Gradation for Green Tea Bags: Why Precision Screening Matters — and How the Sivtek Tumbler Screen Delivers It

Introduction—gradation is where tea-bag quality begins

For green tea bag manufacturers, grading leaf size is not a cosmetic step — it determines steeping consistency, infusion rate, pack appearance and, ultimately, consumer perception. Evenly graded leaves guarantee a consistent production of sachets which brew, instead of over- or under-extracting, and blockages of the filling line is avoided.

When tea leaves are processed at scale, even small variations in particle size can translate into inconsistent brewing behavior, excess dust generation, and operational inefficiencies during packing. As a result, gradation becomes a critical quality-control stage — not just a preparatory step.

Why leaf gradation is mission-critical for green tea bags

Green tea bag production demands a narrow, controlled distribution of leaf sizes for three reasons:

• Brew consistency: Similar particle sizes extract at consistent rates; oversized pieces under-extract while fines over-extract.
• Packaging performance: Uniform fill volume, reduced dusting, and fewer nozzle clogs in high-speed baggers.
• Consumer experience: Appearance and mouthfeel matter — visible dust or uneven leaf sizes harm perceived quality.

If gradation is overlooked, brands pay hidden costs through rework, downgraded packs and customer complaints.

Typical gradation challenges with green tea leaves

Leaf gradation presents unique challenges that differ from grain or powder screening:

• Delicate material: Leaves are fragile and tear easily; aggressive vibration creates fines.
• Variable bulk density: Leaf fluff and stem fractions behave differently on a screen.
• Mixed contaminants: Stems, large clusters, and dust often coexist.
• Throughput vs. gentleness: High line speeds need their full capacity because they need to protect leaf integrity during performance.
• Dust control: Tea dust influences the quality of the product and the hygiene in the workplace.

The solution to these problems consists of separation technology that integrates with, rather than goes against the leaf structure.

How the Sivtek Tumbler Screen solves leaf-gradation problems

The Sivtek Tumbler Screen is engineered specifically for gentle, multi-stage separation of leafy and fibrous materials.

• Low-impact tumbling motion: It facilitates the process of stratification, as it does not damage the fragile leaves of the green tea.
• Multi-deck gradation: Allows the grading of oversized stems, bag-grade leaf and dust simultaneously – removes secondary handling.
• Controlled residence time: Adjustable Feed and Motion Parameters Allow for Exact Cut Point Control Over Several Varieties of Tea.
• Consistent mesh performance: This is designed to reduce the effect of blinding and preserve the accuracy of separation.
• Hygienic, low-retention design: Supports fast cleaning, reduced cross-contamination, and efficient grade changeovers.

The result is a dependable, repetitive gradation which ensures the quality of the product as well as the packaging efficiency of the downstream.

Process control insight for tea bag manufacturers

Effective green tea bag gradation depends on maintaining stable particle distribution throughout production. When screening parameters are matched to leaf morphology and packaging speed, manufacturers achieve cleaner separation, lower dust carryover, and smoother bag-filling performance — turning the grading stage into a quality assurance checkpoint rather than a corrective step.

What manufacturers gain

• Brew behavior consistency across production batches
• Cleaner packs with better visual and sensory quality
• Fewer stoppages on the bagging line and less weight variation
• Lower rejection, rework, and dust-related losses
• More ability to react to numerous tea grades and blends

Conclusion

Gradation determines how a green tea bag performs — both in the cup and on the production line. The Sivtek Tumbler Screen transforms heterogeneous tea leaves into consistently graded fractions while preserving leaf integrity and supporting high-throughput operations.

Contact Galaxy Sivtek to schedule a technical consultation which will help you enhance tea bag quality and decrease dust emissions and achieve stable packing results. Our experienced professionals can assist you in determining the correct screen configuration and separation parameters based on your tea type and production needs.