CTC Tea processing


 Processing of CTC Tea

  •  CTC Teas - In the process we use CTC(Curling Tearing Crushing) machines for crushing & cutting of leaves and turn them into small rounded teas after processing. These teas are strong & hard in liquor.
  • Discovered & patent by - W. Merkhar in 1930

  • Black Tea - The value of a tea from its infusion (,clour, brightness, quality, strength,  briskness & flavour) and appearance of the dry leaf particles(Fibre less, blackish & brightness like black pearl).


  • Quality of Tea - It is something that stimulates the taste- buds of the tonge and has the effect of enhancing the value of aroma.


Stages of manufacturing -


1. Plucking - The process in which pluck 1 bud with 2 & 3 leaves leaves and single banjhies from top of bushes.


2. Collection - The plucked leaves is collected after weighment in crate to maintain their softness. 


3. Transportation - Then by vehicle, it is send to factory in crate for manufacturing


4. Withering - By this process we deduct moisture from  leaves to concentrate theine alcoloid in control measures.

  1. For CTC -  28 - 34% loss the weight of leaves (66 to 72% withering). Leaf quality is bad then 74%.

  • Determine moisture% - By K.B. moisture meter we can determine withering. In this process we take 5 gram CTC cutting wither leaves and keep it in K.B Moisture Meter for 25 minutes and then weight, the loss in weighment from 5 gram is percentage loss of moisture from leaves.(Example - After 25 minutes we found 3.5 gram then(5-3.5=1.5 gram) withering (1.5/5x100=30%) is 30%.)
                                     Or

  • Making a box in  1' X 1' X 1'(Length x Width x Height ) size and keep it in trough with received leaves after weighment. After 6 to 8 hours take a weighment for withering%.

  • A) Kind of Withering -

  • i) Chemical Withering - It is automatic withering and take 16-24 hours after Plucking.

  • ii) Physical withering - When withering done by blowing of Air & hot air to loss moisture not more than @ 4% per hour.


  • Process  of withering -

  1. After Receiving of green leaves from plucking, spread it in trough with air and after shuffling blowing air 1 hour and every 3-4 hours shuffle them. For early withering blow hot & cold air in ratio 1:1 hour. 
  2. When received wet leaves then start blowing of air for 1 hour with spreading and then blow hot air. After 3-4 hours stop hot air and again shuffle the leaves. Then start hot & cold air in ratio 1:1 hour.
  3. Always rotate fan in forward direction but when green leaves not ready then for quick withering of upper part of trough's leaves, rotate backward direction of fan.


  • B) Trough - It size and nos depends of green leaves quantity(Generally 75' X 6' & 50' X 5'). We use 3 to 5 HP motor in trough.

  1. For planning we expect 1% leaves any day in year of total crop(as for 5 lakh MT = 500000÷0.225(22.5% recovery)=2222222 kgs green leaves  X 1%= 22222 kgs )
  2. Size - Generally 75' length X 6' breadth
  3. In 1 square feet with 8" thickness holds 2 kgs green leaves .
  4. Trough require -22222÷75x6x2 = 24 to 25 nos.


5. Cutting - In cutting process we cut @ 600 to 800 kgs withered leaves /hour with the help of CTC.

  • A) Rotorvan(RPM 30- 35 @ 20 kgs w/leaf per RPM) is first step of CTC machine use 20 HP motor and in fine leaves we should apply the principle hard the Rotovan(Open 40%) and soft the cutting. 


  • B) CTC - Crushing, Tearing & Curling machine.
  1. During cutting of leaves temprature should not be more than 30°C(room temperature) and load not more than 14AMP:12AMP:10AMP(1st:2nd:3rd Roller). Change roller after 50 hours.
  2. 3  Cut CTC - In this leaves has cut 3 times and arrangment of rollers as per TPI :- 8-10-8  (for more broken MT) &                8-10-10(for more dust MT). In it use 25,20 & 20 HP motors, which consume 128 kw/h.
  3. 4 Cut CTC - In this leaves has cut 4 times and arrangment of rollers:- 8-8-10-8. Motors 4 nos(25,20,20,20 HP).


  • C) Roller - Difference between Chasing & milling in roller is 0.012"(12 though).Depth of chasing & milling in 13"Roller and 80 /100 Helical groove is
  • 08 TPI 2.65 mm 
  • 10 TPI. 2.08 mm

  1. There are two type roller as per TPI
  2. 8 Teeth per Inch (TPI) - 80 nos Helical.
  3. 10 Teeth per Inch (TPI)- 100 nos Helical


R. Size(36"/38/42)- RPM -Output(W.L./hour)

1. 13" (D.) X 36"( L) - 550 RPM - 600 to 800 kgs

2. 9.5" (D.) X 36"( L) - 650 RPM -500 to 750 kgs

3. 8.5"(D.) X 36"(L)  - 720 RPM - 450 to 650 kgs


  • Calculation of RPM -Motor RPM X Motor pully Diameter ÷ Gearbox pully Diameter
  1. (Also by using Tekometer )


6. Sifting - After cutting spread leaves in Googie for good quality of round balls.


7. Fermenting - 

i) In Floor -  Spread CTC leaves on floor upto 1.2 inch(hold 1.5 kg/sq.feet).

ii) In CFM machine - It is a Continuous fermenting machine with 6 or 7 or 9 module  and one or 2 stage. Spread CTC leaves upto 2". Maintain other activities as per floor fermenting.( Motors use 10,5 & 1 HP).

  • For both - 

  1. Fermenting Time -  In CTC 1.20 hours & in winter 1.50 hours.
  2. Temprature - 26° to 30°C° & difference in dry & wet bulb temprature should be 2°C.
  3. Humidity - Above 98% must be maintained, 


8. Drying - 


  • Type of Dryer -

i) Fluid digestion Al conventional Dryer(Quality dryer/ECP) - It consume in about 15 to 20 kwh energy & taken 24 minutes time for drying fermented tea in black tea.

  1. Inlet Air Temprature 210°C & exhaust Air temp. - 120°C(Relative humidity 50% should be maintained at the exhaust)
  2. Output - 120- 130 kgs.


ii) VFBD(Vibro Fluid Digestional Bed Dryer)- It is consume 50 kwh energy and taken 14 minutes time for drying of tea.

  • Maintain Temprature in as...

  1. T1-120-125°C in winter 126°C
  2. T2 - 92-  97°C in winter 99°C
  3. T3 - 40-  45°C
  4. T4 - 85-  90°C
  5. Output of Tea in EE model-300- 350 kgs.
  6. Output of Tea in FF model -400- 500 kgs.


iii) Conventional cum Fluid Digestional Dryer- It is mixed type dryer.


  • For All dryer -

  1. Feeding tea in the dryer with 6" thickness and in middle it should be 4" and on outlet should be not more than 2" thickness. 
  2. the Drying Speed -The rate of evaporation of 3% of moisture/minute is effective.
  3. Moisture in Black Tea - 3% is best


9. Sorting - The process of sorting as below..

  1. First in electrostatic fibre extractor(10'/12' X 3'/4') with 2 set of 7 PVC rollers(2000/2500 rpm) for preliminary cleaning of fibre & stalks.
  2. Then the Tea fed to the Myddleton (9'x4') for pre- sorting.
  3. Then the Tea passes to one or two successive Arnotts(sorter) for different grading.
  4. Then fed to Macintosh (has 5 trays (8,19,12,20,24/30) & 7 discharge outlets), machine for final grading,
  5. Then in Java tunnel(winnowing machine) for final cleaning.
  6. The spillover from the Myddleton is passed through the Andrew Breaker and recycled for grading.
  7. Send dust in additional sorting machine for dust grading.


10. Grading - Divide tea in different categories as per their size & quality is grading.


  • i) Grades in CTC -Broken & Fannings is 75% of total Tea -

  1. BPL/BPS - Broken Pekoe Large
  2. BP - Broken Pekoe
  3. BOP - Broken Orange Pekoe
  4. BPSM - Brok. Pe. Sauchong(small)
  5. PF - Pekoe Fannings

  • Dust is 22% of total Tea -
  1. PD - Pekoe Dust
  2. CD - Churamani Dust
  3. Dust
  4. BOP1- Secondary Broken Teas.
  5. D1 - Secondary Dust tea

  • Residue  is 3%


  • Grade percentage including mesh size(Hole in 1" gauge wire)...

  • Grades  -      %     -          Mesh No
  1. BPS           -      2%     -            Above  8
  2. BOP          -      8%    -            Below  8
  3. BOPSM    -     13%    -            Below 10
  4. BP             -     40%    -            Below 12
  5. PF             -     18%    -            Below 18
  6. PD             -     10%   -            Below 24
  7. Dust          -     10%   -            Below 30
  8. CD            {       %      -            Below 30
  9. BP-1         {      5%     -            Below 30
  10. D-1           {        %     -            Below 30



11. Recovery Percentage - 21- 23%


12. Gapping - Before packing warming process ( by dryer) of black tea to maintain the moisture 3% is called gapping.


13. Packing - Pack the tea after weighment gradewise in a lot called packing.


14. Other Equipments use during processing -

  1. Generator of required BHP
  2. Lathe machine
  3. Welding machine
  4. Motors as required
  5. Packing machine
  6. Weighment machine
  7. Storage Bins
  8. Trolleys, plastic tube & baskets
  9. Humidifying machine
  10. Water pump


  • Terms of Tea during processing -


1. Bakey - Undesirable characteristic developed due to high temperatures during drying.


2. Bright - Its mean to a bright appearance of both liquor and infused leaf.


3. Brisk - A live character of liquor that is not flat or soft


4. Twist - This indicates the style of the leaf created during rolling.


5. Minty - A mint like flavour found in some teas.


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