tea manufacturing operations

8/13/2019 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


2/13

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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6/13

;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

tea manufacturing operations

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