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Tea-Manufacturing
Global Tea Production
• Black Tea accounts for 83%.
• Orthodox tea accounts for 44% of the world market.
• CTC caters 39% of the world market.
Global Tea Production
• Orthodox Tea – increased by 1.88 per cent.
• CTC Tea - increased by 0.56 per cent.
Domestic Consumption
• Growing in
• India by 3.5 per cent.
• Kenya by 8.8 per cent.
• Sri Lanka by 1.5 per cent/annum.
Exports from India
• Orthodox tea have increased by 3.20 per cent
• CTC tea have increased by 6.79 per cent increase.
Region wise Production
• South India – increase by 12.23 per cent.
• North India – increase by 1.27 per cent
Per capita consumption
• India – 0.8 Kg
• Sri Lanka -1.2 Kg
• UK -2.5 Kg
Major Players
• The major players in the tea industry are: • Hindustan Lever • Tata Tea • Williamson Magors • George Williamson • Harrisons Malayalam • Mcleod Russel • Bishnauth Tea • Dhunseri Tea • Warren tea • AFT Industries
Plucking
Plucking
• Only the young tender shoots are skillfully hand plucked as soon they are ready.
• Each tea bush is plucked every 6-8 days depending on the season.
• Plucking begins in March and closes by early December; the cold winter months of December to February are a period of dormancy.
• Each kilogram of fine tea consists of more than 20,000 individually hand plucked shoots.
Types of Tea
• Fermented – Black Tea
• Unfermented – Green Tea
• Semi-fermented –White Tea
Oxidation
• Polyphenols in the leaf gets oxidised with the help of endogenous enzyme namely polyphenol oxidase.
• When the leaf gets crushed during rolling the polyphenol and the enzyme are mixed in the presence of oxygen.
Fermentation
Oxidation Process
• Polyphenol is broken into theaflavin and thearubigin.
• Theaflavin – Briskness and brightness.
• Thearubigin – Colour and strength.
Oxidation
Factors influencing Oxidation
• Duration – 60-90 min ( South-India)
• Temperature - 27 deg C
• Humidity – around 95%
• Aeration -optimum
• Thickness of spreading-Floor fermentation
• Cleanliness - Hot water steralization
Orthodox/CTC
• Orthodox Manufacture:
• Maceration is done by rolling tables.
• CTC( Crush,Tear & Curl):
• Rollers rotating at high speed in opposite directions.
CTC (Crush,Tear&Curl)
• Withering
• Rolling(CTC)
• Fermentation• • Drying
• Sorting
• Grading
Orthodox
• Withering
• Rolling
• Sifting
• Fermentation
• Drying
• Sorting &Grading
Withering
• Removal of 10-15 % per cent moisture from plucked leaf.
• Duration to 12-18 hrs.
Enclosed Withering
Withering
Rolling (CTC)
• Shifter
• Rotorvane
• CTC Roller
Rolling (Orthodox)
• Mechanical development of original hand rolling process.
• Compressing and turning the leaf over.
• Roller consists of three parts, a circular table, a cylindrical box and cap to apply pressure.
Rolling
Rolling
Rolling
Drying
Processing
• Withering : Aroma precursors formed.
• Fermentation: Oxidation takes place & giving rise to aroma and colouring constituents.
• Firing : Stops the Oxidation process.
Drying
Drying
Grading
Assam Tea
• Elevation: 45 – 60 metres.
• Rainfall : 2500 – 3000 mm.
• Type: rich,full bodied,bright tea liquor.
Darjeeling Tea
• Elevation-90-1750 meters.
• Grown in the foothills of the snowcovered Himalayan range.
• Golden or amber in colour and delicate flavour of muscatel grapes.
Manufacturing Darjeeling Teas
• Darjeeling leaves weigh less due to severe withering process.
• Very exacting, time consuming traditional or Orthodox tea.
Dooars and Terai
• Elevation:90-1750 meters.
• Rainfall:3,500 mm.
Kangra
• Elevation: 700-1000 metres.
• Rainfall: 2,300-2500 mm.
Nilgiris
• Elevation: 1000 -2634 m
• Rainfall : 1,000-1500 mm.
• Uniqueness: Fragrance and aromotic tea.
Anamallais
• Elevation: 900 -1600 metres
• Rainfall : 3,000 -3,800 mm
• Uniqueness: Fragrance with biscuity and floral notes.
Wayanad
• Elevation - 850-1400 metres.
• Rainfall - 2000 – 2500 mm.
• Uniqueness –Earthy reddish liquor,Mild and mellow.
Karnataka
• Elevation-750 -1000 metres.
• Rainfall :2000-3500 mm.
• Uniqueness : Simple and fragrant teas.
Munnar –High Ranges
• Elevation – 950 -2600 metres
• Rainfall : 1300-7000 mm.
• Uniqueness: Clean and medium toned fragrance of sweet biscuit in dip malt.