Method of Manufacturing and Fermentation of Tea

1. Methods of Manufacturing and
Fermentation of Tea
By Sakif Ahmed
Reg. No.:2012337021
Dept. of Food Engineering and Tea Technology

2. Manufacturing Methods of Tea
There are mainly two methods.
1. Orthodox Method.
2. Unorthodox Method.

3. Orthodox Manufacturing of Tea
traditional method of tea manufacturing.
Preserves the integrity and flavor of the leaf.
Whole tea leaves are rolled into various sizes and styles.
It is an artisan method.
Takes longer to produce but produces an attractive full leaf tea
with complex flavor and aroma.

4. Figure 1:Orthodox manufacturing
Figure 2: Orthodox tea

5. Unorthodox Manufacturing of Tea
Also known as CTC ( Crush, Tear and Curl ) manufacturing of
Tea.
Yields small, intentionally shredded pieces of tea.
Originally designed for Commercial Tea Bags.
This is mainly a machine-driven production method.
Can only produce a one dimensional flavored tea (lacks the
ability to produce a wide range of teas and tea flavors ).

6. Figure 3:Unorthodox manufacture
Figure 4: Unorthodox Tea

7. Withering
Rolling
Fermentation
Sorting and
Grading
Drying
Withering
CTC
Fermentation
Sorting and
Grading
Drying
Orthodox Manufacture Unorthodox Manufacture
Figure 5:Flowchart of orthodox and unorthodox manufacture

8. Fermentation
An oxidation process.
polyphenols in the leaf gets oxidized by polyphenol oxidase
enzyme.
Figure 6:Tea Fermentation

9. Objectives of Fermentation
Enzymatic oxidation of leaf constituents.
Theaflavin Formation (responsible for briskness and
brightness of tea).
Thearubigin Formation (responsible for colour and strength
of tea).

10. Biochemical Changes During
Fermentation
 Mainly two types of changes occur.
i. Enzymatic
 Formation of theaflavin and thearubigin.
 Breakdown of chlorophyll.
 Changes in carotenoids , organic acid and neucleotides.
ii. Non enzymatic
 Interactions of oxidized polyphenols and sugar with amino acids.
 Tanning of enzymes and other proteins.
 Reduction of number of microorganisms.

11. Factors Influencing Fermentation
Time of fermentation (60-90 minutes)
Temperature (optimum 27°C)
Humidity (RH=95%)
Aeration (air contact is essential)
Thickness of spreading (higher density leaf should be
spread in lesser thickness than the lower density leaf)
Cleanliness (sterilization)

12. Methods of Fermentation
Conventional:
i. Floor fermentation (better air contact)
ii. Sheet metal rack and glazed tiles (ensures cleanliness)
Modern Methods:
i. Trolley fermentation (economical)
ii. Drum fermentation (gives tea better appearance)
iii. Continuous Fermenting Machine (CFM)
(eradicates microorganisms)

13. Floor Fermentation Rack Fermentation
Figure 7:Conventional fermentation methods

14. Drum Fermentation Continuous Fermenting
Machine (CFM)
Figure 8:Modern fermenting methods

15. Hygiene Control
Cleaning of Fermenting room daily.
Roller should be frequently cleaned.
Fermenting room should be more ventilated.
Humidified air flow should be maintained.

16. References
http://www.tocklai.net/activities/tea-manufacture/factory-hygiene/
https://en.wikipedia.org/wiki/Crush,_tear,_curl
http://www.upasitearesearch.org/orthodox/
http://www.upasitearesearch.org/ctc/
https://www.teatulia.com/tea-101/tea-processing.htm
Tea Science by D.L. Sana

17. Thank You