Green Peace Lincoln College

Itahari, Sunsari
An Assignment on Tea Manufacturing Process

Submitted From:- Approved By:-

-Pujan
Contents
Introduction
1.Orthodox process
2.Company’s Detail
Definition of tea manufacturing process
Tea processing cycle
INTRODUCTION:-
With the advantage of diverse agro-climatic conditions and eco-friendly
cultivation methods having very little or no inorganic fertilizers and
pesticides in use, Nepal is producing very good quality tea both ctc (black
tea) or orthodox tea as the demand for orthodox tea in the world market
is increasing due to the health conscious customers which can also help
to uplift the economy condition of our country Nepal.

Today Nepal has an estimated 10000 hectares of its land under tea
plantation. Tea grown in terai is used for making ctc(black tea) and hill
tea is exclusively processed for making the orthodox tea .Nepalese
orthodox tea which is produced at altitude between 3000ft to 7000ft are
famous for their aroma, bright liquor and fruity flavor. Tea in Nepal has
good prospects due to agro-ecological conditions, expanding markets,
environmental considerations, emplyoment and rural development. The
major hill plantation districts are llam, terathum, dhankuta and
panchthar. Terai tea plantation is jhapa district.

There are major tea manufacturing companies in Nepal .

Ilam tea producers pvt.ltd is also one of the company which is producing
orthodox tea.Whole leaf teas that manufactured using the traditional
process of making tea are basically orthodox teas. It is located in sriantu,
ilam , Nepal. It is the oldest company which is manufacturing orthodox
tea production. It was established in 2052 bs and is working in food
retailers , tea retailers business activities. .Industry owner name is Ashok
murakar and manager name is kishan Giri. Factory product name is Antu
valley tea. In this industry number of worker depend on season demand.
Head office of this industry is situated in Kolkata. Total investment of the
company is around 5-6 million and total production is around 320 lakhs
per kg year. Their daily production is 12000kg. This industry export their
production in india, Nepal and other country.
  TEA MANUFACTURING PROCESS
Tea manufacture is the process of transformation of freshly plucked green tea leaves
to black tea. The process itself is long, requires much care, attention, control and a
scientific understanding of the complicated physical and chemical changes in the
leaf as the manufacture progresses. There are several distinctive processes that take
place in the manufacture of black teas.

Fig: Orthodox Tea Machinery

 1.PLUCKING:
Plucking or harvesting tea is picking fresh tea
leaves from the tea tree.

The green leaf is harvested on a regular basis at intervals ranging from 5

days to 8 days from each field. The plucking of the soft two leaves and the
bud is generally undertaken by well trained women. The manufacture
begins from the time the leaf is plucked in the field, and to ensure its
freshness, the leaf is sent to the factories from the fields three to four
times a day.
 2.WITHERING:
Withering is a process where conditioned air is circulated between the
leaves to breakdown the tea juices. It takes 10 hours to 14 hours for the
physical and chemical changes to take place and bring the leaf to soft and
smooth condition suitable for the next stage of manufacture.
 3. Rolling:
It is the process by which the leaf is twisted to bring the juices to
the surface of the leaf. The rolling machine have a pressure cap to
apply pressure on the leaf. This process takes about 20 to 30
minutes.

Thereafter to separate the twisted leaf from the untwisted and to reduce
the heat the rolled leaf is passed over a roll breaker. This machine has
meshes which separate rolled leaf. The unrolled is put back into the
rollers for further rolling where the rolled leaf is fermented.
 4.FERMENTATION:
Tea juices is an essential process in the manufacture of black tea.
Fermentation is the oxidization of the enzymes in the juices which
bring out the flavor strength and the colour of the liquors.
Fermentations is generally carried out on glass or tiled tables.

As fermentation progresses there is a colour change of the leaf from

greenish to coppery brown. The degree of fermentation is judged by the
colour .
 5. DRYING:

The primary objective of drying is the extraction of moisture and

fermentation. The fermented leaf contains from 45% to 50% moisture.
The leaf is passed through dryers.

The drying process takes about 20 to 25 minutes and the initial

temperature is about 120 Degrees F(50 Degrees C) and is finished off at a
temperature of 200 Degrees F (93 Degrees C) to 220 degrees F (105
Degrees C) .
 6.Gradi
ng(SIFTING):
The fired teas after cooling are graded / sifted according to size and
shape, as the trade demands. On completion of the grading, teas are
stored in airtight bins of boxes. The sifting is carried out on a series of
grading and cleaning machines to separate the tea particles to the various
grades of tea and to remove the dust and fibre.
 6. PACKING / DESPATCHING:

Teas are very hygroscopic as well as absorb moisture. When sufficient quantities of
teas are collected, they are packed in plywood tea chests of aluminum craft paper and
despatched or packed into tea packs of various forms for direct export/distribution.
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