation process. These
factors include: Ambient temperature, leaf standard, wither, standard of cut,
fermentation temperature etc.
D) How to keep records in at processing room. Records made include:
Feeding rate, temperature of tea undergoing fermentation process at different
sections/modules in different lines, depth of tea undergoing fermentation at
different lines in different sections/modules and amount of metals attracted by
magnet.
e) How to measure the moisture content of dhool leaf (this was done in quality
control Room).
The table below gives the moisture content of dhool at different times

Time %
moistur
e
content

8:30 am- 59.44

9:15 am
 10:00 68.32
am-
10:40
am

11:00am 70.12
-11:40
am

Drying
These are the activities which I did at drying section:
I. How fluid bed dryers operate.
II. How to use thermometers and manometers in monitoring the temperature and air
pressure in various sections of dryer.
III. How temperature is regulated in the steam area.
IV. How to achieve expected drying curves.
V. How radiators operates in regulating the temperature in Fluid bed dryers.
VI. How dampers operate (used in balancing the hot air in Fluid bed dryers in cyclones).
Sorting
These are the activities which I accomplished when I was in sorting section:
a) How the machines operates for tea sortation such as fibred rollers, winnower, vibro-
screen, hummer mill and hopper.
b) How to grade tea by use of: BPs (broken pekoe), PF 1(pekoe fanning 1), PD (pekoe
dust), BMF (broken mixed pekoe), D 1(dust 1), PF 2(pekoe fanning 2) and BP
1(broken pekoe 1).
c) How fibers are extracted by use of fibred rollers.
d) How teas are weighed by use of weighing indicator. Weighments are in form of
kilograms.
e) How to keep records in sorting section.
f) Identification of how graded teas are stored in the bins.
Teas are graded according to their sizes. This is achieved by varying the sizes of
mesh in vibroscreen. The following is a table showing the grade, mesh size and
no. of holes per inch.

Grade Mesh size Holes per

inch/25.4 mm

BP 10×24 10

BP1 12×24 12

PF 14×26 14

PF 1 24×28 24

PD 30×30 30

D1 40×36 40
g) Process flow in sorting section

Drier discharge Conveyor 1st fibrex sorter 2nd fibrex sorter

Vibroscreen (for grading).

BP1 PF1 PD D1

The following is a table which is used in assessment of sorted teas.

Date A B C

Previou BP 1 PF 1 PD
s

Tim
e
Current BP 1 PF 1 PD

Time

Key
BP 1- broken pekoe
PF 1-pekoe fanning 1
PD-pekoe dust
A, B, C-Lines
Assessment is done hourly to check whether there is some deviation from the
expected one.
g) How to calculate top grade, out turn percentage and densities.
Out turn percentage=Total made tea ×100 %
Total green leaf
Total made tea= (PF 1+BP 1+PF + PD + BMF) Kgs.
Out turn percentage= 9098×100%=21.37 %
42565
Top grade percentage=Total made tea-off grades ×100%
Total made tea
9098-615 ×100%= 93 %.
9098
Packing

The following are the activities which I did in the packing section:
 i. Identification of packing machines.
ii. Operation of packing machines such as: packer machine, leveling machine, strapping
machine, pallet truck and fork lift.
iii. Operation of stenciling machine and sewing machine.
iv. How packed teas are weighed.
v. How to carry out stock check.
vi. How teas are dispatched.
vii. Actual packing of teas.
Quality control
These are the activities that I did in quality control section.
I. How tea quality is accessed and parameters used.
II. How to keep records in the section.
III. How to determine the quality parameters and various machine used. Quality
parameters include: moisture content, cuts involved, liquors and density of sorted teas.
IV. How to infuse teas to ascertain the quality of fermentation quality of cuts (in residue)
and liquors (in bowl) are tasted for briskness, strength, firing quality and other
characters contained in tea.
V. How to ascertain correct fermentation process by checking the appearance of liquors,
good color and body.
VI. How to use standard samples and standard of cuts samples, standard samples include:
BP 1, PF 1 and PD. Standard of cuts of 1st ,2nd ,3rd and 4th cuts in line A,B and C.
Boiler section
The following are the activities that I did in the boiler section.
I. How steam is generated, distributed and used.
II. How firewood is operated, utilized and their required ratios.
III. Identification of health and safety rules in the section.
IV. Boiler water treatment operations.
Water treatment operations
The following are some of the activities that I went through when I was at the
water treatment operation plant:
I. Operation of pump in pumping water from the water inlet dam to the storage tank for
treatment with chemicals and from the cleaning tank where chlorine is added to the
buyers/ consumers. Pump used was run by electricity.
II. Chemicals used in the treatment of water includes: Aluminium sulphate, sodium
carbonate and chlorine. Aluminium sulphate acts as a coagulant, sodium carbonate
acts as Ph booster and chlorine is used as a disinfectant.
Aluminium sulphate causes compression of the double layer and thus the
neutralization of the electrostatic surface potential of the particles. The
resulting destabilized particles stick sufficiently together when contact is made.
When they stick together they become denser and moves to the bottom where
they are blown out of the tank.
Sodium carbonate is a Ph booster since Aluminium sulphate work best in a Ph
of 6.5-7.5.
 Chlorine is added as a disinfectant due to the fact that it can kill micro
organisms such as bacteria.

Garage
The activities which I executed in garage section.
I. The use of shielded manual metal arc in welding purposes and process of welding in
garage section.
II. The importance of flux and the shielding gas during welding process.
III. Safety and health rules that should be adhere to in the garage section.
IV. How to use other machines in the garage section such as drilling machine,cutting
machines etc.

CHAPTER 6
6.1 CHALLENGES ENCOUNTERED DURING ATTACHMENT PERIOD
These are some of the challenges that I faced when I was in my industrial training attachment at
Litein Tea Factory:

I. Finance –The institution didn’t pay for the students on attachment program. I was
therefore required to use my pocket money in paying for rent and food.
 II. Inaccessible machines- The industrial chemistry student was not given an opportunity to
operate some of the machines, the operators would rather ask you to watch as you learn.
III. Inadequate facilities- The company or establishment did not provide enough facilities
and equipment which make the programme difficult for me because the company didn’t
provide accommodation for students.
IV. Problem of securing a place of attachment- I had most of problem searching for a place
for attachment. Most of institutions rejected my request giving reasons or the other that
they don’t want a student.

6.2 RECOMMENDATION OF HOW THE ATTACHMENT PERIOD CAN BE

IMPROVED BY THE UNIVERSITY
I. The company/establishment should also provide access to students to make use of their
machine know how to operate and make use of their machinery.
II. The company should pity student by providing allowance package to help them finance
their unavoidable needs.
III. The establishment should provide adequate facilities to make the program enjoyable to
students.
IV. The company should be willing to accept and encourage student that are seeking for
placement in their company.

6.3 CONCLUSION
My industrial training programme was very educative and enjoyable because the programme
exposed me to learn many things and to be self reliant without depending on anybody. I was able
to appreciate the theory on tea processing steps.

REFERENCES