Tea Manufacturing & Packaging

1. Assignment
On
Tea Manufacturing & Packaging
Course Name: Tea Manufacturing & Packaging
Course Number: FET 425
Submitted To
Mr. Md Afzal Hossain
Assistant Professor
Department of Food Engineering & Tea Technology
Shahjalal University of Science and Technology, Sylhet.
Submitted By
Avisheak Ghosh Reg. No: 2011337053
Mahmudul Hasan Reg. No: 2011337061
Fatema Farhana Reg. No: 2011337062
Mamunur Rashid Reg. No: 2011337069
Department of Food Engineering & Tea Technology
Date of Submission: 12 October, 2017
Shahjalal University of Science & Technology,
Sylhet

2. Contents:
1. Manufacture of Black Tea
2. Withering
3. Orthodox manufacture, Un-orthodox manufacture
4. Fermentation
5. Drying
6. Sorting & Grading, Storage & Packaging
7. Tea Testing
8. Green tea
9. Processing of Instant tea
10. Organic tea
11. Semi-fermented tea
12. Quality control of Tea

3. Introduction:
Tea is the oldest and the most popular aromatic beverage in the world today. Millions of people
across the world begin their day with a hot cup of tea and there are scores of people in the
modern world who can’t live without it. It refreshes our body & mind. Tea is a refreshing
beverage which is produced and processed by some series of steps. We can say that as long as
humanity exists tea exists
Black Tea Manufacturing :
Leaf quality assessment: Greenleaf loaded lorry/tractors are after weightment taken at trough
house unloaded very soon and spread over trough beds as early as possible. Ballometer count and
leaf analysis is done before withering.
Leaf Standard: The liquoring quality of a tea is measured in terms of total oxidisable matter
(catechins) or primary polyphenols and caffeine. If the plucking is coarse, the percentage weight
of two-leaf shoot will be much less. An average plucking standard should have ideally about
75% fine leaf by weight comprising bud and two leaves, soft banji, undeveloped bud plus two
leaves. For achieving quality the fine leaf should not be diluted with coarser leaf. Approximate
contribution of different shoot components in different plucking standards is given hereunder.
Depending on the plucking standard, the tender components of the shoots vary as follows: Shoot
component % in 2 and a bud % in 3 and a bud Bud 14.0 7.0 1st leaf 24.0 12.0 2nd leaf 45.0 24.0
3rd leaf 33.0 3rd leaf Upper stem 17.0 8.5 Lower stem - 15.5 12 The figures given above may
vary because of climatic and other factors, but are fairly representative. Imperatively increase in
fibre content and ashy substances as well as decrease in enzymic activity and soluble solids in
the coarser leaf affect quality.
Analysis of green leaf: Quality of made tea depends on plucking standard. So analysis of green
leaves is necessary. Analysis of green leaves is done in two ways as Ballometer and count leaf
count.
Ballometer Count: Green leaf shoots equivalent to 100 numbers of balls of equal size are
picked up at random from each withering trough and thereafter these are separated into fine
leaves and coarse leaves. The fine comprise of two leaves and a bud, smaller shoots and also soft
banjis. The separation of fine leaf from coarse leaf is done, where necessary, by breaking back
the two and a bud/soft banji from the plucked shoot. In the case of three and a bud shoot, the two
and a bud comprises the fine leaf and the rest of the broken stem is coarse leaf. Thereafter, the
fine leaf is weighed against the equivalent number of balls/coins and this gives the
Ballometric/Paisometric Count. It may be noted that the loading of the trough should be done
prune-wise, plucking challan-wise and also section-wise, if possible, for each of the three

4. weighments. Leaf/Bud Count: Total hundred shoots are collected at random from each plucking
challan for each of the three weighments and thereafter these shoots are separated into one and a
bud, two and a bud, three and a bud, single banji, double banji and 13 single/coarse leaf. This
count enables tracking of the percentage of different sizes of shoots being plucked. Damaged
Leaf Count: Total hundred shoots are collected at random and are separated into damaged shoots
on one side and undamaged shoots on the other side. The damaged shoots are counted and this
gives the Damaged Leaf Count for each of the three weighments. Analysis of green leaf by
counting: Leaf % by weight one leaf and a bud 10% two leaf and a bud 65% three leaf and a bud
05% Soft single bhanji 15% Soft double bhanji 05% 100% Bolometer count- Soft leaf 70% hard
leaf 30% 1.1.3 Reasons of green leaf damage: The flowing are the main reasons of leaf getting
damaged – When the large quantity of leaf is tightly held up in the pluckers hand. Pressed to the
baskets/leaf cloths. Compressed walking or sitting on the top of the leaf. Bulked in large
quantity or shaken during transportation. Exposed to sun. Damage during transportation.
Damage by heat.
Green leaf handling: Effect of leaf packing Density in Baskets/Leaf cloths: Tightly packed leaf,
gets heated easily as respiration continues after plucking and heat cannot escape. Unless the heat
generated due to the exothermic reaction caused by respiration is allowed to dissipate,
temperature of the leaf mass continue to increase and the rise may even be beyond 10°C. Storage
of leaf in heaps in excess of 8 kg/m2 of floor area has been found to lead to heat development
that affects quality. Ramming or compression of leaf into the basket results in ripping of leaves
and generation of excess heat leading to oxidation (fermentation) even before the arrival of the
leaf in the factory. With the compactness of packing of the leaf in the basket/bag there is a
considerable loss of quality of the made tea. There is a significant decrease in TF content, as the
Theaflavin (TF) get converted to Thearubigin (TR) over the time. This ultimately reduces
brightness and briskness of the tea. The rise in temperature disturbs the entire cell component
resulting in likely occurrence of enzymic oxidation of catechins prior to maceration, which is
undesirable. Thus one must take utmost care while packing the leaf in basket/bag at the field.
Effect of green leaf temperature on made tea quality: The principal precursors for liquor
characteristics are primary polyphenols, which through enzymatic processes are converted to
large polyphenols like TF and TR. Leaf temperature and storage time have got a significant
effect upon the variation of TF and TR profile. The effect is more prominent when the leaf
temperature rises beyond 35°C. Rise of temperature increases the enzymic oxidation of primary
polyphenols and the products, which are formed by the oxidation process, overtakes the enzymic
hydrolytic reaction desirable for quality.
Effect of physical damage of leaf on made tea quality:Apart from damage of the quality
attributes in green leaf due to heat generation, leaf can be damaged through rough handling,
causing bruise and tear in the leaves. Cell damage is the ultimate objective in the manufacture of
black tea. However, if the damage is initiated before withering and is indiscriminate, the leaf
may undergo uneven oxidation process adversely affecting the desirable chemical constituents in

5. the end product. Also, damaged leaf withers at a faster rate, as the structure of cuticular waxy
layer of the leaf is disturbed. This ultimately influences the water holding capacity of the leaf and
will lead to uneven wither.
Effect of red leaf formation and quality of made tea: The green leaf can turn brown/red as a
result of physical damage arising from bruising of leaf and heat stress. The red color is observed
to be prominent when the leaf temperature exceeds 35°C. The increase of red leaf percentage has
got detrimental effect on quality. The cause of red leaf formation is mainly due to oxidation of
polyphenols. Reddening of leaf may occur more rapidly when the leaf temperature exceeds
40°C. With the increase in percentage of red leaf formation there is significant increase in
undesirable TRs. It will reduce brightness and briskness of liquor along with reduction in
essential “volatile flavour constituents” (VFC) of made tea. Careless handling and transportation
resulting in bruising and tearing, therefore, leads to reduction in quality. Care should be taken to
allow the heat to dissipate and avoid friction to save the leaf from bruising and tearing. It is
imperative to remember that the shoots as raw material, determine the value of the end product.
During manufacture the value can decrease due to faulty operation, but the inherent quality
attributes cannot be enhanced. It is, therefore, essential that the quality attributes be not affected.
Chemical changes after plucking: Once the leaf is plucked the anabolic reactions practically
cease and catabolic reactions leading to the breakdown of large organic compounds to simpler
molecules start. Burning of sugar molecules produced earlier through photosynthesis provides
the energy required to run these biochemical reactions in the shoots. There is rise in temperature
in the mass of the plucked leaf during storage and transportation due to respiration as well as the
aforesaid reactions. In the process of respiration organic substances in the cells (usually sugar)
get oxidised into carbon dioxide and water with release of fairly considerable amount of water as
may be seen from the following equation:
C6H12O6 (Glucose) + 6O2 (Oxygen) = 6CO2 (Carbon dioxide) + 6H2O (Water) + 674 calories
(Heat)
After the leaf is plucked, biochemical reactions are initiated towards biological degradation of
the shoots. In this direction, large molecules like cellulose and lignin, which are responsible for
the rigidness of the shoots degrade to make the shoots more flaccid. Lipids carbohydrates etc.,
which are also large molecules, degrade. Carbohydrates degrade to produce sugars, which burn
in presence of oxygen and produce energy to run various biochemical reactions, which are
enzymatic and temperature dependent. If in the plucked shoots sufficient oxygen is not available,
anaerobic reactions take place. Those reactions produce much less energy than aerobic reaction
mentioned above. Secondly, the results of anaerobic reactions are different and are not desirable
for making quality teas. Adequate oxygen availability is, therefore, a must. The lipids degrade to
produce smaller molecules, which are quality attributes. Therefore, if before the lipids are
degraded, cell rupture and manufacture are initiated, quality attributes will be missing. It is,

6. therefore, essential to make the lipids degrade by providing proper conditions, i.e. temperature
and time. 17 Following points should be taken into special consideration while spreading of leaf:
- No delaying of green leaf loaded lorry/tractor to be unloaded at trough house and spread over
trough beds to arrest generating lean heat and leaf burning which lead to loose of bio chemical
parameters which means tea.
- Leaf weighment taken should strictly monitor.
- Unloading of leaf is to be supervised to minimize damage. Sharpen bamboo or wooden stick
should not be used while unloading leaf to minimize damage.
- Leaf condition on arrival i.e. wet or dry, red or damaged should be noted against the
appropriate trough number in the withering control register. Source of damage should be
rectified.
- To ensure minimum damage and good uniformity in the weight-tovolume ratio, handling and
spreading of leaves should be done carefully and evenly.
- Should be organizing to achieve rapid turn round of vehicles and reduce holding periods of
bulk loads to avoid heating of leaf.
- If there somehow few brunt leaves come from field should be sorted out while spreading
leaves. - Bolometer count and leaf analysis should be strictly done duffa wise at trough house to
check the leaf quality and should meet the desire level.
TWO WITHERING OF GREEN LEAF “Good teas are made in the withering house” – this
statement is indeed true! Withering plays a major role particularly in CTC manufacturing
contributing significantly to quality. So our utmost effort must be there to achieve correct degree
of weather. In practice, weathering is a rather simple operation, but it is an important process and
theoretically complicated rather much attention will be paid in this subject. After plucking
chemical changes started in the leaf whether physical withering takes place or not. Through these
changes certainly do affect the quality of the finished product, the physical effect of withering
are considered to be of the foremost important in CTC manufacturing. Withering: Withering is
the first step of tea manufacturing. It is principally a drying process to remove the surface
moisture and partially the internal moisture of the freshly harvested green leaves by conditioning
physically, as well as, chemically for subsequent processing stages. In addition, withering is
done to get the correct physical condition, which will allow the leaves to be rolled without
breaking. Also, the withering promotes dissipation of heat generated during continuous
respiration (chemical changes). Based on achieving the desired level of withering, one can make
better quality teas and, on neglect, can invite serious problems in subsequent steps of
manufacture.

7. Withering is controlled by the thickness of spread, and the length of time of the withering phase.
The quality of made tea influenced by length of drying time, inlet temperature, air speed and
thickness of spread of leaf which effect the chemical part of drying.
Percentage of Wither: Percentage of wither is defined as the weight to which 100 kg of leaf is
reduced at the end of the withering process. In conventional parlance, 70% withering signifies
that 100 kg of fresh green leaf has been reduced to 70 kg after withering and 30 kg of water has
been removed. This method of expressing wither is irrespective of the initial moisture content of
the leaf. Thus, depending on initial moisture content, the same 70% withered leaf, would lead to
various moisture contents. This is an anomalous situation and was introduced when it was not
possible to measure the moisture content of green and withered leaf accurately. The following
table illustrates how the variability in the moisture content of the withered leaf, depending on the
initial moisture content of the leaf, vary even though the leaf has been subjected to the same 70%
wither. It is, therefore, not desirable to wither the leaf throughout the season to one and the same
weight as this may require elimination of different quantities of water in different periods.
Besides, during the withering process though there is carbohydrate degradation and consequent
respiration leading to loss of 4% soluble solids, there is some increase in caffeine and other
constituents. Thus, for practical purposes the loss is compensated. It would be better to ascertain
the degree of wither by use of the ratio of dry matter to moisture.
Objectives of weathering: The main objectives of withering are to reduce the moisture content
of to concentrate the juices to bring the physical condition to rubbery state in which it will stand
twisting without breaking up into flakes. - It minimizes water logging during oxidation. Since the
excessive moisture interferes with the free supply of oxygen which interferes with the oxidation
itself. - It concentrates the cell sap. - It minimizes the loss of essential solid matter from the green
leaf with the excess water at the time of rolling. - To breakdown complex chemical compounds
in the cells to simpler compounds which along with other simpler molecules then recombine to
contribute to quality attributes of tea like the ‘body’ and ‘flavour’ at a later stage. This is known
as the Chemical Withering of the leaf. - To reduce the moisture content of the fresh leaf which
ranges between 7 To make the leaf `flaccid’ or `rubbery’ which is essential for the subsequent
step of processing (maceration) or rather for ‘twisting’ or ‘curling’ etc. - It minimizes bacterial
contamination since under withered leaf is liable to contamination. - It minimizes the fuel cost
Benefit of withering: Increase in amino acids - Increase in caffeine - Increase in certain flavory
compounds - Increase in cell wall permeability - Decrease in poly saccharine and protein
Types of withering: There are two types of withering which are commenced and continued of
leaf plucking.
These are:
Physical Withering: In physical withering it is necessary to allow the leaf to be twisted, there by
distorting the leaf cells. By losing moisture in form of water vapour, leaf becomes flaccid and

8. correct withering is essential for quality, although, it has always been a difficult task to
determine the end-point of wither. The same reduction in moisture percentage and increase of
flaccidity of leaf to the desired level can be achieved in a shorter period; a longer period is
necessary for chemical wither. Therefore, physical wither is regulated at a slower rate, so as to
22 reach the desired physical withering in the same interval as required for the chemical wither.
The objectives are achieved by passing air through the leaves. Moisture content of the fresh leaf
varies during the different parts of the season. To maintain a consistent standard of tea in make
and style the moisture content in the withered leaf should be constant. So with varying moisture
in green leaf physical wither has to be varied to maintain constant moisture in withered leaf. The
simple equation given below is useful for obtaining the physical wither of leaf needed with
different fresh leaf moisture contain –
100 - Pw =(Mf-Mw) /( 100 – Mw)
Where, Weight of wither leaf
Pw = Physical wither in percentage
=(Weight of wither leaf /Weight of fresh leaf ) × 100
Mf = Moisture percentage of the fresh leaf.
Mw = Moisture percentage in wither leaf.
Physical wither depends on moisture contain of the fresh leaf. The variation is presented in the
following table. Physical wither of leaf needed with different fresh leaf moisture content:
Physical wither (Pw) required for leaf with initial moisture content Type of manufacture
Optimum moisture requirement in W.L Mw (%) 75% (dry) 78% (Average) 83% (Wet) Rotor
vane (CTC) 70 83 73 57 Roll- CTC 68 78 69 53 Orthodox 65 71 63 49
Chemical Withering: Chemical wither starts immediately after plucking. It is independent of
the rate of loss of moisture and is a function of time and temperature. Although the desired
moisture level may be reached in a few hours, the catabolic changes, which had been initiated at
the time of plucking, will take time. The chemical composition of the leaf will thus be unsuitable
for manufacture after the leaf has been desiccated for a few hours. This changes are depends on
temperature and time rather than moisture. It is, therefore, necessary to continue to supply
sufficient air and wait for breakdown of large organic molecules to simpler structures.
Bio-chemical changes during withering are:
1) Increase of polyphenol oxide activity.
2) Increase of caffeine which is responsible for cup character of black tea (Briskness of tea).
3) Increase of organic acids which are responsible for Volatile Flavour Components (VFC).

9. 4) Release of carbon dioxide and water due to break down of larger molecules.
5) Changes in enzyme activity.
6) Broken of chlorophyll and proteins to amino acids which are responsible for the formation of
aroma of made tea. 24 The above chemical changes are all intrinsic of the biochemical structure
of the leaf, but the range and the extent of the reactions depend on the jat, cultural practices and
physical parameters like temperature, humidity etc. This process normally takes about 12 – 16
hrs. and cannot be hastened. The concentration of the chemical compound decreases with the age
of tea leaf to the shoot.
Withering and Recovery Percentage: The ratio of made tea to green leaf is termed as
“recovery percentage” alternatively, as “out turn”. This ratio varies depending on the initial
moisture content of the leaf. Leaf with moisture content of about 83% during wet period
produces 16.5 kg black tea from 100 kg of green leaf. Similarly, leaf with moisture content of
72% during dry period produces as much as 27.5 kg of tea from 100 kg of green leaf. Taking an
average of 77-78% moisture for the whole season, 22.5 kg of made tea is expected from every
100 kg of green leaf. 2.4 Withering Process: Trough withering broadly used method. After
unloading from transported green leaves are spread immediately on the trough. Fans are used in
anti clock direction for the first hour to take away the hit and cool the leaves. Then fan are used
in front for two hours and next two hours fans are remain stop. Turning is done during this stop
period. Then fan are used for two hours again. This cycle are followed until leaves are withered
properly.
Hygrometry and Relative Humidity: Dry and wet bulb thermometer is used as main guide for
withering. Usually, Wet and Dry Bulb Thermometers are used to measure relative humidity. The
difference between the wet and dry bulb readings is known as Hygrometric Difference. When
dry and wet bulb temperature difference are more than 4°F 25 (2.2°C), then best withering can
be achieved and a difference of 4°C (7°F) has been found to be optimum under normal
conditions, but with wet leaf a difference of 6-8°C (10-14.5°F) is used initially to drive off the
surface moisture after completion of which the hygrometric difference is brought down to 4° C.
In rainy days when relative humidity is very high the difference becomes less than 4° F. Then
worm air will be required to raise the moisture absorption capacity during the withering period.
In this case it is ensured that wet and dry bulb temperature difference does not exceed 8° F after
application of heat.
Trough withering: Various ingenious systems viz., Tat withering, Tunnel withering, Drum
withering and Trough withering have been in use. Of these the Trough withering is the most
popular system currently being used all over the world. Withering Trough is a rectangular duct
with one opening for letting the air in and the leaf bed acts as an outlet or exhaust. Air is blown
into the trough by an axial flow fan fitted at the inlet with the help of a tapered expansion hood,
termed as the diffuser, which smoothens the airflow and reduces the turbulence. The escaping air

10. thus carries moisture in the leaf away. The advantages of a Trough withering system are: -
Economy - Greater flexibility with respect to capacity and degree of wither, - Flexibility of
construction, - Saving in space and - Economy of labour and easier operation.
Trough size: Withering troughs can be of various sizes. However, for convenience of loading
and unloading, a width of about 1.8 m (6 feet) is preferred in which case the length is 100-120
feet.
Trough house capacity: Due to long duration of withering, the trough cannot normally be used
more than once a day. Therefore, sufficient capacity must be provided to hold the entire quantity
of a day’s leaf input in the factory. Capacity to hold green leaf equivalent to 1% of the annual
crop is considered as a reasonable provision for the purpose, since this capacity exceeds only on
2 or 3 occasions in a year.
Thickness of leaf spread: The spread of leaves actually act as a valve and create the necessary
system resistance for the airflow helping to even out the static pressure in the plenum chamber.
Leaf is generally spread uniformly on the trough at the rate of 2.5 kg/sft for CTC.
Withering fans: Fan is one of the most important components of withering trough. For the
purpose of withering axial flow fans are used. The direction of airflow in axial fans is essentially
parallel to the axis of the impeller. These fans operate at a static pressure of 12 mm (½ in) water
gauge and can handle large volumes of air. One advantage of axial flow fans is that their
direction of rotation can be reversed to make the air flow in the reverse direction. But with
reversal, capacity of the fans reduces nearly to half. Even if the blades are specially designed to
give same air flow in both directions the power required will be 40- 60% higher than the power
required for normal blades.
Operation of trough fan: As soon as green leaf spread over trough bed withering fan should run
anti clock wise for first half an hour to remove the lean heat generated inside the heap of leaves
then fan run to clock wise for 3-4 hours to reduce the moisture from the leaves. After that one
hour interval this process should repeated to continue until leaf become withered at desired level.
Period of Wither: The period of wither is ascertained by taking both physical and chemical
wither; physical wither can be achieved in 3-4 hours but chemical wither requires 12-16 hours.
Problems of under withered leaf: In case the leaf is under withered, the following problems are
foresees: - Under withered leaves are difficult to twist and tends to break up during processing
and open, flaky are produced, which would not respond to the subsequent processing steps and
produce unacceptable teas. - If the leaf were under withered valuable water-soluble solids would
be lost during the leaf conditioning process. - Under-withered leaf when rolled turns into a wet
watersogged mass; the sogginess restricts supply of oxygen and hinders uniformity in the
subsequent oxidation reaction (fermentation). - Maceration of under withered leaf also leads to
formation of lumps during fermentation. - At temperature more than 25°C with under withered

11. leaf, chances of bacterial contamination increase and hence a negative point of quality. - Reduces
the dryer output efficiency and imparts higher costs to evaporate the extra moisture from
fermented leaves.
Problems of over withered leaf: Withering of leaf should be at desired level i.e. 70% withered.
Over withered leaves are difficult to cut in CTC manufacturing. - Good cut of tea could not be
achieved as it tends to join the CTC rollers. - Fermentation will be arrested as insufficient
oxygen will pass through the CTC cut tea which will hamper the liqure quality later on. - Grainy
tea is not will not produced. - Tea wastage will be high as flacky tea will be high.
Good practices for trough withering: - The days withering program is to be laid down by late
afternoon for the following evening and night’s operation. A withering trough control register
should maintain to facilitate planning of day’s operation. - While hot air blowing temperature
should not exceed 35°C. An air temperature of a steady 25-30°C is ideal, but if it goes above
35°C the leaf may become overheated and quality will fall off very rapidly. - Surface moisture
from wet leaves should be removed as quickly as possible to prevent bacterial contamination. -
Spreading of leaf should be uniform across the length and breadth of the trough. Bunching of wet
leaf should be avoided. - Air velocity should be such that the leaves are not lifted up. - Leaf
should be handled carefully. Drainage during spreading must be avoided and the labourers must
not be allowed to walk on the leaf. Withered leaf bruisesmore easily. - The duration and
temperature of withering influence the character of made tea.While low temperature favours
development of quality, high 29 temperature may develop colour at the expense of quality.
Unwithered teas are flaky – they may be brisk but with poor quality. - A period of 12-14 hours of
wither is essential for completion of chemical wither. - Proper monitoring of withering through
use of hygrometers, dry and wet bulb thermometers, moisture meter, weighment before and after
wither, will help in producing better quality tea. - Effort should be made to wither evenly over
the entire period of withering, so that the rate of loss of moisture proceeds at a uniform rate. This
will to allow the chemical reaction to proceed in the desired manner. - At the end of withering
ambient air should be blown to cool down the leaf. - Hot air should not be used to force wither in
latter stage. - Measuring of how much moisture has been lost from the withering leaf is
traditionally carried out by examining and squeezing a handful of leaves. Checks are also run by
weighing a cage of leaf into the withering scale and then hang it to a measuring scale of a certain
weight (i.e, 02 kg of green leaves) taking out at intervals and weighing it again to see how much
moisture has been evaporated during that time. The first of these monitoring methods depends on
the skill and experience.
Good practices for leaf turning at trough: - Leaf turning at trough bed should be monitor if
there are no spot bulky leaves and leaf should be turn completely up to trough bed surface to
proper aeration inside the spreading leaves for even weathering. - If possible few times leaf
turning may carry on air blowing inside trough (clock wise direction) which will help to
removing of trough bed mesh cell blocking to improve even aeration.

12. Energy saving approach for withering: To control gas consumption or efficiently use in case
of wet leaves or cold weather its may better hot air not to use at night period it will consume
much more gas and should use at daytime at least 01 hour later of spreading leaf after taking
away the hit and cool the leaves. Prevent leakage. Leakage of trough body or open spaces at
spreading leaves will prolong the withering time and lose of energy. ƒ Hot air blowing burner
cover surface should be insulated. Never allow the withering fan to strive for air.
Tea Manufacturing mainly classified into two types:
1) Orthodox Manufacture.
2) Un-orthodox Manufacture.
Orthodox Manufacture:
1) Orthodox Machine consists of a vertical metal cylinder hopper having opening at both ends.
2) The lower ends of cylinder rests on a larger circular table having a series of rides or batten’s
across the surface.
3) The weight is placed on the upper end of the cylinder to compress the leaf.
4) The cylinders are then rotate centrifugally over the surface to the table for 20-30 min to be
rolled bruised and broken up into fragments,
5) According to the requirements of practice size by the factory management both pressure and
rotation should be unorthodox manufacture both pressure and rotation should be adjusted.
Un-orthodox manufacture
Un-orthodox manufacture may be subdivided into five types:
a) The Lawrie Tea Processor
b) Crush Tear Curl machine
c) The Rotorvane
d) The Boruah Continuous Roller
e) The Leg Cutting Roller
1) The Leg Cutting Machine: It uses a series of knives to macerate tea leaf resulting in a more
even size and pattern grades. In absence of sufficient crushinh and cell disruption of the tea leaf
and with the introduction of tea bags the leg cut tea is not desirable.

13. 2) The Boruach continuous roller: It consists of a conical shaped rolor vane within a fixed
chamber having battens grooves and other inside surface. The pressure and gap between the
working surface can be adjusted by the movement of the axially moment conical section.
3) The Rotorvane: It consists of a horizontal cylinder having a central conveying rotor including
a worm to drive the leaf forward and a series of vanes which squeeze the leaf against resistor’s
fixed on the inside surface of the barrel of the machine. It has opposed vanes with every
successive pair.
4) The Lawrie Tea processer: The LTP consists of a central rotor with a nimber of knives and
beaters free to rotate on a central shaft placed in a type of cylinder. Leaf comes down through the
upper openings of one end of the cylinder having bruised and cut into pieces by the rotating
knives and beater’s and come out in the lowering opening of other end of the cylinder.
5) Crush Tear Cure Machine: The CTCmachine system consistsof a pair horizontally
mounted opposite spin stainless steel roller. A series of teeth is engraved on the outer surface of
the rollers. The pair of roller’s are so mounted that their teeth mesh together
Orthodox Tea Manufacturing process:
Withering
Rolling
Rotor Vane
Roll breaking and green leaf sifting
Fermentation
Drying
Grading and Sorting

14. Withering: Normally withering is carried out by spreading the leaves thinly on banks of trays or
“tats” made of tightly stretched wire-netting. Withering means partial removal of moisture. Leaf
containing (74-80) % moisture and (20-26) % solid matter. After withering moisture level reduce
down to (55-60) %. The average length of time for withering is 18 to 20 hours where tray are
used.
Rolling: When a satisfactory wither has been obtained the leaf is ready for rolling, which twists
the leaf, breaks it up and expresses the juices (substrates and enzymes). This step facilitates
mixing up of cell constituents viz, enzymes and substrate thereby starting fermentation.
Rotor Vane: The rolled leaves are fed into the rotor vane, which mixes the leave thoroughly
aiding in the cell maceration and extraction of the juice thereby facilitating subsequent processes
viz, rolling and fermentation.
Roll breaking and green leaf sifting:These two steps are involved mainly for the orthodox type
of manufacture. On discharge from the roller the leaf mass is more or less compressed into
lumps. These are broken up in the sifting process by the machine which usually combines the
operation of roll-breaker and sifter.
Fermentation: During fermentation, the leaf changes color and turns into a dark coppery tone.
Typical aroma develops at this stage. The ideal conditions for fermentation are dhool
temperature <30 *c, moisture ~55%, pH 4.5 to 5.0 and humidity >90 %.
Drying: Endless chai pressure driers as described in the CTC process are also commonly used in
orthodox tea manufacturing. After firing, the tea is spread out to cool and then temporarily stored
to wait sorting.
Grading and Sorting: Grading is carried out on mechanically oscillated sieves and fitted
meshes of appropriate size.
CTC Machine
The CTC machine achieves the three actions of Crushing, Tearing and Curling, Tearing and
curling in the same machine at one go. Instead of working on large volumes of leaf, the CTC
takes a fast, thin, but steady stream of leaf to pave that the continuous processing in place of the
batch mode of orthodox rollers. Leaf appearance, make, grade percentage, fiber content, liquor
and infusion depend on the cut obtained in the CTC machine.
Two stainless steel rollers with circumferential as well as helical grooves machined to certain
definite specification, meshed closely, rotated in opposite directions at a speed differential of
1:10. The diameter of the roller varies between 20.3 cm (8 inch) –20.95 cm (8-25 inch) . The
large 33cm (13 inch) diameter CTC machines are gaining popularity now a days

15. Definition: Fermentation is actually an oxidation process. In this process the polyphenols in the
leaf gets oxidized with the help of endogenous enzyme namely polyphenol oxidase. Before
rolling polyphenol and polyphenol oxidase are located in the different compartments in the cell.
When the leaf gets crushed during rolling the polyphenol and the enzyme are mixed in the
presence of oxygen and biochemical changes take place. The products of fermentation are
theaflavin and thearubigin which are responsible for briskness, brightness and color of liquor.
Theaflavin is orange red in color and thearubigin is red brown in color.

16. A flow diagram depicting the steps of oxidation involving the fermentation tea is given below:
Classification Of TEA based on fermentation: On the basis of fermentation tea can be
classified into 3 groups-
1. Fermented Tea: Fermentation process has been underway for several months to many
years in this kind of tea. For example, Black Tea.
Figure: Black Tea

17. 2. Semi Fermented Tea: This type of tea is allowed to undergo 20% to 70% fermentation.
For example, Oolong tea.
Figure: Oolong Tea
3. Non-fermented Tea: This type of doesn’t have a process of fermentation which makes
them retain quite a bit of their original flavor. For example, Green Tea.
Figure: Green Tea
Methods Of Fermentation:
There are two methods of fermentation-
1. Conventional Method:
i) Floor Fermentation
ii) Rack Fermentation
iii) Al. Sheet Fermentation

18. 2. Modern Method:
i) Trolley/Trough Fermentation
ii) Drum Fermentation
iii) U.V Fermentation/CFM
Conventional Methods are described below:
i) Floor Fermentation: Floor fermentation is practiced by putting the rolled leaves on the floor
to 2-3” height depending on the climatic condition. Floor fermentation is always better than
drum fermentation as it is having better air contact with leaves. But in floor fermentation the cost
of labor is high. The rate of the fermentation depends on the concentration of substrates in the
leaves, availability of oxygen, activities of the enzyme and temperature. The most important
advantage is the control of heating of the leaves. Cement concrete floor is considered good. It
takes 60 t0 90 minutes for the fermentation.
ii) Sheet metal rack and glazed tiles: Aluminum sheets are used to make racks for fermentation
of tea leaf. The disadvantage of sheets is that during fermentation the leaf gets heated. On the
other hand, the advantage is that it can be kept clean. Glazed tiles are widely used but there are
chances of bacterial
Contamination in the tiles joint.
Modern methods are described in the next page:
i) Trolley Fermentation: A trolley fermenter has a perforated bottom where the rolled leaf is
spread to a height of 8”. After spreading the leaf in the trolley it can be moved to fermenting
room where connected to a humidifier. It is easy to control temperature, humidity and air flow. It
is an economize process from the point of labor, time and space.
ii) Drum Fermentation: Drum fermentation is mostly practiced in the CTC Tea Manufacture.
Drum fermentation produces more density and better granulation which give better appearance
as compared to floor fermentation. The fermenting drum is simple cylindrical drum with conical
feeding and discharge ends. The standard drum is 16-20 feet long with 5 feet diameter. Conical
segment is 4 feet. The capacity of the drum will be 1.6kg of rolled dhool for every one square
foot area of the drum. A figure of the machine is given below:

19. Figure: Drum Fermentation Machine
iii) U.V Fermentation / CFM:The objective of CFM is to eradicate the microbial contamination
in tea. The microorganisms occur as contaminants during tea processing due to the presence of a
layer of fermented juice on the processing machines and other equipment. The continuous
fermenting machine consists of a tray made up of conveyor racks with three to four tire system
like quality drier arrangements. The fermented dhools travel in a thin layer on the conveyor rack.
Above or below the tray ultra violet lamps are fitted which are used to kill the external bacteria
and triggers the activity of polyphenol oxidase. The machine is generally used for NRC tea
manufacture.
Figure: Continuous Fermenting Machine
Fermenting Techniques:
Tea fermentation is essentially an oxidation process. For activating better oxidation, the location
of fermenting drum, the quality of air plays a vital role. Importance should be given to the
quantity of air, direction of flow and loading rate of the drum. The temperature of the air used in

20. the fermenting drum should be maintained between 25 to 27 degree Celsius with 95% relative
humidity.
Air Quantity:The quantity of air flowing inside the fermenting drum depends on the size of the
fan and RPM of the motor. For better oxidation, for every one cubic feet of the drum 2.8 cubic
air/minute is essential.
Air Quantity and Direction: For better fermentation the drum should be connected with a fresh
air supply duct. The direction of fresh air supply is very important. Fresh air supply should be
connected with the feeding side of the drum as more fresh air is required during the initial stages
of fermenting.
Role of flights in the fermenting drum: In order to increase the air contact to the rolled dhools
and to break ball formation, flights are recommended in the fermenting drum. Spiral flights are
fixed at 2” interval on the circumference of the drum by means of a base plate. Along the drum
the flights are fixed with 2.5’ interval leaving a space of 2 from the cylindrical portion.
Factors influencing fermentation-
a.Time of fermentation
b. Temperature
c. Humidity
d. Aeration
e. Thickness of spreading
f. Cleanliness
a. Time of fermentation: During fermentation, a series of complex bio-chemical
changes take place. The duration of fermentation depends on type of manufacture,
quality of green leaf, temperature, humidity. It is important to arrest fermentation as
soon as TF and TR are formed in correct ratio which are responsible for brightness,
briskness and color of the liquor. Generally, under South Indian conditions 60-90
minutes may be needed for correct fermentation. If the temperature time is less than
27 degree Celsius the fermentation time is prolonged.
b. Temperature:At the optimum temperature the rate of fermentation is maximum.
Below the optimum temperature the rate of fermentation is slow. Above the optimum
temperature the enzymes start getting inactivated resulting in the lowering of rate of
fermentation. Below 16 degrees Celsius the enzyme activity is quite low. When the
temperature reaches 32 degrees Celsius, the enzyme activity declines. The
temperature considered to best for fermentation is 27degree Celsius.

21. c. Humidity: For better and even fermentation, the relative humidity of the
fermenting room should be maintained around 95%. If the relative humidity in the
fermenting room is low, evaporation of water from the surface of the leaf takes place.
As a result, there will be uneven concentration of juice in the different parts of the
leaf leading to uneven fermentation. Due to high rate of evaporation the leaf surface
gradually turns black.
d. Aeration: The adequate oxygen supply is a must for better fermentation. During
fermentation of polyphenols, a large amount of CO2 is released. Proper aeration and
air flow are necessary for achieving better fermentation and for removal of CO2 from
the leaf particle.
e. Thickness of spreading: Thickness of spread depends on the type of leaf and the
severity of cut. The layer should be thin enough to absorb more oxygen. The density
of leaf also influences the process of fermentation. Higher density leaf should be
spread in lesser thickness than the lower density leaf.
f. Cleanliness: The juice adhering to the surface of the drum floor becomes a source
of bacterial contamination. Bacterial contamination is responsible for darker liquor in
the made tea. If the bacterial infestation is severe, a fruity smell emanates from the
made tea. Hence it is necessary to wash the fermented drum floor after the
manufacture is over. Hot water can be used for sterilization.
Steps of tea processing:
• Withering
• Rolling
• Fermentation
• Drying
• Sorting & Grading
• Storing & Packaging
(1)Drying:
In order for processed tea leaves to be shelf-stable, they must be dried. There are two reasons for
• drying tea though, to dry the leaf, making it shelf stable, and

22. • to enhance the flavor.
At times, these can be two distinct steps in processing and at other times, it can be seen as more
of a continuum, and sometimes teas are only dried for shelf-stability.
Most common drying methods:
• Commercial dryers: where perforated conveyors move the tea leaves through a heat
source in an endless chain, or fluidized bed dryers where tea leaves are dried on a bed
of hot air (see above photo).
• Oven drying: where tea is set on perforated trays in an oven and hot air is circulated
through the tea via convection.
• Sun drying: where tea leaves are spread outdoors usually on shallow bamboo baskets
to dry in the sun (see photo at top of post).
Less common drying methods:
• Charcoal firing: where tea leaves set in a shallow bamboo basket are heated slowly
over hot coals.
• Drying on heated floor: where tea leaves are dried on a thick masonry floor heated
from below.
Drying For Shelf-Stability:
Drying for stability means reducing the moisture level in the tea leaves to 2-3%. Doing so makes
the leaves shelf stable and slows oxidative processes within the leaves to nearly a full stop. Tea
makers control the temperature of the air, the volume of air moving past the tea, and the amount
of time that drying occurs to produce a palatable tea. Drying the tea too slowly results in stewing,
and drying it too quickly results in the outside of the leaves drying much quicker than the inside,
a condition known in tea production as case hardening. In fact, “an average loss of more than 4%
moisture per minute leads to bitterness and harshness in made tea. Moisture loss at 2.8-3.6% per
minute has been found to produce teas with good quality.

23. Drying For Flavor Enhancement
Drying for flavor enhancement refers to two optional processing methods known as finish-firing
and roasting. Both involve heat, and can be seen as distinct processing steps, or part of drying for
shelf-stability. Not all teas are finish-fired or roasted, typically these processes are reserved for
higher-end teas and are skipped in commercial tea production.
Finish-firing refers to a very low temperature heating of tea leaves for several hours, typically in
an oven or in shallow bamboo baskets over hot coals before being packed and shipped. This
enhances the flavor and aroma of the leaves but doesn’t necessarily change it.
Roasting on the other hand refers to a method of heating that is meant to change the flavor and
aroma of the tea, typically adding toasty, burnt notes and resulting in a darker tea and a darker
infusion depending upon how long the tea is roasted and at what temperature. Roasting also
occurs in an oven or in shallow bamboo baskets over hot coals.
(2)Sorting:
Sorting is a mechanical process. It has been found that in order to get good prices at the
tea auction, proper sorting is essential for all grades of tea in general, and broken grades in
particular. One of the objectives of sorting is to classify tea according to the size of the particles.
Today, no distinct division can be made between sorting, cleaning and grading since the
processes are carried out simultaneously and procedures are common to all. There are four
important characteristics:
✓ Size
✓ Shape
✓ Specific gravity
✓ Surface characteristics of the particles

24. Basic Processes:

25. Tea sorting process:
Tea sorting procedure are consist of three steps such as :
1.Fibre Extractor
2.Sorter
3.Grading of CTC Teas
1.Fibre Extractor:
The fibre extractor works on the principal of static electricity. There are 4-6 PVC roller
arranged in a row. When the tea is fed in the machine after firing, frictional force between the
roller( +ve ) and the fibre (-ve ) takes place and gets separated by the attraction. Then the fibre is
collected from the PVC roller.
Sorting Machines:
There are lots of sorting machines using by the tea industries locally and internationally.
Such as:
Myddleton, Rotary shifter, Electrostatic Fibre extractor etc. From these 2 sorting machines are
described elaborately.
(a)Myddleton:
The Myddleton tea stalk extractor is a common machine in all types of tea manufacture. It is
used widely in almost all tea growing areas as an initial sorting machine. It performs the
operations of grading and making tea free of stalks.
Important Parts:
Trays:
There are two trays in the Myddleton, the top and bottom trays. The top tray is 9' x 4'
and the bottom tray is 8'5 inch x 3'10 inch. The trays are made of thick aluminum sheet, with
lines of small bosses, each with a perforation at the top. The trays are easily removable and
sieves of different specifications can be fitted into the frames to suit the tea being treated. One of
the Myddleton's two sieves is normally has 3/16 inch perforations and 1/8 inch high bosses.
Pulley:There is a 10 inch pulley with a 3 inch face, suitable for a 2.5 inch drive. This can be
attached directly to a motor.

26. Crank Shaft:
The crankshaft imparts reciprocating motion to the machine via connecting rods. The
crankshaft is made of very strong steel bars.
Grafton Phillips Attachment:
The Grafton Phillips Attachment is used for removing dust and fluff from the tea. It has
two superimposed trays, fitted with brass wire mesh number 16 on the top and number 32 at the
bottom.
The tea discharged from the top tray of the extractor is passed to the top tray of this attachment.
An oscillating motion causes the tea to be thoroughly sieved as it passes over the gauge. The
finer parts of the tea and the dust fall onto the lower tray. On this tray, a similar operation takes
place - the cleaned fine tea passes over the end of the tray while the dust falls.
through into a collector underneath. The tea discharged over the ends of both trays is
clean and free of dust and fluff.
Working principle:
An oscillating motion is imparted to the sieves wit the help of a crankshaft, which revolves at
200rpm. Leaf is fed to the Myddleton machine at spread thicknesses of approximately 1.3 to 1.9
inches. The tea being sorted in the Myddleton moves down a slopped tray between the bosses.
This imparts a slight disturbance to the mass and causes the leaf to hop through the perforations.
The stalk and fibre slide over the bosses pass over the end of the tray, and is thus separated.
Electrostatic Fibre Extractor:
The Electrostatic Fibre Extractor (EFE) is a relatively new machine used for stalk extraction after
firing. In this machine, the principle of static electricity is used for extracting fibre and stalk. It
can be used in continuous manufacture with the help of a conveyor system after the second
firing. The machine is normally 10-12 ft long and 3-4 wide and is considered one of the best for
extracting fibre in CTC manufacture.
Different Parts:
The different parts of EFE are given below:
• Main frame
• The main frame of the EFE is made of mild steel, and is rigidly built. In some
motor-driven models, cast iron wheels are attached to the frame so that the
machine can be easily moved within the factory.

27. • Roller
The machine has seven PVC rollers, placed in two stages of four and three
rollers, respectively, Each roller has a diameter of about 4 inch, and is designed
to rotate at speeds of 2,000 to 2,500 rpm. The rollers rotate smoothly on heavy
duty bearings housed in plumber blocks.
• Motors
The motor used in this machine is of 1400/1500 rpm, 400/440 volts 3
phase 50 cycles.
Working Principles:
This machine works on the principle of static electricity. There are seven PVC rollers
arranged in two rows that run at speeds of 2,000-2,500 rpm. Tea fed into the machine comes into
contact with the PVC rollers, causing friction between the two. As a result, static electricity is
produced with the fibre and rollers developing opposite charges. This causes the particles and
rollers to attract each other. But the fibre is turned over through centrifugal action and collected
in aluminum collecting boxes fixed over the conveyors between rollers. From there it is
transferred to other containers.
(3)Grading:
In the tea industry, tea leaf grading is the process of evaluating products based on the quality and
condition of the tea leaves themselves. The highest grades are referred to as "orange pekoe", and
the lowest as "fannings" or "dust".
Pekoe tea grades are classified into various qualities, each determined by how many of the
adjacent young leaves (two, one, or none) were picked along with the leaf buds. Top-quality
pekoe grades consist of only the leaf buds, which are picked using the balls of the fingertips.
Fingernails and mechanical tools are not used to avoid bruising.
When crushed to make bagged teas, the tea is referred to as "broken", as in "broken orange
pekoe" (BOP). These lower grades include fannings and dust, which are tiny remnants created in
the sorting and crushing processes.
Orange pekoe is referred to as "OP". The grading scheme also contains categories higher than
OP, which are determined primarily by leaf wholeness and size.
Broken, fannings and dust orthodox teas have slightly different grades. CTC teas, which consist
of leaves mechanically rendered to uniform fannings, have yet another grading system.
Broadly speaking, there are four grads of tea. These whole leaf, broken leaf, fannings and dust.
Each of these grads again has various sub-grades. Of the four, only the latter three can be
produced via CTC and leggcut manufacture.

28. Whole leaf grades:
TGFOP Trippy golden flowery orange pekoe
OP Orange pekoe
FOP Flowery orange pekoe
TGFOP1 Trippy golden flowery orange pekoe one
FYH Fine young hyson
YH Young hyson
Broken grades:
Flowery Broken Orange Pekoe
FBOP
Broken Orange Pekoe BOP
Broken Pekoe BP
Broken orange pekoe one BOP1
Broken pekoe souchang BPS

29. Fannings Grades:
Broken Pekoe one BP1
Broken Pekoe two BP2
Broken Orange Pekoe BOP
CTC Pekoe Fannings one PF1
CTC Pekoe Fannings two PF2
Flowery pekoe FP
Dust Grades:
Dust 1 D1
Pekoe Dust PD
Pekoe dust 1 PD1
(4)Storing of tea:
The proper storage of tea is of the utmost importance, as tea which is improperly stored will go
stale or rancid much faster, or can accumulate impurities that both alter the flavor and aroma and
can also harm the body. Therefore it is very important to learn how to properly store your teas so
that they remain as fresh, clean and flavorful as possible.
There are five things which teas are vulnerable to: light, air, heat, odors and moisture. These five
things will rapidly make your stored teas go bad.
Dark Place
Your teas should always be stored in a dark place. Never use glass or clear jars to store as
sunlight or UV rays will degrade your tea very quickly. If you must use a glass jar, be sure to
keep it in a dark cabinet where the light cannot reach it. Sun can also bleach out the teas, making

30. the flavor and aroma almost non-existent. Remember when storing your tea that keeping them in
a dark environment is a top priority.
Airtight
Air is another enemy of tea, as air flow around your stored tea leaves will increase the chances
that the tea leaves will absorb moisture and unpleasant odors from the air. Avoid leaving dry
leaves laying out, or in packaging with excess air inside the bag, or storing your tea leaves in any
porous material such as a resealable zipper package or container.
Hypothermia
Heat exposure will quickly ruin good tea as well. Avoid keeping your teas stored in sunlight or
near heat sources such as stoves, ovens, or other warm places. Heat can degrade the quality of
the tea, removing flavor and aroma, and increasing the chance that your tea will take on
moisture.
Away from Strong Odors
Stored teas are also very vulnerable to odors, which can be useful when creating teas such as
Jasmine Dragon Pearl green tea, because the tea leaves absorb the fragrance and are infused with
the odor of jasmine very easily. However this tendency for tea leaves to easily absorb the odors
placed near them means that you should also keep your teas stored safely away from areas in
your home with strong odors, such as spice cabinets, trash cans, refrigerators and other areas
which contain odors which the teas can absorb easily.
Away from Moisture
Moisture is the worst enemy of tea and can ruin an entire batch of it within minutes. Dried tea
leaves are considered shelf stable because they are completely dry. Unfortunately dry leaves
absorb moisture from the air very easily and quickly. Therefore, it is important that you keep
your dried tea leaves away from humid areas in your home, boiling water, and other sources of
moisture such as above a dishwasher vent or inside a refrigerator. Keep it far away from
moisture until you are ready to brew the tea leaves, or the moisture will cause molding, caking
and other unpleasant results.

31. (5)Packaging of tea:
Packaging performs five main functions
1- product containment
2- preservation and quality
3- presentation and convenience
4- protection during Distribution and Processing
5- provide storage history
Packaging categories:
1-primary packaging: surrounds the product
and features labeling
2-secondary packaging: ease of manual movement of products
3- transit packaging :wrapping used to bundle the boxes or crates
for transport and distribution.
Selecting the right material
Material selection is based on:
Technical properties (strength, flexibility, etc.)
fitness for purpose (moisture barrier, cushioning, etc.)
availability
manufacturing capability
cost
environmental impact
regulations
Types of packaging materials:
Cans
Glass Containers
Rigid plastic containers
Flexible plastic packaging
Paper & board

32. Aluminium foil & laminates
Glass containers:
Characteristics:
Chemically inert - wont react with its contents
Non porous
Odourless & hygienic
Contents can be seen as glass is transparent
Great strength (continually getting stronger &
lighter)
Easy open & re-sealable
Variety of shapes & sizes
Long-term storage & extended shelf-life
Sustainable - can be recycled or re-used
Uses: Semi-liquid, liquid & solid foods
Preparation: Air blowing, rinsing with warm water, washing in
detergent, sterilising (aseptic)
Paper& Paperboard:
Paper:
Used for a wide variety of products
Versatile & cost effective
Variety of shapes, textures & thickness' available
Greaseproof paper can be used when packaging
products such as confectionary & butter. They act as
a barrier to odours & moisture
Paperboard (thicker paper-based packaging)
Can be laminated with other materials to create
strength & moisture resistance E.g. Tetra packs
Pulped Fibreboard
Offers protection for products such as eggs because
of the airsplace between the particles
Rigid plastic packaging:
Advantages:
Lightweight & strong
High resistance to breakage
Available in a wide variety of colours, shapes, sizes
& textures
Can add to the sale appeal of the product
Cheap and easy to produce compared to other packaging materials.

33. Aluminium Foils:
Most foils made from aluminium
Advantages:
light
flexible
strong
Able to withstand moderate heat
Examples:
Tubes - condensed milk
Trays - frozen foods
Product seals - sour cream, butter & yoghurt
Wrappers - Cadbury chocolate block
Laminations:
Aluminium foil joined with other materials such as plastic and paper to create a
stronger packaging material.
Example:
Muesli bar wrapper (paper, foil & plastic)
Tetra Packs:
Multi-layered laminations known as composite
packages
Each layer provides a different purpose
Metallising:
Plastic coated in a fine layer of metal. E.g. Twisties
chip packets
Tea Testing:
Tea testing is the process in which a trained taster determines the quality of a particular tea.
Tea is famous for its sweet smell and bitter test. The strength of tea is also famous as it helps to
remove stress. We can easily taste these factor by following tea tasting method.

34. The United States Food and Drug Administration tested tea
Tea testing principle: ISO 3103 is a standard published by the International Organization for
Standardization commonly referred to as ISO , specifying a standardized method for brewing tea.
The abstract states the following:
The method consists in extracting of soluble substances in dried tea leaf, containing in
a porcelain or earthenware pot, by means of freshly boiling water, pouring of the liquor into a
white porcelain or earthenware bowl, examination of the organoleptic properties of
the infused leaf, and of the liquor with or without milk, or both. Cupping is the quickest way to
get acquainted with the characters of different teas and to compare different quality selections of
the same tea variety. It is also the trade’s main gate in quality control.
Tools and Materials:
1. A few selections of tea that you want to study and compare , it is wise to compare selections
from the same category each round, in the beginning, before you are really very confident in the
process.
2. Taster’s Mugs, 150 ml capacity, coupled with tea bowls for holding the infused liquor.
3. Tasting Spoons.
4. Bowl for warming the spoons
5. Bowl for used spoons

35. 6. Tea Holders
7. Water Kettle, preferably electric ones with 2000W heating capability or above, 1 litre capacity
or above, or instant tankless Water Boiler.
8. Kitchen thermometer
9. Electronic Scale, 0 ~ 20 g
10. Electronic Timer
11. White bread
12. Optional warm milk, cheese, or soda crackers just in case there is a little stomach un-
comfort for over-drinking.
Preparation Of Tea :
1. Use a kettle that boils a lot of water quickly, i.e. one that has a higher output power and larger
capacity. Good ergonomic should be a consideration as well.
2. Measure 3 grams of each tea and put inside the leaf-holders in a line ready for use (note the
sequence so you know which tea is which)
3. Preheat mugs in a steamer, oven, or by filling with boiling water for a couple of minutes.
4. Line the mugs in a straight line, with enough hand space in between, say 4 inches (10 cm)
5. Put the measured tea in the mug, in the same sequence as the line up
6. Set the timer to the required infusion time
7. Fill the mug, to the rim, consecutively with water at the temperature designated for the
specific tea, timing the intervals between the filling of each mug
8. Cover the lid immediately after filling of each mug
9. Let steep for the required time, 5 or 6 minutes, but have to be the same for each mug
10. While steeping, put a tea bowl in front of each mug
11. Warm the tasting spoons in a separate bowl of hot water
12. When the first mug is infused to the needed time, decant by holding tight the lid and letting
the liquor drain through the slits into the bowl.

36. Testing:
1. Make sure palate is clean.
2. Starting from the tea which will be the lightest taste not necessarily the lightest colour .
3. Scoop a spoonful to slurp in (with air, please don’t mind the manner) and let it roll in
your tongue. Let the liquid rest a second and roll it again before swallowing.
4. Feel your palate, tongue, throat and stomach for their reactions with the drink.
5. Halt for 5 to 10 seconds before you go for the next mug, after taking a small bite of bread
to clean your palate and clear the lingers of the previous tea. Remember to clear the
palate every time when you go back to cross compare different selections
6. When the infused leaves are a bit cooler, sniff them. Compare the appearance and smells
7. Keep notes for each selection for later reference. ex:
1. The liquor smell
2. The inside of the mug lid smell
3. The aroma linger
4. Which part of it lingers longer or shorter
5. Part of the aroma remind you of another substance
6. The liquor taste
7. Any part of the taste come first and some other later
8. The different parts of the taste remind you of
9. The taste stay
10. The taste changing during the process of tasting
11. The texture of the tea liquor
12. Feeling taste at the throat or elsewhere
13. The infused leaves smell. Same as the liquor or different
14 .The characteristic differences between different selections

37. Infusion Parameters
The ISO standard for professional tasting advises 2 g to each 100 ml of liquor. That means
roughly 3 g in a 150 ml mug. However, when dealing with very delicate fine greens, like those
that are only tiny shoots put 4 grams.
The same ISO standard sets the infusion water temperature at 100°C. This is quite useless for
most varieties other than BOP grades or under, or other older whole leaf black teas, or post-
fermented teas.
Infusion time is recommended at 6 minutes by the ISO. This is a good for using bigger pots. For
infusing a small pot of traditional fine tea, 5 to 5.5 minutes is good enough.
Those who are not used to drinking a few different teas at a time would easily be taken away by
the process and over drink. Tea-drunk can have as nasty a hangover like alcohol-drunk. It is
advisable for beginners to have taken a good hot meal, no alcohol and not too tired when cupping
Normally a person can drink as many cups as she wants in a day without problem, when we are
dealing with fine teas. Tea drunk happens mostly only with chain drinking strong infusions in a
very short time, and particularly when involving different categories of tea.
Green Tea:
Green tea is made from the leaves of Camellia sinensis that have undergone a process of
steaming, multiple rolling and drying. The step of fermentation (oxidation) is skipped after
rolling, as the enzymes are inactivated through steaming. Green tea brew has a delicate taste and
is light green or golden in color.
Types of Green Tea:
1. Sencha.
2. Fukamushi Sencha.
3. Gyokuro
4. Kabusecha
5. Matcha
6. Tencha
7. Genmaicha
8. Hojicha.
9. Sincha

38. Manufacturing Process:
➢ Plucking: Freshly plucked leaves are processed.
➢ Drying: After the tea leaves are plucked, they must be dried to prevent fermentation,
which stops enzymes activity, to prevent oxidation.
➢ Steaming: The leaf is weighed and dispatched to the lofts from where it is sent through a
barrel shaped steamer, in which steam at high pressure softens the leaf and coats it with
its own cell fluids.
➢ Rolling: The tea is then rolled partially and dried partially to bring down the moisture to
enable a second rolling.
➢ Drying and 2nd
rolling: The partially dried leaves are rolled again to give it shape.
➢ 2nd
Drying: The rolled leaves are fully dried
➢ Sorting & Grading: A special machine grades and cuts the tea by particle size, shape, and
cleanliness, depending on the final qualities desired. The machine uses mechanical sieves
or sifters fitted with meshes of appropriate size, as well as cutting devices to achieve a
quality tea.
Health Benefits:
1. It is a rich source of Manganese, Zinc, Chromium, Fluoride and Selenium.
2. It’s most important active component is Epigallocatechin gallate (EGCG)
3. Also contains L- theanine a type of Amino acid.
4. Green tea is a source of antioxidant nutrients.
5. Green tea is rich in polyphenols (Catechins and garllic acid)
6. It protect against oxidative damage in body.
7. Green tea inhibit many cancers in the body.
8. Reduces blood pressure and cardiovascular disease risk.
9. The oxidation of LDL-cholesterol is inhibited by green tea.
Semi Fermented Tea: This type of tea is allowed to undergo 20% to 70% fermentation. For
example, Oolong tea.
Figure: Oolong Tea

39. Oolong Tea Manufacturing Process:
1.Harvesting: Oolong tea leaves are picked 3 to 4 times a year in spring, summer (once or twice)
and autumn, which depending on the local climate conditions. Oolong tea is made from more
mature leaves consisting of one bud with 3 or 4 leaves.
2. Withering: After picked, the fresh oolong tea leaves are immediately transferred onto large
wooden plates to be dried. Most leaves are dried both indoors and outdoors to balance the effects
of heating and cooling. This is important: the level of moisture determines how quickly tea
polyphenols oxidize.
3. Bruising: This is the most important step of the process. Bruising determines, to a very large
extent, the quality and taste of oolong tea. A variety of techniques are used to bruise the leaves,
including shaking and tumbling. Bruising is usually repeated many times to achieve an ideal
level of oxidation.
4. Fixation: The main purpose of this process is to kill enzymes and stop oxidation. If it lasts too
long, the leaves will lose too much moisture.
5. Rolling and Shaping: During this step, oolong tea leaves are rolled and rubbed into the right
shape.
Depending on the varieties, oolong tea can be either long and curly, semi-rounded or fully-
rounded. After the tea has been rolled, it is heated in some way, then rolled again. This process
should be repeated several times.
6. Baking: If bruising “releases” the taste of oolong tea leaves, the second round of drying
strengthens what has been released. Both high and low heat are used to completely remove
moisture from the leaves and finalize their chemical profiles.
7. Sorting, Cooling and Packaging: Tea leaves are sorted to remove sub standard leaves and
twigs before they are transferred for packaging. This step is almost always done by hand, and
skilled inspectors pick out inferior leaves.
Instant Tea
Instant teas are produced from black tea extracting the liquor from processed leaves, tea wastes,
or undried fermented leaves, concentraing the extract under low pressure, and drying the
concentrate to a powder by freezing-drying, spraying drying or vacuum drying. Low temperature
used to minimize loss of flavor and aroma.

40. Instant Tea Processing
Extraction
Decreaming
Aroma stripping
Concentration
Drying
Organic Tea Processing:
Organic tea processing is also done by traditional methods using the tea leaves from the organic
tea estate. Every leaf is picked by hand, and the leaves that will be used to produce the organic
tea are boiled and then roasted in a traditional fry pan and finally dried under the sun to craft a
distinctive taste and flavor.
These sustainable techniques create high-quality organic teas while keeping the environment
safe. Bigger manufactures may rely on mechanical processing to create large batches of lower-
quality blended teas, but Assamica Agro uses organic cultivation and processing techniques to
produce a bold, flavorful organic tea with unique qualities .
Benefits:
1.Organic tea is produced using environmentally-friendly methods of cultivation.
2. Instead of relying on hazardous chemicals that damage the environment and can remain
behind on the finished product, organic tea farmers use traditional, natural methods of pest and
weed control.
3. To produce healthy, vibrant crops and strong, flavorful teas.

41. Quality control of Tea:
A system of maintaining standards in manufactured tea products by testing a sample (tea) of the
output against the specification.
This procedure involves :
Appearance: It involves observing the shape and color of the tea leaves.
Inner quality: It involves aroma, color and taste of the liquid
Quality parameters:
The major quality parameters that are tested in made tea include Theaflavins (TF), Thearubigins
(TR), High polymerized substances (HPS), Total liquor color (TLC) and Total soluble solids
(Water extract).
Conclusion: From the above discussion, we can conclude that The manufacturing procedures for
making good quality of tea is one of the most important operation to give desirable
characteristics and make the tea ready for consumption. So, we have to be careful to perform the
manufacturing procedures to maintain the better quality of Tea.