Ready-to-drink herbal and functional teas are one of Southeast Asia’s fastest-growing beverage categories. A wellness brand in Kuala Lumpur engaged us to design a turnkey RTD herbal tea line that could faithfully reproduce their traditional botanical recipe at scale while meeting strict clarity and shelf-stability standards.
Project Background
The brand had built a loyal following with small-batch brewed herbal teas but could not scale manually. They needed automated extraction, precise blending, and a filling process that would not degrade the delicate aroma of their chrysanthemum, luo han guo and honeysuckle blend.
Line Configuration
- Extraction: multi-stage counter-current extraction tanks with temperature control for herbs and tea leaves
- Filtration and clarification: bag and plate filtration plus centrifugal clarifier for a clear finished tea
- Blending: automatic batching of extract, sweetener and functional additives
- UHT sterilisation with holding tube for commercial sterility
- Hot filling: 6,000-8,000 BPH into PET or glass, with capping under controlled temperature
- Cooling, labelling and secondary packaging
Challenges Solved
Herbal extracts are prone to sediment and colour drift after sterilisation. Our two-stage clarification plus a validated UHT profile delivered a stable, sediment-free product with true-to-recipe taste. We also tuned the hot-fill temperature to protect heat-sensitive aromatics.
Results
The client moved from a few hundred bottles a day by hand to several thousand bottles per hour with consistent quality. The stable, preservative-light formulation supported their premium wellness positioning and enabled national retail distribution.
Ready to scale your herbal or functional tea brand? Explore our Herbal Tea Production Line.
Related case: browse more turnkey beverage project cases.
