Tea Processing

TEA PRODUCTION
• The tea plant is cultivated in tropical and subtropical regions of varying climatic conditions:
– with a temperature range of 13°C–29°C,
– altitude 2460 m above sea level, and
– acidic soil rich in iron and manganese with a pH range of 3.3–6.0, preferably 4.5–5.5
• Tea is the most widely consumed of ancient beverages.
• The world production of tea in 2016 was 5.95 Million metric tons.
• India is the 2nd largest producer after China, with a total production of tea approaching 1.25 Million
metric tons in 2016.
• The other major tea producing and exporting countries are Sri Lanka, Turkey, Kenya, and Indonesia.
• Among 30–40 countries, the United Kingdom, Russia, Japan, Pakistan, the United States, and Egypt
are the top importers and consumers of large quantities of tea and tea products.
• According to a recent U.K. market survey, tea was assessed far ahead of coffee as a beverage,
considered the ideal choice in the morning by 81%, at breakfast by 75%, at midmorning by 67%, and
in the afternoon by 77%.
 TEA: HISTORY
• The tea plant belongs to the genus Camellia (Camellia sinensis), a
member of the family Theaceae.
• Taxonomically, two basic varieties of the tea plant are
recognized: viz., the Chinese variety C. s. sinensis, and the
Assamese variety C. s. assamica.
• The plant originated in East Asian countries, China, Burma, Laos,
and Vietnam.
• Its use as a beverage in China dates back to 350 C.E..
• Tea reached Europe in the 16th century.
• Tea was discovered in 1823 in the Indian province of Assam,
where it was first cultivated, and gradually spread to South India,
Indonesia, and Sri Lanka.
• Large-scale cultivation spread to many other countries in Asia,
the former Soviet Union, Africa, and South America.
 TEA: PRODUCTS
• Non-conventional tea products are
• Conventional teas are
– instant tea (cold- and hot-soluble),
– (a) totally fermented black – flavored tea, and
tea, – decaffeinated tea.
– (b) raw or unfermented – Canned or bottled teas,
green tea, and – soluble tea mixes,
– tea beverages,
– (c) partially fermented
– frozen tea liquid, and
Oolong (red and yellow)
– tea tablets
tea,
• Liquid tea concentrates, tea mixes, iced tea mixes, and fruit
• These three types can be tea mixes have shown tremendous increase in the U.S.
market.
made from the same tea
• Decaffeinated tea, both plain and flavored, is finding
leaves, depending on how expanding markets in the United States, United Kingdom,
the leaf is processed. Germany, and other countries.
 BLACK TEA

• Black tea is made from young leaves and unopened buds of the tea plant.
• The major steps involved in the manufacture of black tea are:
 plucking,
 withering,
 leaf distortion,
 fermentation,
 firing,
 grading,
 packaging and storage
 Ceylon tea is a popular type of black tea that
is also known as Sri Lankan tea.
Served as an iced tea or nice and warm,

Earl Grey tea is a tea blend which has been

flavoured with the addition of oil of bergamot.
Bergamot is a variety of orange that is often
grown in Italy and France

English breakfast tea is a traditional

blend of teas originating from Assam,
Ceylon, and Kenya.
It is one of the most popular blended teas,
common in British tea culture.
English breakfast tea is a black tea blend
usually described as full-bodied, robust,
rich and blended to go well with milk and
Oolong tea is a traditional Chinese tea. Oolong tea represents sugar, in a style traditionally associated
only 2% of the world's tea, but it's well-worth discovering. Oolong with a hearty English breakfast.
tea is an incredibly healthy tea related to green and black tea. is a
traditional semi-oxidized Chinese tea (Camellia sinensis)
produced through a process including withering the plant under
strong sun and oxidation before curling and twisting.
TEA LEAF CLASSIFICATION
 HARVESTING
• The fresh green tea leaves are usually harvested
by hand, at intervals of 7–14 days, throughout • The chemical composition of tea flush as
percentage of dry weight
the year.
Constituent %
• Generally, only the rapidly growing shoot tips Flavanols 25%
down to about the second or third unfolded leaf caffeine 4%
are plucked and used. amino acids 4%
organic acids 0.5%
• Long plucking interval or use of clones that monosaccharides 4%
deviate from the desirable leaf standard results polysaccharides 13%
protein 15%
in varying chemical parameters, such as
cellulose 7%
lowering of levels of theaflavin, caffeine, and lignin 6%
volatile flavor compounds and imparting of lipids 3%
poor sensory properties, such as sweet, flowery, chlorophyll and other pigments 0.5%
ash 5%
and grassy aromas.
and volatiles 0.1%
 WITHERING
• When tea leaves are plucked from the bushes, the moisture content is about 75%, and is then reduced to
approximately 45%. The fresh leaf is spread out on withering troughs about a foot deep and a flow of
cool air helps reduce moisture. This process can last from 8 to 18 hours depending on weather
conditions. Significant chemical changes occur during withering. The cell membrane permeability is
increased allowing for disruption of cell structure.
• PURPOSE:
• Withering is the most critical process in black tea manufacture. The primary aims of withering are to
reduce the moisture content of the leaf and to soften it, so it becomes pliable and will withstand the
subsequent process of ‘rolling’, without breaking up into flakes. Additionally, controlled moisture
extraction from fresh leaf is required to activate a series of bio-chemical reactions. These enzymatic
changes are ultimately responsible for the production of various biochemicals desired for achieving
quality parameters in made tea.
• CHEMICAL REACTIONS
• Significant chemical changes occur during withering. The cell membrane permeability of the leaf is
increased allowing for more disruption of cell structure. As a result, amino acids, caffeine, organic acid
levels and polyphenolase activity is increased.
 ROLLING
• Rolling of the withered leaf was perfected over centuries, a process which brings out flavour in tea. Rolling
assists in establishing proper conditions for enzymatic oxidisation of the flavanols by atmospheric oxygen.
This is achieved by disruption of cell structure which facilitates enzyme substrate contact.
• PURPOSE:
• The purpose of rolling is to achieve the final curved appearance and to break the leaf cell walls so as
to release essential oils to start a chemical reaction of fermentation. The leaf is rolled several times.
The first roll, known as the pre-conditioning roll is very gentle, of which the aim is to cover the twisted
particles with the juices from the leaf. The rolling process is what releases the colour, strength, aroma
and the taste of the liquid we ultimately pour into our cups.
• CHEMICAL REACTION:
• When the leaf cells are ruptured following the rolling of the withered leaf, the enzymes in the leaf
come in to contact with the oxygen in the air which initiates chemical reactions that are necessary for
the production of black tea.
• ROLL-BREAKING:
• Roll breaking has two primary objectives. To remove the twisted leaf off the rolled shoots that clogs
and impedes circulation, and to facilitate further twisting action on the large leaf. Additionally, it also
cools the leaf which would have risen in temperature during the process of rolling.
 LEAF DISTORTION/ROLLING FOR
MANUFACTURE OF ORTHODOX TEA
• After the withering process, the leaf is distorted by rolling or
cutting.
• Conventional processing of leaf requires rolling in order to
produce orthodox teas, viz., black tea and green tea.
• Leaf distortion immediately after plucking is not advisable.
• The rolling technique wrings out the juice from the leaf and
twists the leaf.
• A roller consists of a circular table, a cylindrical box or
jacket, and a cap to apply pressure.
• The leaf is bruised and twisted, then broken into small
pieces by increased pressure and sifted by green leaf sifters.
• The remaining bulk is rolled.
• The duration of each roll varies from 15 to 60 min, and the
number of rolls varies from two to five in normal practice,
depending on such factors as degree of wither, type of tea
required, roller charge and speed, rolling conditions, and
temperature.
 LEAF DISTORTION FOR
NON-WITHER TEAS
• In the case of non-wither teas, a number of leaf distorting
machines are used.
• Versatile modern machines (Legg-cut, CTC [crushing, tearing,
curling], and Rotorvane) are used singly or in combination.
• The object is intensive maceration of the tea leaf to ensure
rapid and complete fermentation.
• The CTC machine consists of two engraved metal rollers
running close together and works as a mangle, one at 70
rpm and the other at 700 rpm.
• The soft withered leaf is cut, torn, or rolled in the small gap
between the serrated surfaces of the rollers.
• The made tea is discriminated in the trade. The liquor
qualities are enhanced.
• Machines used for leaf distortion include the Triturator,
Ceylon continuous tea processing machine, Tocklai
continuous roller (TCR), Barbora leaf conditioner (BLC), and
USSR continuous rolling expresser.
 FERMENTATION
• During fermentation, also known as Oxidation, green leaf is converted to black tea. Although
this is referred to as fermentation, it became recognised as oxidisation, a process initiated by
the tea enzymes. This process starts at the onset of maceration during the rolling process, and
it is allowed to continue under ambient conditions. The temperature of leaf is maintained at
around 25-30 degrees. Mild acidification of the oxidised tea increases the levels of the tea
theaflavins.
• PURPOSE:
• The finer particles collected after roll breaking are fermented to bring about the changes necessary
to make a tea liquor palatable. This process can only take place when the cells of the tea leaf are
properly ruptured. Here, in the coolness and darkness of the fermentation room, an oxidising
enzyme produces brown products from the remaining water in the tannin. During this process, the
green leaf is converted to black tea. Although this is referred to as fermentation it became
recognised around 1901 as an oxidisation process initiated by the tea enzymes.
 FERMENTATION
• Fermentation is the step in black tea processing most important for the
necessary chemical and biochemical changes.
• The process starts at the onset of leaf maceration and is allowed to continue
under ambient conditions.
• The green leaf after rolling and sifting in the case of orthodox tea or macerated
leaf (CTC type) is spread in thin layers 5–8 cm deep on the factory floor or on
racked trays in a fermentation room.
• Temperature control and air diffusion are facilitated by using humidifiers or
cool air.
• Time of fermentation varies between 45 min and 3 h, depending on the nature
of leaf, maceration techniques, ambient temperatures, and requirement of
made tea.
• Temperature varies between 24°C and 27°C.
 FERMENTATION
• At the end of fermentation leaf color changes from green to coppery red along
with development of a pleasant characteristic aroma.
• The termination point is determined by the skill of the tea maker or by
instrumental techniques.
• Fermentation can be assessed by measuring the theaflavin and thearubigin
content, which are formed in the ratio of 1:10, under ideal conditions of
fermentation.
• Estimation of tannin is another useful method.
• Tannin decreases during this period, from 20% in green tea leaf to 10%–12% in
fermented tea.
• Modern developments in fermentation technology such as skip, trough, and
drum continuous fermenting systems have merits such as controlled optimal
temperatures, reduced cost, lowered floor space requirement, and improved
 FIRING & BAKING
• During this process, hot air is passed over the tea leaves to deactivate
fermenting enzymes. Many organo-chemical processes are accelerated
during this process, as are the enzymatic reactions before thermal
inactivation. Firing also reduces the moisture level to 2-3%. This is critical as
incomplete inactivation can cause accelerated deterioration of quality. There
are several grades of tea, such as leaf grades, broken grades, fannings & dust
grades.
• PURPOSE:
• The fermented leaf is dried to stop any further chemical reactions taking place. Passing
hot forced air over the tea leaves deactivates fermenting enzymes. Many organo-
chemical processes are accelerated during this period as are the enzymatic reactions
before they are inactivated due to heat. Firing also reduces the moisture levels of the tea
to 2 - 3%. This is critical as incomplete inactivation can accelerate deterioration of the tea
during storage.
 SORTING & GRADING
• Baked tea is sorted into different grades by passing them over a series of
vibrating screens of different mesh sizes - lectrostatically charged rollers
preferentially attract stalk and fiber to remove them from the tea.
• PURPOSE:
• The last operation in this long process of manufacture is the sorting and grading of the
fired tea. Its importance cannot be overstated as it is here that the value of the final product
is often determined.
 GRADES OF TEA
• Green leaf from a single plantation is converted to various grades of tea in a
common manufacturing process. These grades are:
Leaf Grades Broken Grades Fannings Dust Grades

BOP - Broken Orange BOPF - Broken Orange

OP ‘A’ - Orange Pekoe ‘A’ D1 - Dust 1
Pekoe Pekoe Fannings

OP - Orange Pekoe BP - Broken Pekoe PF - Pekoe Fannings D - Dust

FBOP - Flowery Broken FBOPF - Flowery Broken

P - Pekoe PD - Pekoe Dust
Orange Pekoe Orange Pekoe Fannings

FOP - Flowery Orange BPF - Broken Pekoe

FP - Flowery Pekoe
Pekoe Fannings

BM - Broken Mix F - Fannings

 PIGMENTS
• Flavanols of tea in the group of catechins constitute 25%–30% of the dry matter of the tea leaf.
• Tea quality is mainly related to the flavanol concentration of the fresh leaf.
• Epigallocatechin gallate constitutes a major portion of the flavanols in the fresh leaf and levels of
gallated flavanols decrease as the leaf ages.
• The major catechins and the reactions in the formation of tea pigments are shown in Fig. 1
• All catechins undergo oxidation.
• Epigallocatechin and epigallocatechin gallate are readily oxidized.

Fig. 1: The flavanols that occur in tea

• Quinone formation (Fig. 2) is the primary driving
force in fermentation;
• It results in the formation of the coloring pigments of
black tea.
• The oxidized polyphenol complex of black tea is
generally referred to as tannin but has no relationship
to tannic acid (pentadigalloyl ester of glucose), which Fig. 2 Quinone formation
does not occur in tea.
Pigment Colour More Information
Theaflavins bright orange-red • concentration in black tea varies from 0.3% to 2.0%
• Prolongation of fermentation decreases theaflavin
content.
Theaflavic Acids bright red, acidic • present only in very small quantities in black tea
substances
Thearubigins red-brown • About 75% of the catechins are converted to a complex,
poorly defined, and incompletely separated group of
substances, known as thearubigins
• The ratio of theaflavin to thearubigins is taken as an
index of strength of the liquor.
• The control of these two factors depends upon
 AROMA FORMATION
• The oxidized catechin reacts with the precursor molecules present in green tea and produces the
volatile compounds in black tea, which are mainly dependent on genetic, cultural, and manufacturing
variables.
• Oxidation of amino acids, carotenes, and unsaturated lipids leads to the formation of aroma
compounds during the fermentation period.
• Aldehydes of amino acids formed as a result of Strecker’s degradation reaction are of significant
importance.
• More than 638 aroma compounds in tea have been identified.
• The most important of aroma components are terpenes, terpene alcohols, lactones, ketones, esters, and
spiro compounds.
• The concentrations of aroma constituents and Aroma compounds of some of the world renowned
teas
volatile oil content are high in orthodox tea
Tea Variety Aroma Compounds
compared to those of CTC teas.
India’s Darjeeling linalool, linalool oxides I and II,
• CTC teas give strong brew/body, more tea geraniol
cuppage, and malty aroma, whereas orthodox China’s Keemun tea 2-phenylethanol and geraniol
teas produce a light brew with fine, flowery, Sri Lanka’s Uva tea methylsalicylate, linalool, and
and rich aromas due to high concentrations linalool oxides
Formation of coloring pigments and aroma compounds in black tea
 GREEN TEA
• Around 21% of total tea production is consumed as green tea, which contains larger amounts of
catechins and vitamins.
• Green tea has a pleasant taste, flowery aroma, and light green color with an olive shade.
• Green tea is produced from a bud and two to three lead flushes of tea shrubs.
• Because green tea is unfermented, the development of the oxidative process is regarded as an
adverse factor.
• In the Japanese method, the enzyme is inactivated by steaming, whereas in the Chinese method
the enzyme is inactivated by roasting leaves in a pan.
• The steps of manufacturing of green tea are plucking, steaming/ roasting, primary heating and
rolling, rolling, secondary rolling, drying, refining, firing, sorting, and packing.
• There are 18 different types of green tea, classified as pan fixed (viz., pan dried, basket dried,
cured roasted, sun dried) and steam fixed.
NON CONVENTIONAL TEAS
 INSTANT TEA
• Instant tea obtained by dehydration of tea infusion of black tea or green tea is
a dry powder that is valued for its convenience.
• The product is highly hygroscopic and hence requires suitable packaging.
• Different types of instant tea, viz., hot-soluble and cold-soluble, are available,
depending on end usage.
• Both types are largely used in vending machines.
• Other forms marketed are decaffeinated soluble tea, either plain or with
added flavors, and flavored instant teas.

ASSIGNMENT: Technology of Instant Tea

Submission: On or Before 20/04/2018
 MEDICINAL AND NUTRITIVE PROPERTIES OF TEA
• Some of the valuable compounds in tea, such as caffeine, theobromine, theophylline,
tannin, essential oils, minerals, and vitamins, through their pharmacological and
physiological properties have beneficial effects on digestion, the nervous system, blood
vessels, cardiovascular function, blood pressure, and vital energy.
• Tea, an excellent diaphoretic, stimulates metabolic processes and plays a certain
prophylactic role.
• Tea alkaloids are very good for mental fatigue and contribute to cerebral vasodilatation.
• Tea’s beneficial effects on cold induced fever are commonly known.
• Clinical tests proved that scurvy cannot be cured with the aid of crystalline ascorbic acid
alone, but in combination with vitamin P it can, through their synergistic effect, increase
total resistance to infectious diseases.
• Tea flavonols also have vitamin P activity.
• The antioxidative property of tea catechins has an antiradiation effect.
 MEDICINAL AND NUTRITIVE PROPERTIES OF TEA

• Tea phenolic compounds, as important biological antioxidants, can delay

arteriosclerotic development in the human body, which involves peroxidation of
membrane lipids that is due to lack of biological antioxidants such as tocopherols.
• Tea polyphenols have bactericidal and bacteriostatic activity.
• Because of this antimicrobial action, green tea brew is effective in the control of
dysentery.
• The strong protistocidal effect of tea extract is used against certain protozoan
diseases of humans and farm animals.
• Hypertension, diabetes, poliomyelitis, scarlet fever, other infectious diseases, and
heavy muscle work, especially in hot workshops, result in a phenomenal increase
in the requirement of vitamin P. Green tea, taken in the form of a hot liquor, can
replenish this deficiency.
 MEDICINAL AND NUTRITIVE PROPERTIES OF TEA

• Green tea brew alleviates headache and beneficially influences the

cardiovascular system, fluid electrolyte balance, hemopoiesis, and renal function.
• Green tea brew regulates cholesterol metabolism in atherosclerotic patients.
• Green tea is claimed to protect against the incidence of cancer, especially lung,
esophageal, skin, and gastrointestinal cancers.
• In addition, tea is apparently a good source of fluoride and manganese, which
prevents dental cavities and aids protein and energy metabolism, respectively.