TANGANDA TEA MUTARE FACTORY
Mutare factory is made up of the packing factory and the distribution warehouse both in the eastern border city of Mutare. The factory packs tea and coffee grown at the Tanganda estates in Chipinge but we could source these raw materials from anywhere else.
TANGANDA TEA PACKAGING FACTORY IN MUTARE
Just over 20% of the tea that is manufactured at the estates is brought to the factory for packing into the various brands for the local market and for export. Tea is packed in 3 formats these being loose leaf tea, tagless tea bags and tagged tea bags. A total of about 200 tonnes of tea is packed every month.
On the loose leaf brands, we pack Tanganda Tea, Tips Tea, Joko Tea, Stella Tea, Fresh Leaves Tea and Silver Tea. On the tagless tea bags range we pack Tanganda, Tips, Stella, Healthi Green and Moringa. On tagged tea bags we have Tanganda Special Blend, Tanganda Catering as naked tea bags and Special Blend, Healthi Green and Moringa in envelope tea bags for that personal touch ideal for hotels and airlines.
In addition to black tea, we also pack rooibos and this comes in 2 brand names, Nella and Natra in both tagless and tagged bags format.
The tea comes from four Tanganda Tea estates in Chipinge in its various grades in bulk form. The different grades which are mainly BP, BP1, PF1, PD, BM, D3, F2 and F3 are then blended using special recipes known by the blending team to come up with the brands mentioned above. The blending process is both a science and an art as it involves particle size analysis, sensory evaluation, moisture content analysis, density measurement, cup colour appearance etc in order to come up with consistent brands at all times. Each blend is allocated a code for traceability. This code can be traced back to the various grades that make up the blend, the estate/s that supplied the teas used, the gardens on the estate/s where the tea was grown, the date of manufacture etc. The blending floor is located above the packaging factory and the tea flows by gravity into the individual packing machine where it meets with packaging material and the result is the packed unit.
Packing materials come in various forms depending on the packing machine and the nature of product. There is laminated foil, filter paper, boxes, envelope paper, aluminium staple wire, thread, tags, glue, plastic sheeting etc. Wherever possible, the factory purchases these materials from local suppliers but can source globally depending on quality and pricing conditions.
BULK TEA IN VARIOUS GRADES FROM THE ESTATES
Most of the packaging is done on technologically advanced machinery acquired from Germany and Italy in 2014. Over 100 dedicated men and women are involved in the packing processes. Most of the machines are operated remotely from a user interface such that there is no handling of product and materials ensuring fully hygienical packaging. Such remote machine operations reduce chances of injuries to workers as people do not come into contact with moving machine parts. There has been a 60% reduction in injuries and near misses ever since the introduction of these machines.
The factory is certified to ISO 9001:2015 (QMS) and is gearing up for certification to ISO 22000 (FSMS). Checking of product for correct weight, correct sealing, correct presentation is a continuous process at every stage of the production process. In line with the ISO certification, it is the responsibility of everyone to ensure conformity to standards the final goal being customer satisfaction.
AN OVERVIEW OF THE PACKING FACTORY FLOOR
ZENOBIA LOOSE TEA PACKING MACHINE FROM TEEPACK, GERMANY.
PACKING FRESH LEAVES LOOSE LEAF TEA INTO CARTONS ON THE ZENOBIA MACHINE
THE PMD MACHINE PACKING TIPS LOOSE LEAF TEA.
IMA C51 MACHINE FOR PACKING TAGLESS TEA BAGS. Packing speed 1 400 teabags per minute
IMA C23 MACHINE FOR TAGGED & ENVELOPE TEA BAGS. Packing speed: 220 tea bags per minute.
FINAL SEALING OF THE PACKED CARTONS
The finished product is then moved to the distribution warehouse where it is stored in such a way that the first product in will be the first out for distribution to the other warehouses at Harare, Bulawayo and Gweru or straight to the customer.
ARRANGING PRODUCT IN THE FINISHED GOODS WAREHOUSE
LOADING PRODUCT INTO A DISTRIBUTION TRUCK
TANGANDA PRODUCTS ‘FIGHTING’ FOR SPACE & VISIBILITY IN ONE OF THE MAJOR SUPERMARKET SHELVES.