The document describes several processes for manufacturing green tea. In general, the key steps are: 1) Plucking or harvesting of young green tea leaves. 2) Fixing enzyme activity through steaming or pan firing. 3) Rolling leaves to shape them. 4) Drying leaves through multiple stages to reduce moisture content to around 3-5%. Specific processes may incorporate additional steps like withering, cutting, sorting, and final roasting. Methods can involve different machines, temperatures, times and numbers of rolling and drying stages to produce different types of green tea.

1. TEA PROCESSING
PROCESS FLOW DIGRAMS
RAJAT KATIYAR

2. General tea manufacturing steps

3. GREENTEA PROCESSING
PROCESS FLOW DIGRAMS

4. General processing steps in green tea
Cultivation & harvesting
Steaming & fixing
Pre-drying
Rolling & shaping
Final drying(roasting etc.)
Grading, Sorting & Storage

5. PROCESS FLOW DIGRAMS FOR DIFFERENT
METHODS OF
GREENTEA PROCESSING

6. Tea Research Institute of Sri Lanka,Talawakele,
Sri Lanka:
1.
• Plucking
• It is the process of harvesting of tea leaves.
2.
• Panning
• This operation is accomplished in the 'Chekiang GreenTea Model 180' de-enzyming
machine. Furnace temperatures ranging from 250 to 550°C, exhaust temperatures from
45 to 65°C, feed rates from 5 to 15 kg min'1as well as single and double passes.
3.
• Cooling
• Panned leaf was cooled immediately in a stream of cold air.This was
done by manually spreading the panned leaf in front of a 40 cm (16") X-
pel air fan mounted on a 0.6m (2 ft) stand.

7. Tea Research Institute of Sri Lanka,Talawakele, Sri Lanka
…continued
4.
• Roll breaking
• Roll-breaking was carried out on- a standard 1.3m (4.5 ft) rotary roll-
breaker fitted with a No. 4 Gl mesh.
5.
• Drying
• In drying the moisture of the tea leaves is brought down up-to 3-5% by
usingWalker's pressure driers 'Standard' model MK 1.
6.
• Shifting & sorting
• The sifting machines used were Myddleton stalk extractor, Michie sifter,
Japanese tea cutter and suction winnower.The perforations of the two
bubble trays of the Myddleton stalk extractor was top tray 0.47 cm (3/16")
and bottom 0.6 cm (1/4").

8. Processing of “Sencha” green tea:
1.
• Steaming & cooling
• When the fermentation stops, the steamed leaves take on a
fresh green color.The leaves now contain about 75 % water.
2.
• Rolling
• Rolling is carried out several times in Primary drying tea roller,
Tea roller, Secondary drying tea roller, Final drying tea roller.
3.
• Drying
• This machine consists of an air heating furnace, a drying
chamber, and net conveyors.The aim of this step is to
uniformly reduce the water content in the leaves from
about 13 % to 6 % while maintaining the quality and
fragrance.

9. Processing of “Sencha” green tea:
4.
• Final roasting
• After storage, the aracha is loaded into a microwave oven for roasting.
When the water has evaporated from the leaves, their temperature starts
to rise. When this temperature reaches a temperature in the vicinity of
150° to 170° C., the process is complete, or very nearly complete.
NOTE
• ARACHA
• It is the same tea that is processed by same above procedure upto
step 3.
NOTE
• Aracha tea is also known as “crude tea”.

10. Standard in making process of crude tea(Sencha)
S.no. Machine Revolution
RPM
Air temp. Time
required
Less weight Water
content
1 Tea steaming machine 35-50 Steam 30-60 sec. 0% 75%
2 Primary drying tea roller 36-38 90-110 30-45 min. 55-60% 50%
3 Tea roller 22-28 Non heating 15 min. 0% 50%
4 Secondary drying tea roller 26-28 50-60 30-40 min. 58-70% 30%
5 Final drying tea roller 50-60 (cpm) 80-90(pan temp.) 30-40 min. 73-75% 13%
6 Tea dryer ______ 70-90 25-30min. 77% 6%

11. Green tea processing inVarieTea,Tea Garden,
Assam
1.
• Plucking
• Harvesting of green tea leaves
2.
• Storage
• Storing of tea leaves in a controlled atmosphere
3.
• Withering
• It is done under controlled atmosphere.
4.
• Cutting
• Providing the tea leaves of a particular shape.
5.
• Drying
• To bring down moisture content in the tea leaves up to 3-4%.

12. Another method for processing green tea
1.
• Plucking of green tea leaves
• Harvesting process of green tea leaves.
2.
• Fermentation stopping
• Either by steam or hot water.To achieve this with a drying drum, the temperature
inside the drying drum should be kept at about 250 - 300°C. Or, if you are using
boiling water to steam the tea, then the metal basket containing the fresh leaves
should be dipped in the boiling water for 20-60 seconds.
3.
• Rolling
• It is done in rolling machine and tea leaves are rolled to provide shape to the tea
leaves.
4.
• High temperature drying
• The rolled tea is placed in the drying drum with a hot fire kept at a temperature of about 95 - 100°C.

13. Another method for processing green tea
………..continued
5.
• Low temperature drying
• Once the tea has reached about 40 - 45% water content, reduce the heat of the fire.
Continue turning the drum slowly but not too slowly.Try to hold the tea at a
temperature of 70 - 75°C.Continue drying the tea at this temperature until the tea
reaches a water content of only 4 -5%. As a rough estimate, this will take about 30
minutes.
6.
• Classification
• To separate the higher-grade tea from the lower-grade tea.
• One of the criteria used to judge tea quality is the grade (in other words, the
physical size and form of the pieces of tea).
• To ensure that all the tea in a specific grade has a similar size.
7.
• Final roasting
• "Roast" the tea at a relatively high temperature for a few minutes, turning the
drum slowly. But, do not allow the tea to scorch.
• This final roasting gives the tea a good flavour.

14. GreenTea ProcessingTechnique
Ing. Agr. Patricia A. Parra ,Buenos Aires,Argentina July 2014
1.
• Plucking
• Young and tender material is collected for a high quality GreenTea.The raw material should be tender,
even and fresh.
2.
• Fixation
• first step in GreenTea primary processing, critical to obtain high quality. It aims to
destroy the enzyme activity of fresh tea leaves with high temperature
3.
• Rolling
• The tea leave quantity, time and pressure, are major technical factors during rolling.
4.
•Drying
•Necessary to achieve a high quality GreenTea. Shape is defined and fragrance finishes its development.
This process needs several stages, such as: 2nd drying, 3rd drying and final drying.

15. Processing Technology of Green Tea
1. • Plucking or harvesting of green tea leaves
2. • Withering
3. • Pan frying or steaming (up to 2 minutes)
4. • Initial rolling (10 minute)
5. • Final drying (30 minutes)
6. • Final rolling (15 minutes)
7.
8. •Green tea
• Shaping

16. MANUFACTURING PROCESS OF GREENTEA
LEAVESWITH FRYER
1.
• Plucking
• Harvesting of green tea leaves.
2.
• Roasting
• Roasting was done by fryer (250 ̊̊̊̊̊̊̊̊̊ᴄ & 25 minutes).
3.
• 1st Rolling
• Using rolling machine rolling was done.
4.
• 1st Drying
• Drying was done by fryer(180 ̊̊̊̊̊̊̊̊̊ᴄ & 15 minutes).
5.
• 2nd Rolling
• After 1st drying 2nd rolling was done for providing final shape & size to the tea leaves.
6.
• 2nd Drying
• Final drying was done by fryer(100°C, 40 minutes).

17. MANUFACTURING PROCESS OF GREENTEA
LEAVESWITH FRYER & FIR
1.
• Plucking
• Harvesting of the green tea leaves.
2.
• Roasting
• Roasting was carried out with Fryer & FIR(250°C, 15 min & 300°C, 5 min)
3.
• Rolling
• Using rolling machine rolling was done.
4.
• Drying by fryer
• Drying was carried out by using fryer(180°C, 15 min).
5.
• Rolling
• After drying by fryer 2nd rolling was done for providing final shape & size to the tea leaves.
6.
• Drying by fryer
• Drying was carried out by using a fryer(100°C, 40 min).
7.
• Drying by FIR
• Drying was carried out by using a FIR(300°C, 15min).