Tea-Manufacturing

Global Tea Production

• Black Tea accounts for 83%.

• Orthodox tea accounts for 44% of the world market.

• CTC caters 39% of the world market.

Global Tea Production

• Orthodox Tea – increased by 1.88 per cent.

• CTC Tea - increased by 0.56 per cent.

Domestic Consumption

• Growing in

• India by 3.5 per cent.

• Kenya by 8.8 per cent.

• Sri Lanka by 1.5 per cent/annum.

Exports from India

• Orthodox tea have increased by 3.20 per cent

• CTC tea have increased by 6.79 per cent increase.

Region wise Production

• South India – increase by 12.23 per cent.

• North India – increase by 1.27 per cent

Per capita consumption

• India – 0.8 Kg

• Sri Lanka -1.2 Kg

• UK -2.5 Kg

Major Players

• The major players in the tea industry are: • Hindustan Lever • Tata Tea • Williamson Magors • George Williamson • Harrisons Malayalam • Mcleod Russel • Bishnauth Tea • Dhunseri Tea • Warren tea • AFT Industries

Plucking

Plucking

• Only the young tender shoots are skillfully hand plucked as soon they are ready.

• Each tea bush is plucked every 6-8 days depending on the season.

• Plucking begins in March and closes by early December; the cold winter months of December to February are a period of dormancy.

• Each kilogram of fine tea consists of more than 20,000 individually hand plucked shoots.

Types of Tea

• Fermented – Black Tea

• Unfermented – Green Tea

• Semi-fermented –White Tea

Oxidation

• Polyphenols in the leaf gets oxidised with the help of endogenous enzyme namely polyphenol oxidase.

• When the leaf gets crushed during rolling the polyphenol and the enzyme are mixed in the presence of oxygen.

Fermentation

Oxidation Process

• Polyphenol is broken into theaflavin and thearubigin.

• Theaflavin – Briskness and brightness.

• Thearubigin – Colour and strength.

Oxidation

Factors influencing Oxidation

• Duration – 60-90 min ( South-India)

• Temperature - 27 deg C

• Humidity – around 95%

• Aeration -optimum

• Thickness of spreading-Floor fermentation

• Cleanliness - Hot water steralization

Orthodox/CTC

• Orthodox Manufacture:

• Maceration is done by rolling tables.

• CTC( Crush,Tear & Curl):

• Rollers rotating at high speed in opposite directions.

CTC (Crush,Tear&Curl)

• Withering

• Rolling(CTC)

• Fermentation• • Drying

• Sorting

• Grading

Orthodox

• Withering

• Rolling

• Sifting

• Fermentation

• Drying

• Sorting &Grading

Withering

• Removal of 10-15 % per cent moisture from plucked leaf.

• Duration to 12-18 hrs.

Enclosed Withering

Withering

Rolling (CTC)

• Shifter

• Rotorvane

• CTC Roller

Rolling (Orthodox)

• Mechanical development of original hand rolling process.

• Compressing and turning the leaf over.

• Roller consists of three parts, a circular table, a cylindrical box and cap to apply pressure.

Rolling

Rolling

Rolling

Drying

Processing

• Withering : Aroma precursors formed.

• Fermentation: Oxidation takes place & giving rise to aroma and colouring constituents.

• Firing : Stops the Oxidation process.

Drying

Drying

Grading

Assam Tea

• Elevation: 45 – 60 metres.

• Rainfall : 2500 – 3000 mm.

• Type: rich,full bodied,bright tea liquor.

Darjeeling Tea

• Elevation-90-1750 meters.

• Grown in the foothills of the snowcovered Himalayan range.

• Golden or amber in colour and delicate flavour of muscatel grapes.

Manufacturing Darjeeling Teas

• Darjeeling leaves weigh less due to severe withering process.

• Very exacting, time consuming traditional or Orthodox tea.

Dooars and Terai

• Elevation:90-1750 meters.

• Rainfall:3,500 mm.

Kangra

• Elevation: 700-1000 metres.

• Rainfall: 2,300-2500 mm.

Nilgiris

• Elevation: 1000 -2634 m

• Rainfall : 1,000-1500 mm.

• Uniqueness: Fragrance and aromotic tea.

Anamallais

• Elevation: 900 -1600 metres

• Rainfall : 3,000 -3,800 mm

• Uniqueness: Fragrance with biscuity and floral notes.

Wayanad

• Elevation - 850-1400 metres.

• Rainfall - 2000 – 2500 mm.

• Uniqueness –Earthy reddish liquor,Mild and mellow.

Karnataka

• Elevation-750 -1000 metres.

• Rainfall :2000-3500 mm.

• Uniqueness : Simple and fragrant teas.

Munnar –High Ranges

• Elevation – 950 -2600 metres

• Rainfall : 1300-7000 mm.

• Uniqueness: Clean and medium toned fragrance of sweet biscuit in dip malt.