CONTINUOUS FERMENTING MACHINE

INTRODUCTION Planters are aware of the fact that Fermentation is the single most important factor affecting the Quality of black tea processing. The traditional system of floor fermentation has been widely accepted by Tea Industry but it suffers from inherent disadvantages of requirement of large floor area besides being labour intensive, batch production type & difficult to optionally control the Fermenting time. The introduction of Trough Fermentation System, popularly known as Gumlah Fermentation, with forced draught through the material, though reduce the space requirement considerably yet remained labour intensive with the same inherent problems faced to maintain correct parametric conditions of floor fermentation with an additional inconvenience due to handling of higher thickness of material. The most important disadvantage in both the systems is their inability to design a continuous online process system between Rotorvane & Grading. Mechanized fermenting operation therefore became an obvious necessity. In the past decade Vikram had continuously been researching on the development of Continuous Fermenting Machine to suit the custom needs of different clients & can today boast of at least several different models of Fermenting Machines which ensures more uniformity of the oxidation process due to higher opening area (40%), more hygienic in operation, easy to maintain & more aesthetic in look. THE CONCEPT The macerated & sized leaves are fed to the short feed PVC conveyor belt where it is spread to the desired width of the main PES Belt / Tray with the help of an incorporated helical spreader on the feed conveyor at desired thickness. This spread sheet of leaf drops into the feed end of the PES Belt / Tray Fermenting Surface. Humidified air controlled at around 95% R.H from a suitably designed humidification unit consisting of a misting / air washer chamber & a centrifugal blower fan, is supplied through ductings to the modular plenum chambers under the moving belt / trays. The oxidation / fermentation process can be regulated through individual controlled dampers in each module. Wide ranging speed / time variation essential for proper fermentation is done by an effectively & sturdily designed variable drive system. PES BELT CFM SALIENT FEATURES M/C Load Capability: The fermentor Belt with standard supplied motor is designed to sustain a loading of upto 8 kgs of macerated leaf / sq.ft area. Low Height: The machine is only 47 high from the ground level, easy to supervise, clean and maintain. Pes Belt: High tensile woven PES Belt of varying width & higher opening percentages (upto 46%) allows more humidified air through the leaf for proper fermentation as well as cooling of tea bed. Drive: A sturdy variable speed mechanical drive system facilitates wide variation in fermenting time from 30 minutes to 140 minutes in steps of 2-3 mins. With optional electrical variable speed drive unit more infinite variations can be available. Controlled Feed: A suitable Feed Conveyor with variable speed arrangement is provided for uniform controlled feeding, which automatically enhances the performance of the machine. Discharge conveyor can be incorporated on customers request at extra cost. Air Distribution: An aerodynamically designed air duct facilitates uniform distribution of humidified air at 95% RH through the effective area of the machine to ensure uniform and even fermenting. Centrifugal Blower: A dynamically balanced centrifugal blower suitably designed to carry the humidified air from the mist chamber to the air duct through a ducting system is provided to achieve the desired temperature graph as well cooling of tea leaf. (Air Chamber to Blower mouth duct is optional). Hygiene: Suitable design features are incorporated to check bacterial contamination. Self cleaning easily removable brush cleans the PES Belt in the return circuit. The return circuit of PES Belt is exposed for easy inspection and maintenance. Flexibility: Suitable for both CTC and orthodox manufacture. Design: Neat as well as sturdy. The tea bed is uniformly and evenly maintained throughout. All parts are easily accessible for inspection, cleaning and maintenance. No accumulating or spillage of tea. Low Maintenance Cost: This machine is ideal for on line manufacturing process.