A) Chemical wither – To breakdown complex chemical compound in the cell to single compound which along with other simpler molecules they recombine to contribute to quality attributes of tea like ‘body’ and ‘flavour’ at a later stage. Chemical wither starts immediately after plucking. This process normally takes about 12 to 16 hours.
B) Physically wither – Physical withering reduces moisture content in the leaf and makes the leaf ‘flaccid’ which is essential for the subsequent steps for processing and for twisting or curling. This process takes about 4 to 6 hours.
The principal objectives of leaf maceration are to undertake cell rupture in the rolling or CTC machine where progressive disintegration of cellular organelles takes place. The mechanical breaking of shoots of this stage also results in the formation of particles of various shapes & sizes on the method adopted.
A) Orthodox process of manufacture – In the Orthodox process of manufacture maceration of the disruption of the leaf cell is carried out in the Rolling Table. During Rolling, juice from the leaf is worn removed / extracted out and the leaf is twisted and broken into a small particle.
B) CTC process of manufacture – The CTC machines achieve the three actions of Crushing, Tearing and Curling in the same machine at one go. Leaf appearance make, grade percentage, fibre content, Liquor and Infusion depend on the cut obtained in the CTC machine.
Fermentation is the process during which the polyphenols in the tea leaf are oxidized in presence of the enzymes and subsequently condensed to form coloured compound contributing to the quality attributes of Tea. Fermentation starts immediately after cell rupture. Following physical and Bio-Chemical changes take place during fermentation.
A) Physical Changes –
B) Bio-Chemical Changes –
Drying is the last stage of making Black Tea. The process is to arrest enzymic reaction as well as oxidation (Fermentation) and to remove moisture from the leaf particles. It also helps in producing a stable product with good keeping quality.
Sorting is the operation in which particles of Bulk teas are separated into various grades, different sizes conforming to the trade requirements.
Four main grades are produced, namely, whole leaf grades, Brokens, Fannings and Dusts within each of these sections. Tea is further split up into grades of varying qualities.
After the tea has been manufactured and sorted into its respective grades, it is necessary to be packed it in suitable containers so that, its quality does not deteriorate. Bulk packing containers should be fed from a hopper at a regular flow to ensure no loss of bloom and damage of leaf.
Orthodox teas leaves are the traditional produce with long leaf and flavoury, where milk need not be added to savour the flavour.
CTC (Crush, Tear & Curl) teas are granular with stronger malty liquors, which also give more cuppage. Usually milk is added to enhance its taste.
