Business plan for the production of tea. Tea leaf processing

Tea is included in the list of the most consumed products in Russia, which means that a multimillion-dollar sales market is open for a novice businessman. Tea production - whether the tea business is profitable or not, what is the technology for making tea and the equipment necessary for this.

Varieties of tea

Tea spread around the world from China, where it was originally used as medicine. Now many countries and areas are engaged in own production tea, which is given their name - Chinese, Indian, Ceylon, Japanese, Indochinese, African.

All types of teas are made from the leaves of the tea bush, they differ in the degree of processing:

1. Black tea goes through a long fermentation process.
2. Green tea does not undergo fermentation or passes for a short time.
3. White tea is made from unblown buds (tips) and young leaves, withered and dried.
4. Yellow tea is prepared like green tea, simmered in a closed container until the drying stage.
5. Oolong is fermented for 2-3 days, acquires a specific taste and aroma.
6. Pu-erh is a green fermented tea with a long exposure.

Depending on further processing, teas are:

• Baykhovye - traditional sheet.
• Pressed - in briquettes, plates, tablets.
• Granular - crushed on special equipment.
• Extracted - instant teas in the form of a liquid extract or powder.
• Packaged - in addition to tea bags, they also produce products in sticks and capsules.
• Flavored - crushed additives are added to the tea or the leaves are stored next to the flavor and soaked in its smell. The most popular are jasmine, bergamot, lemon, mint.

Tea is consumed mainly as a drink, hot or cold. Less often - as seasoning and salad. Caffeine, vitamin P, dyes are also obtained from the leaves, and oil is obtained from the seeds.

Manufacturing technology

The most popular are two varieties of tea - black and green. Although the same raw materials are used for production, further processing differs. The first two steps in the production of any kind of tea are growing and harvesting.

The world leaders in the cultivation of the tea bush are China, India, Africa, Sri Lanka. The plant is demanding on living conditions, it needs a very warm and humid climate on the slopes of the mountains so that the roots do not stop in the water. In the tropics, they harvest 4 crops a year. On the territory of the Russian Federation, tea grows in the southern part of the Krasnodar Territory, where the climate is considered subtropical.

For the production of different types of tea, a certain type of leaves is used, mainly only the top of the bush, and for higher grades - the buds of the plant, so the collection and sorting is carried out manually. To get 1 kg of dry tea, you need to collect about 4 kg of fresh raw materials. Mechanized harvesting is used in the production of third-rate tea or pharmaceutical products. The first crop after planting is harvested after 2 years.

Making black tea

To obtain a fragrant drink, tea leaves undergo the following processing steps:

1. Drying.
2. Twisting.
3. Fermentation.
4. Drying.
5. Sorting.
6. Aromatization.
7. Packaging.

To remove excess moisture from tea leaves and give flexibility, they are subjected to withering - drying in the fresh air (in the shade or in the sun), indoors or in drying machines. The exposure time ranges from 4 hours using the equipment, up to 24 hours in natural conditions. The duration of this stage also depends on the initial microclimate and the type of tea produced. In different regions, shrinkage is adjusted to 40-50%.

In the open air, tea leaves are laid out on large baking sheets or nets with a layer of about 12 cm, shaken regularly to dry the entire mass, blown using special equipment. Normal conditions for withering - at a temperature of + 24-25 ° C and a humidity of 60-70%.

At the stage of twisting, the integrity of the tea leaves is violated, they become similar to the usual tea. This squeezes out the juice and starts the fermentation process. For the production of expensive elite varieties, manual twisting is used, tea of ​​lower quality is rolled in rollers.

The industrial method uses CTC (Crushing, Tearing, Rolling) equipment to produce granulated tea. The higher the degree of twisting, the stronger the welding will be.

The leaf rolling technology for producing long leaf tea takes place in 3 stages, 45 minutes each, at a humidity of 96-98% and a temperature of +22-26°C. Between them, the raw materials are divided into grades.

Fermentation is the chemical process of oxidizing rolled leaves to acquire the characteristic aromatic and flavor properties of black tea. Fermentation is carried out in special rooms at a humidity of 96-98%, a temperature of +15-22°C and a high oxygen content for approximately 3-5 hours.

Raw materials are laid out in layers of 10 cm on aluminum sheets. When the color of the leaves becomes dark and tea aroma appears, the process is stopped by high temperatures.

At the drying stage, the fermentation processes are stopped, the acquired color, aromatic and taste qualities tea, all remaining liquid is removed. Long leaf tea factories use equipment that operates at a temperature of about 100 ° C for 15-20 minutes, and drying is carried out to a moisture level of 2-5%. It is important to quickly cool the mass after the end of heating, so as not to overcook the tea.

The resulting dry tea mass must be sorted by size and quality of the components. In industrial factories, this is done using various sieves and the output is:

• whole leaf tea;
• broken tea;
• bran;
• chit.

At a large tea factory, the technological process stops at this point, wholesale batches of tea are sent to packaging enterprises. There, tea can be flavored, blended and additionally sorted. Then there is packaging in containers of various shapes and weights and sale to the distribution network.

Making green tea

The main difference in the way black and green tea is produced is the degree of oxidation of the leaves. To obtain black tea, complete fermentation is carried out, the production of green tea does not include the stage of oxidation, or the fermentation is carried out partially. As a result, green tea retains more useful substances in its original form.

Tea production technology:

1. Steaming.
2. Drying.
3. Excerpt.
4. Twisting.
5. Drying.
6. Sorting.
7. Package.

Steaming is carried out in ovens at 95-100°C for 2.5-3 minutes. Then the raw material is placed in drying, where within 15 minutes evaporates about 40% moisture at 90-95°C. Leaves prepared in this way are rolled on rollers once or twice within 70-80 minutes.

Then the tea leaves are dried in the same way as black tea is dried, with a semi-finished product of green color and a moisture content of 3-5%. After that, sorting, blending, flavoring and packaging are carried out.

Other types

Yellow and red teas are somewhere between black and green. They are obtained either by blending or by separate production cycles.

The fermentation of raw materials for the production of white tea is stopped by steaming for about a minute. When oolong is made, the 15-minute high-temperature drying is carried out several times in between the twisting stages. To obtain pu-erh, raw materials are stored for a long time at high humidity, while natural aging of tea occurs.

Equipment for the production of

In addition to plantations for the growth of tea bushes, the production of tea on an industrial scale requires the following equipment:

• dryers;
• mixers;
• crushers;
• presses;
• twisting machines;
• sieves with different mesh sizes;
• containers for blending;
• weighted equipment;
• packaging equipment.

There are ready-made production and packaging lines for loose and bagged tea on sale.

In Russia, due to the predominance of a cold climate, tea cultivation is possible only in the south of the Krasnodar Territory. There, this industry receives state support. However, to determine whether it is profitable or not to do business on tea, you need to draw up a business plan and calculate all the risks.

Although it is possible to grow a tea bush at home, it is economically justified to engage in a full cycle of tea production in the presence of large tea plantations. At the same time, multimillion-dollar investments will begin to pay off no earlier than in 2 years. Therefore, it makes sense for a novice entrepreneur to engage in contract manufacturing or open a tea shop.

Contract production of tea involves the production of products commissioned by third parties. To do this, you need to install the necessary equipment, obtain permits, purchase semi-finished tea from manufacturers. Trade enterprises that place orders for packing tea under their own brand can act as customers.

Opening a tea shop is the least expensive project both financially and organizationally. But in the trade sector, supermarkets, markets and cafes are more competitive.

mini plant

How to open a tea business from scratch? First of all, you need:

1. Register an enterprise in the form of a limited liability company so that additional capital can be raised.
2. Be registered with the tax authorities.
3. Get permission to operate.
4. Issue a declaration of conformity for the goods.

The production line takes up a lot of space, so an area of ​​​​about 100 square meters is required to accommodate equipment, warehouses and an administrative department. m. Communications, heating, electricity, plumbing must be in good condition, comply with the standards of SES and fire supervision.

The choice of filling equipment is quite large, you can purchase a new line or a used one. Specifications allow to produce about 60,000 packs of tea per month, 1,000 tea bags are packaged per minute.

Tea semi-finished product is purchased mainly from foreign suppliers, as there are few domestic raw materials. It is most profitable to purchase wholesale lots at a reduced price, however, it is difficult for beginners to immediately find a reliable manufacturer of quality tea in the world market, and at first they will have to work with dealers. Tea is packed in paper and cellophane bags, boxes, then in boxes.

3-4 operators, a shift supervisor, a technologist work in the production of tea. To service the mechanisms you need a mechanic and a handyman. Warehouse accounting is maintained by a storekeeper and an accountant, a manager is engaged in the purchase of raw materials and the sale of products. In total, 9-10 people will be required to operate the mini-factory.

Calculation of costs for the launch of the project:

№	expenditures	Amount, rub.
1	Registration and permissions	100 000
2	Room rental (for 2 months)	400 000
3	Repair	200 000
4	Equipment	1 500 000
5	Raw materials and packaging	100 000
6	Advertising	200 000
7	other expenses	500 000
Total		3 000 000

Monthly income planning:

Fixed costs for rent, utilities, salaries, purchase of raw materials and repair of equipment account for approximately 80% of gross turnover. The estimated payback period for investments is a little over a year. With such indicators, the factory can become a profitable enterprise.

Video: production of tea bags.

tea shop

The first thing you need to start tea trading is to find a room in a good place, at the intersection of traffic flows, near large shopping and entertainment centers. This arrangement will ensure the attendance of the store and a stable turnover.

To legally conduct business, it will be enough for the owner of a shop to register an individual entrepreneurship and register with the Federal Tax Service.

From the equipment you will need showcases, shelves, scales, a cash register. To sell loose tea, you need bags, jars, twine, adhesive tape, scissors, spoons.

Distinctive feature tea shops is high quality products and a large assortment, designed to attract regular customers.

Judging by the feedback from entrepreneurs, the tea business has a lot of advantages:

• It doesn't take a lot of money to open.
• The storage of tea does not require special conditions, it does not apply to perishable products.
• Tea is bought regardless of the season.
• You can expand the range by coffee, souvenirs, sweets, dishes.

To open a small outlet, you need to spend about half a million rubles, which will pay off within a year.

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Production technologies and tea are quite similar, however, the organization of a business related to the production of tea requires much more investment. It is worth noting that such a high investment with the proper organization of the enterprise is fully justified, therefore, if you weigh all the pros and cons of opening a tea factory, you will be interested in reading this article.

Features of the tea business.

Perhaps the fundamental feature of the opening of tea production is directly raw materials (this feature, by the way, increases the amount of necessary investment).

All tea, depending on the raw materials used to create it and the production technology, can be divided into:

1. Baikhovy - loose tea, is the most popular in Russia;
2. Pressed - tea made from scrap, or post-fermented tea of ​​a high category, such as pu-erh;
3. Granulated tea is produced according to a special technology: after oxidation tea leaf processed by a special device, which gives it a special shape;
4. Flavored - tea containing aromatic additives, such as essential oils, flowers, pieces of various fruits and spices;
5. Extracted tea. A type of tea that does not require brewing, thanks to the special processing of the tea leaf. May be presented as a powder, paste or aqueous extract.

Tea plantation in Indonesia

The raw material for the manufacture of any kind of tea is the tea leaf, but the whole problem is that this raw material requires a special climate for growth and special preparation conditions. In the Russian Federation, tea is grown exclusively in the Krasnodar Territory, so it is likely that in order to expand the number of tea suppliers, you will have to turn your attention to countries such as India, Kenya, China, Indonesia, Taiwan and Sri Lanka.

Cooperation with foreign suppliers will require costs and additional knowledge regarding the international transportation of goods from you. It should be noted that the raw materials that you plan to use for the manufacture of teas must have the necessary certificates and comply with the requirements of Russian legislation on the content of chemical and organic substances in products.

The process of making tea.

The production technology must be not only efficient, but also safe. Of course, first of all, you should think about fire safety. Be sure to purchase fire tanks (you can order on the website https://www.npommz.ru/pozharnye-rezervuary)

The production of tea consists of the processes of withering, rolling, fermentation and drying. In fact, all these processes take place at the tea manufacturer, which will be your supplier. You will open a tea-packing factory, the basis of which will be not technological processes for creating tea, but mechanical ones. You can additionally subject tea to blending, package and bring finished products to the markets.

To open a factory, you need to purchase a production line, as well as a filling and packaging line. The price of equipment is about 3 million rubles, this amount depends heavily on the brand and manufacturer, as well as on what type of tea your company will specialize in. The production line usually consists of dryers, presses, crushers, tea leaf curlers, sifters, tedders.

At your enterprise, raw materials will be screened in order to separate whole leaves from scrap: whole leaves will be used as raw materials for long leaf tea, and pressed tea will be made from scrap, thanks to presses. Blending drums are designed for mixing raw materials in order to obtain flavored teas. Rolling machines provide additional fermentation.

The premises for organizing a tea factory must comply with sanitary standards, have a constant temperature and a certain humidity. The factory should be equipped with large storage facilities.

For the operation of your factory, you will need to obtain permits, such as a registered recipe and production specifications, a hygienic conclusion from the sanitary and epidemiological service.

With a rational organization of production, the profitability is about 40%, and the payback period is about 2-3 years.

It is hard to imagine how many inventions civilization would lose if some of them were not spontaneous, invented by chance or by the will of a combination of circumstances. Starting with Archimedean "Eureka!" and the discovery of the hydrostatic law, ending with the first iPhone model, long called the “Jesus phone” by journalists. Between these events there were matches, Velcro, cornflakes and a number of other ideas and products, little known and popular. The production of tea bags was not originally conceived as an offshoot of the traditional bulk trade. The public embraced the packaging of tea in small bags as a new type of packaging that saves time in brewing.

Brief business analysis:
Business setup costs:225 thousand dollars
Relevant for cities with a population:from 800 thousand people
Situation in the industry:high competition
The complexity of organizing a business: 3/5
Payback: 16-17 months

Business Relevance

Man has been drinking tea since the beginning of the 7th century AD, and there is no reason why he would stop doing it. A product, the demand for which is constant, and there is no risk that this demand will sharply decrease, is axiomatically a product that brings income to the business owner. Thus, the question of whether the packaged drink business is relevant is not considered. Another thing is that in order to understand and calculate the prospects in the market, the simplest economic knowledge and analysis of the situation are needed.

Analyzing the demand for the product, let us mention that 6 billion kilograms of tea are consumed annually in the world. Think about this number. It is noteworthy that Russia ranks 4th in the world in terms of tea consumption per capita, although lagging behind Turkey by 2.5 times. Our southern neighbors drink 3.2 kg per person per year.

The popularity of the drink in the world does not lend itself to any dependencies and patterns: the historical traditions of tea drinking in a particular region are important. So, in the top five in the consumption of tea leaves, along with Turkey and Russia, are Great Britain, Ireland and ... Morocco.

The market is highly competitive. Raw materials are grown in 40 countries, the number of producers cannot be accurately estimated, but only in India, 20 million people are involved in the tea industry. This is more than the population of 2/3 of the countries on the planet. For these reasons, the importance of marketing research and market analysis in making a decision is great.

Types of tea bags

A common stereotype says that the production of tea bags uses low-quality raw materials or even waste. Stereotypes appear in order to confirm or refute them. Like bulk, packaged product is made from raw materials of various qualities:

• whole tea leaves, coarse or medium-ground, an option used by image-conscious companies;
• broken leaves - crushed raw materials of a certain fraction; popular brands of average price are made from such leaves;
• cuttings - fragments of a tea leaf of a small-sized fraction. Contrary to popular belief, they are not low quality raw materials, on the contrary: tea made from seedings is strong and tasty;
• tea dust - both production waste and a special grinding fraction for subsequent packaging in bags. Dust is the raw material for the production of product with fruit additives due to its ease of mixing.

In other words, a large tea leaf can be a low-quality raw material if the cultivation or storage technology is violated. On the contrary, tea dust is sometimes a high quality raw material, crushed only for the production of tea bags. For these reasons, the composition on the packaging and taste properties product will say a lot more than appearance.

The same types that are available on the market in a different package are packed in disposable containers. Black, green, flower tea, used in the manufacture of packaged products, is also sold in a 100-gram carton, 500-gram tin cans and other containers.

Tea is also divided into types depending on the material from which the bags are made. The cheapest packaging material is filter paper made from:

• wood fiber - 71% in the composition of the material;
• thermoplastic fiber - 19%;
• abaca fiber (manila hemp) - 10%.

Tea in paper bags was produced unchanged until the mid-1990s. When the market was saturated, there was a diversification of manufacturers towards the modification of bags, packaging made of fine-mesh plastic mesh, nylon, corn starch appeared.

Business organization

The production of tea bags is not a high-tech type of commercial business. The result of a business largely depends on the correct organization and choice of a market niche. The segment of a high-quality and expensive product is attractive due to the low degree of saturation with competitors and high margins, but is characterized by small sales volumes.

In turn, the distribution of a low-quality and inexpensive product implies a large number of distribution channels for the product. Due to the existence of thresholds for entry into attractive retail chains and low profitability, an inexpensive product has a meager profitability.

Answers to questions about the choice of goods that consumers need will be given marketing research market and negotiations with retailers through which the finished product is sold. Marketers of supermarket chains and food wholesalers have a picture of sales performance. Such primary information will help to make a decision about entering a particular segment of tea bags. Let us consider in detail the stages of production, taking into account possible difficulties and technological features of the business.

Workshop room

The correct choice of premises depends entirely on the characteristics of the selected production line. Until the conclusion of the contract for the purchase, supply and installation of equipment, it is impossible to calculate the amount of the required area, the availability of specific premises for the stages technological process. Mandatory components of production include:

• warehouse for acceptance and storage;
• manufacturing facility;
• warehouse for finished products;
• utility rooms equipped with showers and sanitary areas;
• office part for staff and manager.

Raw materials and finished products are subject to increased requirements for moisture content, for this reason, the premises are equipped with air conditioning systems, air dryers. Important milestone- correct calculation of electric power during the installation of power supply.

It is likely that the equipment will operate continuously, in three shifts, for this reason, a negligent approach to the installation of power supply will lead to equipment failure. Integral components when choosing a room of the desired type are water supply and sewerage.

In addition, when registering a business, the sanitary and epidemiological control authorities and the fire inspectorate will contribute to the requirements for premises. It will be necessary to install fire alarms and automatic fire extinguishing systems.

Raw material supply channels

In the production of packaged goods, the raw materials are tea leaves of the desired fraction and material for bags and packaging. Quality affects business outcomes. Choosing a reliable supplier of raw materials of consistent quality is a guarantee of business success. The supply contracts contain requirements in terms of humidity, required fraction, methods of delivery and storage.

You can buy raw materials on the domestic market, but in order to optimize costs, it is advisable to initially pay attention to tea producers. Prices of suppliers in the domestic and foreign markets differ by 1-2.5 times. Major suppliers are Sri Lanka, India, China and Indonesia. The supply of fermented tea is supposed to be ready for consumption and does not require additional processing with enzymes. Supply channels to the domestic market are established, and the delivery process is not difficult.

As noted, the choice of raw materials for tea bags directly depends on the market segment. When choosing the lowest price niche, tea is packaged in filter paper - this is the cheapest material for bags. Finding a supplier in the domestic market is not difficult.

If it is decided to produce an expensive product, special attention is paid to the material and design of the bags. A plastic mesh pyramid automatically transfers the product to the upper price segment. In pyramids, unlike flat rectangular or round bags, high-quality large-leaf tea is packed.

The company's marketers or outsourcers will help develop the original bag shape. There are bags in the form of a goldfish, clothes hangers, an umbrella. Even handmade knitted bags. There are no obstacles to the development of the original form of the bag, which will increase the recognition of the product at times. In a market saturated with competitors, it is necessary to be different, and packaging that is not similar to competitors' products can make a product successful, recognizable and sold.

The final packaging, pouch containers, is the third type of raw material needed for the production of tea bags. The requirements here are similar to the requirements for the shape and material for sachets. The manufacture of an inexpensive product involves the use of cheap cardboard packaging in the smallest possible color range. Such packaging is produced on its own or enter into a contract for the supply of finished packaging.

In the production of high-quality tea for the upper price segment, the packaging must be original, different from the forms presented on the market. Pyramids can be packed in tin tubes, wooden boxes - there is no limit to imagination and creativity.

Production technology

The technological process is quite simple and does not include complex labor-intensive stages. In general, the production process consists of several interrelated stages:

1. Supply of raw materials, subsequent quality acceptance, including defectology and the presence of impurities.
2. Crushing to achieve the desired fraction.
3. Finished product packaging.
4. Quality control and sampling.
5. Delivery of goods to distribution points under concluded agreements or trade from our own small wholesale warehouse.

Tea raw materials are delivered to the acceptance warehouse in multilayer paper bags. Upon receipt at the warehouse for acceptance, a mandatory acceptance for quality in accordance with GOST 1936-85 follows, followed by the signing of an act of acceptance and transfer of products. Quality indicators are fixed in the contract, each batch contains a quality certificate, issued by the Chamber of Commerce and Industry upon import. Significant acceptance criteria include:

• humidity 8% +/-1%;
• homogeneity and absence of impurities;
• fractional composition and mass fraction of fines;
• date of manufacture and shelf life (usually up to three years);
• number of packing places and net weight;
• other indicators according to the supply contract.

After acceptance, the raw material enters the crushing machine for grinding, bringing to the desired fractional composition. The tea of ​​the desired fraction then enters the automatic filling machine. The output is bags weighing about 2 grams, ready for packaging. The last stage can be manual or automated: finished bags are placed in the package and are the final product type. Packages are packaged in cardboard boxes and sent to the finished product warehouse.

Necessary equipment

The complex of necessary equipment depends on the size of own or borrowed funds, production volumes, type and form of products. The line can be complex, including integral units, and consisting of individual elements. The standard line includes:

• crushing machine;
• packing machine;
• packaging machine with the possibility of stacking in boxes;
• cellophane or wrapping machine.

Buying or leasing a production line is easy: equipment suppliers offer domestic and imported lines, new and used. The cost of equipment depends on the capacity for the production of finished products, the price of equipment is from $100,000 to several million dollars.

Business registration

Any business begins with the registration of a market entity - a legal or natural person with the chosen form of taxation. The next stage is obtaining and agreeing with the help of certification centers of technological conditions to ensure product quality. This process is regulated by the Federal Law of June 29, 2015 No. 162-FZ “On Standardization in the Russian Federation.

The conclusion from the sanitary and epidemiological control authorities is an integral stage in the preparation of documentation. The norms of sanitary rules are regulated by SanPiN 977-72 of 05/05/2017, the conclusion is drawn up at the nearest licensing center. Raw materials and finished products are fire hazardous materials, therefore, it is also required to obtain an opinion from the state fire supervision authorities. This document is issued by the regional departments of the Ministry of Emergency Situations.

Structural parts are also equipped technological instructions according to the rules and safety precautions when working with equipment of a certain type. If the budget allows, certification to ISO 22000:2005 (Product Safety Management System) will increase the capitalization and reliability of the business.

Marketing and distribution channels

Self-service and non-self-service stores, as well as wholesale buyers, occupy the main place in the structure of sales channels for packaged tea. In other words, stationary retail and wholesale outlets that sell food products. For this reason, the signing of contracts with these market operators comes to the fore when planning sales.

Sales volumes will be increased by specialized dealers - companies selling tea. Such market entities have well-established sales channels and knowledge about the main players in the market. Finally, the manufacturer enters into agency agreements with independent food retailers who are not major players and do not have distribution networks.

Efforts in advertising and marketing are aimed at increasing the recognition of the product, creating in the minds of end consumers of properties that distinguish them from a number of competitive products. Such distinctive properties are the original packaging, the shape of the bag, the number of bags in the package (for example, not 20, but 22).

A successful product has a memorable name and slogan. Marketing campaigns will help to increase sales and recognition: for example, a tourist voucher to a tea-producing country in every 10,000th package. Or a free tasting in supermarkets with the distribution of souvenirs. There are no limits to fantasy in this area.

Business costs and payback

It was noted that the key to the success of the tea bag business is choosing the right segment to enter. The amount of funds required for the purchase of equipment, the production of containers, and the wages of personnel depend on this. An approximate view of the cost of organizing a production with a capacity of 100 bags per minute looks like this:

• crushing machine: $10 thousand
• Packing equipment: $120,000
• Cellophane: $20,000
• Permits: $10,000
• Bringing the area to the requirements of regulatory authorities: $30,000
• Salary: $5 thousand
• Free working capital, inventory: $30,000

Less powerful equipment will commensurately reduce the cost of entering the business, more technologically advanced and productive equipment will increase costs accordingly. The expenditure part will be $225,000. With one work shift, the production volume will be 46,200 packages of 20 packages each. With a finished product price of $0.7, the gross revenue is $32,340.

In the value of gross income, 15% is wages, 30% is the cost of raw materials and packaging. 5% will be taken away by advertising and marketing of products, 3% - utility costs, 5% - fixed and transportation costs. Thus, the profit before tax is $13,583, the profitability is at the level of 42%, the payback is 16-17 months. Accurate calculation is possible with knowledge of the chosen form of taxation.

Tea is a traditional tonic and healthy drink, the volume of consumption is characterized by seasonality and tends to constantly grow. The market is saturated with competitors, but the potential of the market is open to new players. Current market participants do not have sufficient production or import capacities to fully meet current demand. Competent organization and an exact hit in a niche with an unmet need allow us to talk about the success of the idea for the production of tea bags.

Overview of automatic tea bag production line

Here are a few types of plants that are traditionally used as tea additives.

• mint,
• Melissa,
• yarrow,
• raspberry,
• currant,
• chamomile,
• calendula,
• rose flower,

1. Organizational moments

To start activities, you need to register with the tax office, to start activities, the organizational form “Individual Entrepreneur” is optimal, as well as choose the form of taxation, the most suitable form is “Simplified taxation system, income minus expenses”.

1.1. Obtaining permits

To start tea production, you need to receive the following documents from SanEpidemStation and RosPotrebNadzor:

1. Specifications agreed and registered (TU)
2. Technical instruction (TI)
3. Recipe
4. Permission from the veterinary service
5. hygienic conclusion of SES for production
6. Other (according to the individual characteristics of the project)

The list of documents is large and the collection of all documents takes considerable time, you can either do everything yourself (for a long time), or contact specialized companies that will do everything themselves and relatively quickly, but for a fee.

2. Opening of a tea shop

2.1. Equipment

There are many offers on the Internet for the sale of equipment for the production of tea bags, the most popular are Constanta automatic equipment. (capacity 130-150 bags per minute) and automatic equipment EC-12 (capacity 120 bags per minute).

This equipment can produce leaf or herbal tea as well as fruit teas.

The cost of equipment differs from the brand of the machine, year of manufacture and modification. So the prices for new equipment start from 100,000 euros, used equipment can be bought for 35,000 - 40,000 euros.

2.2. Room selection

Room requirement:

The premises in which the organization of production is planned must comply with the requirements of the SES.

The premises should have several rooms, in one warehouse of raw materials, a warehouse of finished products, a production site, and staff rooms.

The building must have electricity and water supply.

2.3. Staff

To service a small tea production workshop, the staff should have the following employees:

• Director (general management, product sales),
• Technologist (composes a recipe, controls the quality of raw materials and finished products),
• Workers 3 persons (engaged in the production and packaging of products).

2.4. Raw material suppliers

To produce a high-quality and competitive product, it is necessary to choose good suppliers. There should be no problems with suppliers, there are many offers on the Internet for the sale of both loose tea and various medicinal herbs.

You can organize the reception of various field herbs from local residents of the countryside by advertising in advance.

2.5. Markets

Finished products can be sold through several distribution channels:

• Federal and regional grocery chains
• Specialized tea shops
• Internet - shop
• Pharmacy chains

3. Feasibility study

3.1. Capital expenditures:

• Packaging equipment EU-2 (used from 1996) - 1,700,000 rubles
• Obtaining permits - 150,000 rubles
• Repair of the premises (according to SES standards) - 500,000 rubles.
• Holding advertising company: 500,000 rubles.
• Creation of inventory, other 500,000 rubles
• Total 3,350,000 rubles

The productivity of automatic equipment EC-12 is 120 bags per minute or 6 packs of 20 filter bags. For a month (22 days) at 8 hours, this equipment can produce 63,360 packages of tea, with a selling price of 30 rubles per pack, monthly revenue (with 100% sales of manufactured products) will be 1.9 million rubles.

The cost of tea production includes the cost of raw materials and electricity, the markup depends on the type of product, but on average, somewhere around 50%

3.2. Economy

7.3. Payback

The payback of the shop for the production of packaged tea is 14 months.

Many enterprising businessmen have already turned their attention to the manufacturing natural products. And not in vain - today it is used among the population, due to the dominance of low-quality artificial products, in high demand. And looking for an idea of ​​just such an orientation, it is worth thinking about buying equipment for the production of Ivan tea and starting its mass production. Ivan-chai has long been called "Russian tea". This plant was previously exported in large quantities abroad. From the dried stems, leaves and flowers of willow-tea, you can get a delicious drink, also famous for its useful properties- Prevention of many diseases, sedative.

Our business valuation:

Starting investments - from 0 rubles.

Market saturation is low.

The complexity of starting a business is 4/10.

The production of Ivan tea as a business will be beneficial to the entrepreneur from the point of view that it does not require large investments. Let's say more - you can get the finished product right at home, without spending money on the purchase of special equipment. Making Ivan tea at home is not difficult at all, and, following the technology, you can end up with a product that does not differ in quality from what is produced in a full-fledged factory.

Will business registration be required?

Whether it is worth registering your activity, you need to look at the circumstances. If an entrepreneur sells only surpluses from his own subsidiary farm, and Ivan tea is sold only to friends and closest neighbors, then it is hardly worth spending money on processing a package of documents. But with non-certified products, it will not be possible to enter larger markets and conclude profitable supply contracts! Do you want to deliver a quality product, with labels and packaged in original packaging, to store shelves? Then, observing all the rules prescribed in the legislation, you will have to deal with the registration of activities. To produce granulated Ivan tea, as we are talking about food industry, you will need to obtain permission from Rospotrebnadzor to conduct activities and certify the products planned for release. Also, an entrepreneur may think about obtaining a special certificate for the production of a line of healthy teas as dietary supplements.

It does not matter what organizational and legal form the entrepreneur chooses to conduct business. To avoid paperwork, you can first issue an IP.

A mini plant for the production of Ivan tea will supply original products to store shelves if you register your own brand. Here you have to develop your own logo and label design.

What range of products can be produced?

While the technology is only being mastered, an entrepreneur can only produce ordinary tea. But as practice shows, the product is also in demand on the market in a mixture with other components - dried berries and leaves of currants, raspberries, lemongrass. There are a lot of variations, and for a variety of assortment, you can expand the product line.

There is another classification. Depending on what were the fermentation conditions for Ivan tea, the following types can be distinguished:

• Weakly fermented - white, yellow, green.
• Semi-fermented - red, purple, blue.
• Fermented - black.
• Fermented - pu-erh.

And even fermentation of Ivan tea at home will allow you to get different types product.

Where to get raw materials?

The raw material for the production of natural tea is the plant willow-tea angustifolia. Surely everyone saw it in their own dacha or in the field - very often it grows like a weed. It turns out that there are plenty of raw materials for further production. Of course, it is useless to look for dried leaves from suppliers - as a rule, Ivan tea is collected and prepared on its own.

Depending on the specific region, the collection of plants is carried out from June to August. Moreover, it is better to pluck the plants in the early morning - when the dew has just evaporated.

If you believe the experts in this field, then in an hour it is quite possible to collect up to 5 kg of fresh raw materials. But the preparation of Ivan tea leaves should be carried out in a timely manner, because if you leave it for a long time in bags, the leaves will begin to darken and lose their beneficial properties.

To get tea at home, you can collect plants yourself. But if we talk about the industrial scale of production, then in order not to miss the harvest of Ivan tea and in a short time to provide the enterprise with large reserves of raw materials, one cannot do without additional labor. Payment to hired workers can be made by the volume of raw materials collected or by the hour.

Tea production technology

Ivan tea production technology is very simple. And in industrial conditions, the process is almost completely automated.

What stages can be distinguished here?

• Withering. Removal of moisture from leaves to create optimal conditions for further processing of raw materials.
• Preparation of raw materials. Leaves, stems and flowers are cleaned of debris, if necessary - sorted.
• Rolling leaves. The goal is to destroy the cell walls and give the leaves the desired shape.
• Aerobic fermentation. Exposure of leaves under certain temperature and humidity conditions.
• Drying. The goal is to complete the fermentation process.
• Roasting. Processing a product under certain conditions to give it final properties.
• Package. The product can be packaged in containers of any volume.

And at home, getting the finished product is not difficult at all. To do this, freshly picked and slightly dried plants need to be crushed in their hands so that the leaves release juice. It is also possible to ferment Ivan tea through a meat grinder. And this option is even better, since all biochemical processes will go much faster in the future. Wet leaves are “packed” in gauze and placed under oppression in a dark place (up to 2 days). Next, the leaves of Ivan tea are dried. You can do this outdoors in partial shade or in the oven.

What equipment is used to produce Ivan tea?

If we talk about a home business, then in the process of obtaining a finished product, you can use improvised “inventory” - knives, a meat grinder, an oven, baking sheets, containers. But the industrial method will necessarily require the availability of special machines, since considerable volumes of raw materials will be processed here. The price of equipment for the production of Ivan tea will vary in a wide range (800,000-2,000,000 rubles), depending on the power, degree of automation and configuration.

The complete line includes the following names of machines and devices:

• leaf cutter,
• wrapping machine,
• rollerballs,
• tea lump breaking machine
• fermentation machine,
• automatic dryer,
• bake,
• packaging machine.

To get tea packaged in disposable bags at the exit, you will need to purchase a special machine separately.

The industrial production of Ivan tea in Russia is still poorly developed, but some domestic companies already offer for sale machines for obtaining quality product. A specific line should be chosen based on the planned sales volumes of tea and available investments.

The issue of sales and profitability of the enterprise

The product is in demand on the market, so there should be no problems with its sale. True, at first, most likely, you will have to cooperate only with private shops and shops, and not with large retail chains.

The payback period will depend on the investments invested in the business. If there is a meat grinder for Ivan tea and an oven, then no investment may be required to start a home business. Industrial production of the product can be established by spending at least 1,500,000 rubles.

The fermentation methods for obtaining tea are different, and therefore the price of the finished product also varies. On average, Ivan tea is sold at a price of 800-1300 rubles / kg. At the same time, its cost is lower by 40-60%. These are excellent indicators of the profitability of the planned business.