tea manufacturing operations
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TEA
MANUFACTURI
NG PROCESS
Atia Mathai Luke (2224043)
Srikanth Kalakonda (2224051)
Srinivas Thatavarthy (2224235)
Sumanth eddy Arani (2224045)
Sundee! "outham (2224055)#inod #$ %air (2224044)
Siddhartha $illutla (222405&)
'aulty Prof. Rajiv Misra
*ath PGCBM-22
"rou! 18
+entre Beg!"e#$ %&'era(a'
PROCESS ANA)*SIS
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There are t,o ma-or strains o. the tea/
Ca!e++ia Si,e,sis riin .rom +hina
Tiet and a!an6 They are 7 8 15 .eettall 2 inh leaves6 9ave resistant to
very old tem!eratures6
Ca!e++ia Assa!ia riin .rom%orth :ast ;ndia6 They are 45 8
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Tea is manu.atured in t,o di..erent ,ays CTC or Or#o'o/6 +T+ re.ers to the Crs$ Teara,' Cr+!roess ,here the ,ithered reen leaves are !assed in8et,een t,o rollers rotatin in
o!!osite diretions6 There is om!lete maeration o. the leaves and the resultin !o,derymaterial is re.erred to as >cut dhool>6 E,0&!a#i a#io, is iger in the +T+ ty!e o.
manu.ature6 ;n Or#o'o/ ty!e o. manu.ature the ,ithered leaves are rolled on s!eially
desined orthodo? rollers ,hih t,ist and rush the leaves therey ru!turin the ells6 Themaeration is less as aainst +T+ !roessin6 *ut this !roess results in teas ,ith goo' f+avor
a,' aro!a.
This doument ,ill over the !roess o. +T+ tea manu.aturin ,hih is a Co,,e#e' )i,e
F+o or Asse!(+& )i,e6 ;t inludes ,itherin o. harvested ro! reen lea. shi.tin
reonditionin rollin .ermentation dryin radin @ sortin tastin storin and !akin6 Tea
is then shi!!ed to autions loally or loally6 See 'iure 1
IT%ERING
A.ter the !luked lea. arrives at the .atory ,itherin is the .irst and .oremost ste!s involved in
tea manu.aturin6 The eva!oration o. moisture in the reen lea. is rouht aout y lo,in ormovin air over the lea. in the ,itherin trouh6 The urrent o. air !er.orms a t,o .untions vi6
onveyin heat .rom the lea. as ,ell as arryin a,ay the ,ater va!or throuh a ed o. reen
leaves to ahieve !hysial ,itherin6 Bhenever the hyrometri di..erene is elo, 3C+ hot air
is mi?ed in suitale !ro!ortion or heat enery is su!!lied to inrease the hyrometri di..erene,ith the onomitant rise in the dry ul tem!erature o. air6 *ut the dry ul tem!erature o. air
a.ter mi?in should not e?eed 35C+6
+urrently in most o. the South ;ndian tea
.atories trouh ,itherin is !ratied6 The
dimensions o. the trouh in most o. the
.atories vary onsideraly6 The ,idth o. thes#a,'ar' #rog is 34 a,' i#s +e,g# varies
(e#ee, 354 a,' 12546 9o,ever no,adays
,ider trouhs ,ith t,o a?ial .ans are!re.erred6 Sies vary et,een 12D and 15D o.
,idth and
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GREEN )EAF SIFTING
:?traneous matter suh as stones sand or metal !iees may .ind their ,ay in the leaves rouhtinto the .atory/ i. suh materials are .ed into the .ine8tuned ontinuous mahines the movin
!arts ,ill e severely damaed6 Similarly i. the leaves ,ere not .ed evenly into these mahines
they ould eome -ammed or ,ould not .untion e..iiently6 9ene reen lea. si.tin isessential !rior to !roessin6
The reen lea. si.ter is essentially a devie .or
introduin a ontinuous even .lo, o. ,ithered
lea. to the +T+ !roessin setion6 ;t is aviratin tray ,hih is !er.orated ,ith holes
or is o. a ,ire mesh6 $o,er.ul manets have
een !rovided in the reen lea. si.ter to remove
any iron !iees !resent alon ,ith the lea.6
RECON9ITIONING
;n South ;ndia seondary rades and other residues ,hih are otained ,hile leanin the
!rimary rades are round and reyled ,ith the ,ithered lea.6 This !roess is kno,n as
reonditionin6 The !rimary o-etive o. this !ratie is to "ro'e grai,& gra'es as e++ as #ea
of ig 'e,si#&6 ;t also hel!s to minimie or eliminate seondary rade teas6 The Euantity o.
reyled material kno,n as reondition dust varies .rom .atory to .atory it de!ends on the
Euality o. reen lea. the moisture ontent o. the ,ithered lea. and the standard o. mahineryavailale6 The !erentae o. + is mostly e?!ressed on the ,eiht o. reen lea. or made tea
asis6 The lea. shredder and rotor vane omination has een .ound to e ideal to !re8ondition
the lea. .or +T+ !roessin6 The out!ut o. oth these mahines should math ,ith the +T+ as,ell as drier a!aities6 Shreddin o. ,ithered lea. into .ine !artiles inreases the otorvane
a!aity and hel!s e..iient mi?in o. the lea. ,ith reonditioned dust in the otorvane6 The
maerated lea. .rom the shredder has to e in the .orm o. FhutneyG6 To ensure this the shredderlades have to e haned every ,eek6 ;t is im!ortant that the ,eiht o. eah lade should e
less than one K6 and !ro!erly alaned on the kni.e ede6 edution o. a! et,een t,o lades
!roressively hel!s to ahieve etter results6
otorvane is essentially a lare mininmahine and is im!erative to !reondition the
lea. suitale to e .ed into the +T+ mahine as
,ell as .or etter .usion o. + material ,ith,ithered lea.6 There are t,o sies one ,ithylinder o. 2063 m (&H) diameter and the other
lare mahine ,ith a ylinder diameter o. 3&61
m (15H)6 The lea. is !roessed in this ylinderin ,hih a rotor !rovided ,ith vanes rotates
et,een resistors therey !ro!ellin the lea.
.or,ard and disharin throuh an end !late6
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;n drum .ermentation the ,hole !roess
is dynami and the leaves are onstantly
rotatin6 :very it o. tea that is ein.ermented is onstantly layered and
e?!osed to the .resh air or onditioned
air6 uin o. lea. aainst lea. takes!lae and the -uies !resent in the miro
ells o. lea. are evenly oated on the
e?terior o. the tea lea.6 =rum.ermentation !rodues laker teas as
om!ared to .loor .ermentation6 These
teas are usually risker due to etter
aeration6
Sine most o. the (ioe!ia+ rea#io,s orri,g 'ri,g fer!e,#a#io, are o?idative in
nature mass trans.er o. o?yen to the tea !artile is a ritial !arameter in the desin o. any
.ermentor6 The .ermentin drums are eEui!!ed ,ith s!iral .lihts on the interior .or li.tin andsho,erin the solids throuh the air stream and to aelerate the .or,ard .lo, in the drum6 "ood
ventilation and aess to .resh air are !aramount to !ro!er .ermentation6
9R*ING
=ryin is the most e?!ensive !roess in the manu.ature o. tea6 The a!ital investment on thedriers is also the hihest amon the di..erent !roessin mahines6 -etive o. dryin are to
arrest the .ermentation !roess and to remove the moisture and to !rodue tea ,ith ood kee!in
Eualities6
*e.ore oin to the di..erent ty!es o. dryin systems it is essential to kno, the asis o. dryin6=ryin a solid matter indiates removal o. ,ater .rom the solid materials y eva!oration6 =urin
the early staes o. dryin the solid is so ,et that a ontinuous .ilm o. ,ater e?ists over the entire
sur.ae6 The ,ater removed durin this !eriod is mainly su!er.iial ,ater6 The rate o. dryinunder a iven set o. air onditions is onstant and inde!endent o. the moisture ontent6 This
!eriod is kno,n as the o,s#a,# ra#e of 'r&i,gand the tem!erature o. the solid durin this
!eriod a!!roahes the ,et ul tem!erature o. the air6 The manitude o. the onstant ratede!ends on the area e?!osed to the dryin medium the di..erene in tem!erature et,een the
as stream and the ,et sur.ae o. the solid and the air veloity6
The !rini!le involved in the =riers is that .ermented lea. is su-eted to a last o. hot air in suh
a manner that the o##es# air firs# o!es i, o,#a# i# #e #ea avi,g #e +eas# !ois#reo,#e,#6 ;n these driers the .ermented lea. .alls on a series o. movin !er.orated trays on ,hih
it is !assed and re8!assed throuh a movin stream o. hot air6
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The !er.orated trays are mounted on an
endless hain and arraned in a tier o. si? or
eiht units ,hih alternate in the diretion o.motion6 The =esin is suh that at eah stae
o. the dryin o!eration the lea. is su-eted
to a di..erent tem!erature6 As the lea. !asses.rom tray to tray it !roressively omes into
ontat ,ith hiher tem!eratures6 Bhen the
air takes u! moisture the dry ultem!erature .alls6 A .inal moisture ontent o.
et,een 265 and 360J should e the aim6 ;.
the tea is dried elo, 160J it loses some
Euality6 Tea dried to 365J moisture ontentand aove does not kee! ,ell6
The o!timal inlet tem!erature .or +T+ !roessed lea. is 100 5C'6 The e?haust tem!erature
should e maintained at 5464 26IC+ (130 5C')6 ;. the e?haust tem!erature is less than 47C+(120C') the !ost .ermentation !roess ,ill ontinue .or a onsiderale time and ,ill so.ten the
liEuor6 ;. the e?haust tem!erature is reater than 5I62C+ (135C') the rate o. moisture removal is
too ra!id and results in ase hardened tea in ,hih the !artiles are hard on the outside ut
inom!letely dried ,ithin/ suh teas yield harsh liEuors and do not kee! ,ell6 So it is o.!aramount im!ortane to ensure that tem!eratures are ke!t under ontrol to the e?tent !ossile6
SORTING AN9 GRA9ING
Sortin is the o!eration in ,hih tea !artiles o. the ulk are se!arated into various rades o.di..erent sies and .orms on.irmin to trade reEuirements6 ;n other ,ords it asially onverts
the ulk into .inished !roduts6 The !roess o. sortin has t,o o-etives (i) to e,a,e #eva+e (ii) to i!"ar# a+i#&6 "radin o. the manu.atured ulk is there.ore undertaken to
i!"rove i#s !ar7e#a(i+i#&and to otain the !remium that di..erent uyers are ,illin to !ay .or
the sie o. their !re.erene6 +leanin o. .ier is also !art o. the sortin !roedure ,hih is
diretly related to value enhanement6
The leanin o. .ire im!rovesthe lak a!!earane o. tea
,hih is desirale6 *loom is
indiative o. liEuor harater/over sortin and over leanin
an result in loss o. loom6sually a tea ,hih has not
een ,ell .ired loses loommore Euikly6 ;. tea asors
moisture durin the leanin
!roess liEuors an deteriorateand its kee!in Euality redues6
Sortin o. ulk has to e done in three staes vi6 leanin o. .ire radin and ,inno,in6
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+urrently 'iromat ($#+ rollers) are ein ,idely used to remove the .ire as ,ell as .laky teas
.rom the rest o. the ulk6 The !rini!le involved here is that $#+ rollers are (stati) eletrially
hared y the ontat o. a s!one like material kno,n as .elt6 'ire and .laky teas di..er inmany haraters like moisture ontent and density .rom the rest o. the tea6 These eletrially
hared rollers !re.erentially attrat the .ire and .laky teas ,hih are hiher in moisture ontent
and therey they are removed .rom the ulk6
Sortin enhanes the a!!earane andEuality o. liEuor/ at the same time it an
also deteriorate the Euality6 The !resene
o. .ire or .lakes o. oarse lea. in a!rimary rade auses harshness and their
removal makes the liEuor mello,6
;. teas are e?!osed .or loner time in the
humid onditions the di..erene o.
moisture ontent et,een .ire and resto. ulk narro,s do,n/ this redues the
e..iieny o. the removal .rom the ulk6
The ommon rades o. +T+ tea are as .ollo,s
PE: $ekoe 9 =ust
BP *roken $ekoe P9 $ekoe =ust
BOP *roken rane $ekoe P91 $ekoe =ust ne
BPS *roken $ekoe Souhon 91 =ust neBP1 *roken $ekoe one R9 ed =ust
FP1 'lo,ery $ekoe one F9 'ine =ust
OF rane 'annins SF9 Su!er 'ine =ust
PF $ekoe 'annins R91 ed =ust one
PF1 $ekoe 'annins ne G9 "olden =ust
BOPF *roken rane $ekoe 'annins SR9 Su!er ed =ust
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STORING AN9 PAC:ING
Teas are !aked in airtiht ontainers orins in order to !revent asor!tion o.
moisture ,hih is one o. the main auses
.or loss o. .lavor durin storae6 $akin
hests are usually onstruted o. !ly,oodlined ,ith aluminum .oil and !a!er and
sealed ,ith the same material6 +orruatedardoard o?es lined ,ith aluminum .oil
and !a!er saks lined ,ith !lasti are also
em!loyed6 ute as lined ,ith *$$
liners are e?tensively used .or the !akino. tea in the ;ndustries6
As timer is eomin sare and onseEuently e?!ensive the multi ,all !a!er sak !roved to
e suitale alternative and is ein ,idely ado!ted in the tea industry6 These as are later
trans!orted to the loal or loal autions6
Ma,fa#ri,g )ea' Ti!e a,' C&+e Ti!e
Tea manu.aturin is a Make8To8Stok (MTS) !rodut6
The normal a!aity o. a lare .atory in %iliris an !roess 10 tons o. "reen Lea. !er day6
This !rodues an averae o. 2200 2500 Kilorams o. Tea !o,der !er day6 This amounts to 45
to 50 as o. Tea !o,der !er day6 A standard truk an arry around 10 tons !er tri! this ,illmean 4 days o. manu.aturin e.ore 10 tons o. Tea !o,der an e trans!orted to the Autions6
The trans!ortation ,ould take 2 days6
The Manu.ature Lead Time (MLT) .or 10 tons o. manu.atured Tea !o,der to the Autions is