Tea processing

African tea processing industry seeks sustainability and efficiency improvements with DCO Systems

Customer challenge

Black tea processing is energy extensive. Volatility in world oil prices led to many factories switching from oil to biomass (especially wood) to fulfil their steam generation requirements. While this led to a reduction in fossil fuel costs, factories face new pressures. Costs, environmental impact and sustainability of their fuel sources are of concern. The need to identify areas of waste and improve efficiency is more important than ever.

East Africa (especially Kenya) is one of the leading producers of black tea in the world.  In the meantime, world tea consumption is predicted to reach 3.3 million tonnes in 2021. As a result, production continues to increase and yet the need to improve sustainability rises with it.


DCO Systems has implemented our sensing devices and customised monitoring systems throughout the five main stages of tea processing (Withering, CTC, Fermentation, Drying and Sorting). We provide turnkey solutions, developed with tea processors, that optimise production and raise quality standards.   

A typical, medium sized, tea processing factory may require upwards of half a megawatt of electrical power when operating at full capacity and require the generation of more than 6,000kg of steam per hour.  

The savings from optimisation of energy consumption in this environment are considerable both in terms of cost savings and in respect of reduced emissions. High rates of return on investment (ROI) are possible through considered and measured optimisations. 

What monitoring solutions do you need? We are happy to discuss how DCO Systems can implement or upgrade and extend your existing monitoring efforts. To get started with DCO’s affordable monitoring tools, go to our contact page or email us at info@dcosystems.co.uk.

Take control of your costs while making savings on your engineer's time. Eliminate the need for costly electrical installations and battery replacements. Our affordable pricing options begin with a low-cost capital investment that can be scaled up to suit your needs.

Gain a more complete understanding of your entire plant using our whole system monitoring approach regardless of equipment age, size or complexity. Easily pinpoint and diagnose a range of problems in seconds and fix system issues more quickly than before.

We offer energy harvesting sensors as a maintenance-free and battery-free IIoT solution. Our truly wireless equipment sensors can harness power from thermal, vibration, solar and electrical induction. This ensures reliable operation in varying environmental conditions.

Our clients receive valuable data on any device at any time. Real-time alerts and notifications are sent to your smartphone, laptop or tablet in easy-to-read chart format. As the information is stored in a cloud-based dashboard, data can be viewed wherever you are, day or night.

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3 Global Business Park
14 Wilkinson Road
Cirencester GL7 1YZ
United Kingdom

+44 (0)1285 359059

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