Orthodox Tea Processing


Processing of Orthodox Tea


Orthodox Tea - In the process we use rolling tables to roll the leaves and turn them into half opened leaves. These teas are best in brisk & fragrance but soft in liquor.



Stages of manufacturing -


1. Plucking - The process in which pluck 1 bud with 2 small leaves from top of bushes, best if plucked only buds.

 For Orthodox manufacturing we pluck leaves in early morning to avoid tiny black spots on Orthodox teas.


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 for manufacturing



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

For Orthodox - 40-45% loss weight from leaves @4%/ hour.

  • 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%.)


  • 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.


Trough - It size and nos depends of green leaves quantity. 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. Rolling - In Rolling process we roll the 260 -325 kgs wither leaves in 46" rolling table for 30 minutes in 1 Rolling Table. Where give pressure low or medium for 10 minutes and then release for 5 minutes for 2 times during rolling and care to less juice generate during the process.


  1. (RPM of small roller is 70 & Faster roller is 700 in Rolling Tables)
  2. And use 6-7 nos Rolling Tables for 22000 kgs GL or 15556 wither leaves (30% withering).


6. Sifting - After rolling spread leaves in rotary sifter for good quality of buds/rolled leaves.

In orthodox after shifting seperate course or fine orthodox tea for fermenting.


7. Fermenting - 


i) In Floor - Spread CTC leaves on floor in Orthodox upto 2 inch(2.5 kg/sq.feet)


ii) In CFM machine -  It is a Continuous fermenting machine with 6 or 7 or 9 module  and 1 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 - 2.5 to 3 hours.
  2. Temprature - 80 -85°F & keep 2°C difference in dry & wet bulb temprature.
  3. Humidity - Above 98% must be maintained, 



8. Drying - 

  • Type of Dryer -

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


  1. Inlet Air Temprature 210°F & exhaust Air temp. - 130°F(Relative humidity 50% should be maintained at the exhaust)
  2. Output - 110- 120 kgs.



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


  • Temprature maintain during drying....

  1. T1-120-125°C
  2. T2 -92- 97°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.


  • For All Dryer -

  1. Feeding tea in the dryer with 6" thikness and in middle it should be 4" and on outlet should be not more than 2" thickness. 
  2. 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 is starting after cooling the orthodox tea for best bloom as below..


  1. First in double deck myddleton(9'x4') stalk extractor & electrostatic fibre extracter(10'/12' X 3'/4') with 7 pvc roller(2000/2500 rpm) for preliminary sorting.
  2. The output from myddleton the two trays is passed into the Macintosh(has 5 trays(8,19,12,20,24/30) & 7 discharge outlets), where the tea is graded in various grades.
  3. The spillover from the Myddleton is passed to the hexagonal sifter/ghugi/ rotary(5' dia & 3' X 10' long) for sorting(RPM 25 to 30), The mesh combinations are 14, 12 & 10 or 10, 8 & 6, where the TGFOP, GFOP and FOP grades are extracted.
  4. We use tocklai breaker for supporting sorting.
  5. We use colour shorter for perfect cleaning(stalk sorting) of orthodox teas. 



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

Grades in Orthodox - Leaf & Broken is 75 to 80% of total Teas.

  • Leaf Grades - upto 30-40% -

  1. SFTGFOP- Super Finest Tippy Golden Flowery Orange Pekoe 
  2. FTGFOP - Finest Tippy Golden Flowery Orange Pekoe 
  3. TGFOP - Tippy Golden Flowery Orange Pekoe 


  • Broken Grades - upto 47-50% -

  1. FTGBOP - Flowery Tippy Golden Broken Orange Pekoe 
  2. TGBOP -Tippy Golden Broken Orange Pekoe 
  3. FBOP - Flowery Broken Orange Pekoe 
  4. BOP - Broken Orange Pekoe 


  • Fannings Grades - upto 7-10% -

  1. GFOF -Golden Flowery Orange Fannings
  2. GOF - Golden Orange Fannings.


  • Dust(OD) & Secondary -upto 10% -



11. Recovery Percentage - 22.5 - 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 gradwise 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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