Tea Manufacturing Process
Tea transcends the ordinary, blending tradition with serene moments. From refreshing greens to bold blacks, each variety tells its own story shaped by diverse cultures and careful hands. Two main processing methods are CTC (Crush, Tear, Curl) and Orthodox. Orthodox tea, known for its craftsmanship, offers a range of flavors—floral, fruity, malty—created through traditional methods like withering, rolling, fermenting, and drying. CTC modernizes black tea production with razor-edged rollers that crush, tear, and curl leaves into pellets, producing a robust flavor and distinctive color.
Withering
Withering reduces the moisture level in tea leaves to soften them for further processing. After being harvested, leaves are spread out on meshed trays in a cool, shaded area. Each tray is positioned at a height of 2 to 3 feet, allowing for optimal air circulation. This process lasts up to 12 to 17 hours, during which leaves lose about 40% of moisture, triggering physical and chemical transformations that enhance flavor and aroma. Careful and closely monitored withering is essential for creating a balanced and complex flavor profile, highlighting the art and precision of orthodox tea craftsmanship
Plucking
Orthodox tea starts in lush gardens, where premium clones like P126, S3A3, and Nokhroy are carefully cultivated for their unique qualities. Plucking with precision is essential for crafting quality tea. By hand-picking only, the tender top "two leaves and a bud," we preserve the tea’s essential oils, polyphenols, and other compounds that enhance its flavor, aroma, and health benefits.
Rolling
After withering, the tea leaves are placed in nylon bags and transferred to the rolling table, where they are gently pressed and twisted. This process breaks the leaves slightly to promote oxidation and release cell sap, influencing the final appearance—twisted, curled, or pelletized—enhancing aroma and flavor. The artistry and precision of rolling are vital, unlocking the leaves' full potential and shaping the rich flavors of premium orthodox teas.
Oxidation/ Fermentation
Drying halts oxidation and locks in the tea’s unique flavors and aromas. Once the desired oxidation is achieved, leaves are dried using methods like sun drying, baking, or hot air dryers. In this step, they rest on moving trays in a drying chamber with hot air flowing around them, carefully balancing temperature to avoid scorching. Reducing moisture to about 2-3%, drying preserves the flavors and aromas, ensuring the tea is ready for storage and enjoyment worldwide.
Drying
In orthodox tea production, oxidation is a crucial step that develops the tea’s flavor, color, and aroma. During this process, rolled tea leaves are kept in a cool, humid environment where they interact with oxygen. This interaction causes chemical changes in the leaves, breaking down chlorophyll and releasing new flavors. The level of oxidation ultimately determines the type of tea produced.
Sorting and Grading
The sorting and grading process is the final critical step in orthodox tea manufacturing, ensuring consistent quality. After drying, leaves are sorted with mechanical sifters to remove red stalks, fibers, and broken leaves, separating them by size and shape. Grading then categorizes the leaves—ranging from whole leaf, which is the highest quality with intact leaves, to broken leaves, fannings, and dust, with the finer particles typically used in tea bags.
Withering
After harvest, leaves are spread on meshed trays in cool, shaded areas for 12 to 17 hours. Warm weather speeds moisture loss naturally, while colder, humid conditions require heated air via fans and fires. This gradual withering triggers vital physical and chemical changes, such as breaking down proteins into amino acids, enriching flavor and aroma. During this stage, leaves lose about 30% moisture, preparing them for further processing and ensuring the development of the rich taste that distinguishes exceptional CTC tea.
Plucking
The journey of CTC tea starts in lush tea gardens, where superior clones like TV1 and S3A3 are cultivated for their quality and unique characteristics. Skilled harvesters carefully hand-pick only the finest leaves, focusing on the top "two leaf and a bud." This traditional method ensures that only the most tender parts of the tea plant—rich in essential oils and polyphenols—are selected, enhancing both the flavor and health benefits of the tea.
Crush, Tear, Curl (CTC)
Once withered, the leaves are collected by hand or automatically via a monorail. They then move to the Rotorvane, a high-quality stainless-steel apparatus that pre-conditions the leaves before entering the main CTC machine. Even though the leaf has been broken at this stage, it retains a vibrant green hue as the starch inside begins to interact with oxygen. Next, the leaves pass through six sharp rollers, where they are crushed and torn to boost surface area, promoting oxidation and deepening flavor. This dynamic process transforms the leaves, developing the robust character and distinct flavors that CTC tea is known for.
Allowing Fermentation
Following the CTC process, processed leaves drop into a conveyor. From there, the leaves move into the Continuous Fermenting Machine (CFM), where the transformation truly begins—a vital phase that dramatically influences the tea’s color, aroma, and flavor. The duration of fermentation can be adjusted, allowing for the creation of an array of CTC teas, ranging from robust and malty to bright and brisk.
Drying the Tea
To halt the oxidation process, tea is swiftly dried under controlled conditions using hot air. This critical step locks in rich flavors and ensures the tea’s longevity. Various methods, such as hot air drying or pan-firing, can be employed to achieve the desired results, preserving the essence of every leaf.
Sorting and Grading the Tea
Once dried, the tea undergoes a meticulous grading process. This systematic approach categorizes the tea based on size, appearance, and quality, ensuring that each batch meets the high standards set by discerning tea connoisseurs and enthusiasts alike.
