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Beverages
Mudgil

Beverages
Barak
Processing & Technology

Deepak Mudgil Sheweta Barak

The objective of this book is to provide complete course content of beverage processing
Processing & Technology

Beverages
related subjects in ICAR, CSIR and UGC institutions in Food Technology, Dairy Technolo-
gy, Food & Nutrition, Post Harvest Technology, Agricultural and Food Process Engineer-
ing discipline. The book contains fourteen chapters on the topics such as Introduction to
Beverages, Role of Ingredients and Additives in Beverages, Fruit Juice Processing, Deepak Mudgil
Processing of Specific Fruits & Vegetables Juices, Cereal Based Beverages, Soft Carbonat-
ed Beverages, Alcoholic Beverages, Dairy Based Beverages, Sports Beverages, Tea Sheweta Barak
Processing, Technology of Coffee Manufacture, Cocoa and Chocolate Based Beverages,
Packaging of Beverages & Functional Beverages. The content of the book will be helpful
for B.Tech, M.Tech, M.Sc. & Ph.D. students of above mentioned disciplines. These topics
will also be helpful for the students preparing for competitive exams.

Dr Deepak Mudgil is presently working as Sr. Assistant Professor in Department of Dairy

and Food Technology, Mansinhbhai Institute of Dairy and Food Technology, Mehsana,
Gujarat. He did his Master’s Degree in Food Technology at Department of Food
Technology, Guru Jambheshwar University of Science & Technology (GJUS&T), Hisar,
Haryana. He earned his Doctoral Degree in Food Technology from GJUS&T, Hisar,
Haryana. He is author of about fifty papers in national and international journals and five
books. He has also served as review panel member for international journals. He has taught
various subjects in areas of food technology and dairy technology at graduate and
postgraduate level. He has also developed some food products of commercial interest.

Technology
Processing &
Dr Sheweta Barak is presently working as Sr. Assistant Professor in Department of Dairy
and Food Technology, Mansinhbhai Institute of Dairy and Food Technology, Mehsana,
Gujarat. She was awarded Sir C.V. Raman Scholarship for her doctorate research. She is
author of about forty five papers in national and international journals and three books. She
has also served as review panel member for various journals of international repute. She
has taught various subjects at graduate and postgraduate level. She obtained her PhD
Degree in Food Technology from Department of Food Technology, GJUS&T, Hisar,
Haryana. She has also developed some food products of commercial interest.

ISBN: 978-93-87869-36-3
 Chapter - 10

TEA PROCESSING
Vikas Kumar, Jaspreet Kaur, Beenu Tanwar, Ankit Goyal,
Yogesh Gat, Ashwani Kumar & Piverjeet Kaur

1. Introduction
2. Area and Production
3. Composition
4. Types of Tea
5. Processing of Different Types of Tea
6. Summary and Future Perspective
References

1. INTRODUCTION
Tea (Camellia sinensis) is the most widely consumed beverage throughout the
world and is served in several different ways. It belongs to the genus Camellia
and family Theaceae. Basically, there are two different varieties of tea viz.
Chinese variety C.s. sinensis, and the Assamese variety C.s. assamica (Kaundun
and Matsumoto, 2002; Namita et al., 2012). It is a natural, refreshing, cool, thirst-
quenching and virtually a calorie-free beverage when drunk without milk and
sugar. Globally, tea plant is grown in nearly 30 countries across tropical as well
as sub-tropical regions and was primarily originated in South Eastern Asia
(Adnan et al., 2013). It can grow upto the height of 30 feet within a temperature
varying between 13 and 29ºC, pH range of 4.5-5.5, at an altitude of 2460 m
above sea level in acidic soil (Singh et al., 2014). Different types of teas
including black tea, green tea, oolong tea, yellow tea, white tea, red tea etc. are
available in the market which varies in their processing technique, extent of
fermentation and oxidation (Tran, 2013). The various chemical constituents of
tea are amino acids, carbohydrates, vitamins, lipids, minerals, alkaloids (caffeine,
theobromine, theophylline) and polyphenols (catechins, flavonoids). These
components attribute to the quality, richness, taste, flavor and health benefits of
Tea Processing 191

different types of teas (Adnan et al., 2013). Tea is one of the most common as
well as cheapest commodities, which is consumed in more than 65 countries all
across the world. It serves as a source of revenue for several tea producing
countries and is a very important export commodity. Tea has been reported to
have many health benefits including anti-tumour, anti-carcinogenic, anti-
arteriosclerotic, antioxidant and many more protective properties (Adnan et al.,
2013). Being a major export commodity, tea serves to contribute significantly to
India’s foreign exchange earnings.

2. AREA AND PRODUCTION

Tea is one of the chief commodities of the global beverage industry due to its
increasing demand day by day. There has been a substantial increase in the area
and production of tea along with global trade. The principle tea producing
countries include China, India, Sri Lanka, Indonesia and Kenya among which
China is the largest producer followed by India producing 2350000 million tons
and 1239150 tons respectively (Tea Board, 2017). In India, north India
contributes approximately five time more than the south India (Fig. 1). Among
the different states, Assam contributed maximum in production followed by West
Bengal (Tea Board, 2016).

Fig. 1. Tea Production in India (2012-2016)

3. COMPOSITION
Green tea is one of the most popularly consumed beverages and is known to have
numerous health benefits owing to its chemical composition. Green leaf of tea
192 Beverages: Processing & Technology

has more than 700 chemical constituents. It consists of proteins (6%), carbo-
hydrates (4%), vitamins, minerals (5%), lipids (3%), catechins (30%), simple
polyphenols (2%), flavonols (2%), theanine (3%), caffeine (3%), organic acids
(2%), sugars (7%), alkaloids, pigments as well as volatile compounds. Also the
various constituents of black tea are catechins (9%), theaflavins (4%),
polyphenols, theanine, lipids, caffeine (3%), protein (6%), organic acids (2%),
sugars (7%), potassium (5%) and aroma compounds in trace amounts (Graham,
1992; Cabrera et al., 2006; Jayakeerthana, 2016; Kumar and Joshi, 2016).

3.1 Polyphenols
Tea leaves contain 30 per cent polyphenols on dry weight basis. Among the
polyphenols, flavanols, flavandiols and phenolic acids (gallic, cumaric or caffeic)
are present predominantly. These polyphenols are derivatives of catechin and
gallic acid. The various natural polyphenols of tea are, (-) epigallocatechin-3-
gallate (EGCG), (-)-epigallocatechin (EGC), (-)-epicatechin-3-gallate (ECG) and
epicatechin (EC) with highest concentration of EGCG followed by EGC, ECG
and EC in decreasing order. Some other catechins which are present in minute
amount are, (+) gallocateehin (GC), (-)-gallocatechingallate (GCG), (-)-catechin-
gallate (CG) and (+) catechin (Dreosti, 1996; Ruxton, 2008; Namita et al., 2012;
Reygaert, 2017).

3.2 Caffeine
Caffeine is an alkaloid which is naturally present in over 63 plant species. It is
present in tea, coffee, kola nuts, yerba mate and guarana seeds. It is frequently
consumed through tea (12%). The amount of caffeine present in 250 ml of
sweetened iced tea is 15-67 mg and 43-60 mg in tea bag (black, flavoured black)
(Kumar et al., 2018).

3.3 Amino Acids and other Nitrogen Compounds

Tea leaves contain 15.5 per cent amino acids and the chief being theanine and
glutamic acid. The amino acids present in tea play a significant role in imparting
colour to the tea liquor as a result of oxidation by catechins (Adnan et al., 2013).
The other amino acids identified in tea leaves are aspartic acid, glutamic acid,
serine, glutamine, tyrosine, threonine, valine, leucine, glycine, lysine, arginine,
tryptophan, aspargine, proline and theanine (Cabrera, 2006; Jayakeerthana,
2016).

3.4 Vitamins
Tea contains vitamins like vitamin B, C and E. It has also been reported that
vitamin C is decomposed during manufacturing of black and oolong tea (Cabrera,
2006; Jayakeerthana, 2016).
Tea Processing 193

3.5 Inorganic Elements

Minerals are either insoluble (1.5-3%) or soluble (2-4%). The various minerals
and trace elements known to be present in tea leaves include fluorine, sodium,
potassium, calcium, aluminum, phosphorus, cobalt, iron, copper, iodine,
selenium, nickel and strontium which constitutes about 5% dry weight of the
inorganic matter of tea (Cabrera, 2006; Jayakeerthana, 2016).

3.6. Carbohydrates and Lipids

The carbohydrate content of green tea is about 40 per cent (cellulose, pectins,
glucose, fructose and sucrose). Tea harvested in the morning has less starch with
better quality in comparison to afternoon collections. Tea leaves also contain
about 4 per cent lipids (Jayakeerthana, 2016).

3.7 Chlorophyll and Carotenoids

Tea leaves contain pigments such as chlorophyll a and b and carotenoids - (β-
carotene, lutein, violaxanthin and neoxanthin) (2% of dry weight of tea leaves)
and vary seasonally with plant types (Cabrera, 2006).

4. TYPES OF TEA
The conventional teas include; totally fermented black tea, raw or unfermented
green tea, and (c) partially fermented Oolong (red and yellow) tea; whereas, the
non-conventional tea products are instant tea (cold- and hot-soluble), flavored
tea, and decaffeinated tea. Beside these all, recently new trend came in the tea
market with the numerous products such as canned or bottled teas, soluble tea
mixes, tea beverages, frozen tea liquid, and tea tablets are convenience products
(Nagalakshmi et al., 2003). Liquid tea concentrates, tea mixes, iced tea mixes,
and fruit tea mixes have shown tremendous increase in the U.S. market.
Decaffeinated tea, both plain and flavored, is also becoming widely popular in
the markets of numerous countries including the United States, United Kingdom
and Germany. A brief detail of the types of tea and their specific feature are
given in Table 1.

Table 1. Types of teas

S.No. Type of tea Characteristic features References

1. Green tea Steaming fresh tea leaves of Camellia Schneider and Segre,
sinensis produces green tea, resulting into 2009; Tran, 2013
preservation of colour.
Consumption has been known to refer Tran, 2013
back to third century B.C.
194 Beverages: Processing & Technology

S.No. Type of tea Characteristic features References

It arrived in Japan between 729 and 800 Tran, 2013
A.D.
It is especially popular in East Asia, Tran, 2013
specifically in Japan and China.
20% of the tea that is manufactured is in Fatima and Rizvi,
the form of green tea. 2011
Green tea is very well known to possess Tran, 2013
medicinal properties owing to the presence
of various phytochemicals or the bioactive
compounds.
Catechins, the bioactive compounds have Cabrera et al., 2006;
the potency to scavenge the free radicals. Tran, 2013
Therefore, are potent antioxidants.
Due to minimal processing of green tea, Tran, 2013
catechins are more concentrated in the
same making 30-40% of the dry weight of
green tea leaves.
The main active constituent of green tea is Schneider and Segre,
EGCG (the most active ingredient of 2009; Tran, 2013
catechins).
It has various pharmacological properties Cabrera et al., 2006;
such as anti-diabetic, hypocholestrolemic, Tran, 2013;
anti-inflammatory, anti-carcinogenic, Jayakeerthana, 2016
anti-cavity, thermogenic, probiotic, anti-
microbial, anti-viral, anti-bacterial, anti-
mutagenic and anti-oxidant.
One cup of green tea contains Bhattacharjee, 2015
approximately 15-50 mg of caffeine.
Green tea consumption is associated with Schneider and Segre,
the prevention of many different types of 2009; Jayakeerthana,
cancers such as mouth, lung, 2016
gastrointestinal and mammary glands.
It also plays a role in reducing cholesterol Cabrera et al., 2006;
and thus prevents cardiovascular Schneider and Segre,
diseases. 2009
The price and quality of green tea Lee et al., 2014
deteriorate with later plucking.
2. Black tea India is the largest producer of black tea. Ruxton, 2008
Tea Processing 195

S.No. Type of tea Characteristic features References

80% of the total manufactured tea is Fatima and Rizvi,
black tea. 2011
It is the most commonly consumed tea. Ruxton, 2008
It is extensively oxidized before being Ruxton, 2008; Fatima
processed and is fully fermented form of and Rizvi, 2011
tea.
It is primarily consumed in countries like Chaturvedula and
China, Japan, India and some others in Prakash, 2011
North Africa and Middle East.
The chemical composition includes Fatima and Rizvi,
polyphenols (catechins, flavonoids, 2011; Adnan et al.,
bisflavonols, theaflavins), amino acids, 2013
vitamins, proteins, carbohydrates and
alkaloids (theobromine, caffeine,
theophylline).
These polyphenols being large and highly Fatima and Rizvi,
polar aren’t absorbed directly after oral 2011
ingestion but undergo hydrolysis by
bacterial enzymes.
Flavan-3-ol monomers are oxidized and Wright et al., 2002
polymerized to form polyphenols i.e.,
theaflavins and thearubigins while
manufacturing black tea.
It contains nearly 17 mg of caffeine/ Ruxton, 2008
100 ml.
It possesses properties like anti-oxidative, Das et al., 2008;
anti-thrombogenic, anti-inflammatory, Fatima and Rizvi,
anti-mutagenic, anti-carcinogenic, anti- 2011
diabetic and anti-diabetic.
Black tea has been linked to lower down Ruxton, 2008;
the risk of CVDs including CHD, B.P., Greyling et al., 2014
platelet aggregation etc.
It prevents oxidative damage, dental Fatima and Rizvi,
caries, CVDs, cancers, gut microflora, 2011; Bhattacharjee,
mood and mental performance. 2015
3. Oolong tea It is partially fermented. Bhagwat et al., 2003
It is made by withering followed by semi- Fatima and Rizvi,
fermentation resulting into partial 2011
oxidation.
196 Beverages: Processing & Technology

S.No. Type of tea Characteristic features References

It is a traditional tea being especially Komatsu et al., 2003
popular in South China.
Its consumption is confined to Chaturvedula and
Southeastern Asia and Taiwan. Prakash, 2011
Its composition is intermediate between Graham, 1992
green tea and black tea.
Major constituents are caffeine, Komatsu et al., 2003
polyphenols and amino acids.
It contains fewer amounts of catechins Fatima and Rizvi,
and theaflavins. 2011
Oolong tea is prepared by soaking tea in Su et al., 2007
hot water i.e. ˃90ºC followed by careful
stirring and steeping procedures for the
extraction of catechins or theaflavins.
Its astringency is low and is sweet in taste Chaturvedula and
as compared to green tea. Prakash, 2011
It is known to have a significant role in Ng et al., 2017
reducing obesity, CVDs, controlling
diabetes, protecting bones and teeth.
It has the potential to scavenge Su et al., 2007; Ng et
superoxide radicals and therefore, al., 2017
possesses anti-oxidative and antibacterial
properties too.
It has been reported to exhibit stronger Su et al., 2007
anti-mutagenic activity as compared to
green and black tea.
It plays a significant role in weight redu- Komatsu et al., 2003
ction by increasing energy expenditure
and inhibiting nutrient absorption.
4. White tea It is an unfermented tea obtained from Teixeira et al., 2012
young shoots of Camellia sinensis.
It is obtained by drying the bud or first Hilal and Engelhardt,
plucked leaves with minimal processing. 2007
The buds are shielded to prevent exposure Dias et al., 2013
to sun which leads to reduction in the
formation of green pigment i.e.,
chlorophyll which ultimately leads to final
white appearance of young leaves.
Tea Processing 197

S.No. Type of tea Characteristic features References

The countries producing white tea are Blair, 2006
India, China, Kenya, Sri Lanka and
Vietnam.
It has a light and delicate taste. Dias et al., 2013
It is used to reduce oxidative stress and Teixeira et al., 2012
treat obesity.
Epigallocatechingallate (EGCG) is the Saha et al., 2017
main active ingredient and is lower in
caffeine content as compared to green tea.
The various potential protective effects of Dias et al., 2013
white tea against CVDs, cancer, diabetes
mellitus, obesity, central nervous system
and microbes-induced diseases have been
reported.
The properties exhibited by white tea are Dias et al., 2013
anti-thrombogenic, hypotensive, anti-
inflammatory, anti-oxidant, anti-
mutagenic, anti-carcinogenic, anti-
diabetic, hypoglycemic, thermogenic, anti-
stress, anti-depressent, anti-microbial, anti-
fungal and anti-viral.
5. Yellow tea It is partially fermented tea. Hashimoto et al.,
It is unwilted and unoxidised. 2007; Bhattacharjee,
2015; Teng et al.,
The most popular traditional yellow tea in
2018
China is “large yellow tea” which is made
from “one bud 6 leaves” of Camellia
sinensis.
It contains high content of catechins and
vitamins than black tea.
It possesses mild taste and strong aroma.
Its characteristic burnt flavor makes it
highly popular.
Yellow tea has been reported to protect
against liver injury.
6. Dark tea It is an unfermented type of tea. Chaturvedula and
It contains brick tea and pu-erh tea. Prakash, 2011
It is brownish yellow or brownish red in
infusion, stale aroma and has a smoky
taste.
198 Beverages: Processing & Technology

5. PROCESSING OF DIFFERENT TYPES OF TEA

5.1 Conventional Teas

5.1.1 Black Tea

The steps involved in the production of black tea include plucking, withering,
leaf distortion, fermentation, firing, grading, packing, and finally storage (Figure
2).

Harvesting
The fresh green tea leaves are generally harvested by hand at intervals of 7–14
days, throughout the year. Generally, the rapidly growing shoot tips down to
about the second or third unfolded leaf are plucked and used (Srikantayya, 2003,
Rosma et al., 2016). The chemical constituents of tea flush as percentage of dry
weight are as follows: flavanols 25%, caffeine 4%, amino acids 4%, organic
acids 0.5%, carbohydrates (monosaccharides 4%, polysaccharides 13%), protein
15%, cellulose 7%, lignin 6%, lipids 3%, chlorophyll and other pigments 0.5%,
ash 5% and volatiles 0.1% (Srikantayya, 2003).

Withering
Withering involves certain biochemical and physiological changes which assist
the process of rolling and fermentation which result in the final quality of tea. It
results in an increase in amino acid content, carbohydrate, and caffeine levels,
maximal activity of polyphenol oxidase, loss of pectinase activity as well as
breakdown of chlorophyll. The leaves are spread out in thin layers (0.3–0.7
kg/m2) in trays/tats/open loft system/rooms. The period varies from 16 to 20
hours depending upon the leaf condition and final quality of tea. Hot air is blown
from the bottom of the system in order to evaporate the moisture by air ultimately
leading to drying of leaves. Withering procedure for short period of time (12
hours) at low temperature (10°C–15°C) has been reported to produce good
flavoured tea as compared to long time period (20–30 hours) at high temperature
(25°C–30°C) which produces good colour but pose an adverse effect on the
chemical and flavor qualities (Anonymous, 1974; Srikantayya, 2003).

Leaf Distortion/Rolling for Manufacture of Orthodox Tea

Leaf is distorted by rolling or cutting soon after the withering process and it is
not advisable immediately after plucking. Conventional processing of leaf
requires rolling in order to produce orthodox teas, viz., black tea and green tea.
The process of rolling helps to wring out the juice from leaves and twist it. The
leaf is bruised and twisted, then broken into small pieces by increased pressure
and sifted by green leaf sifters while the remaining bulk is rolled. The duration of
each roll varies from 15 to 60 minutes, and the number of rolls varies from two to
Tea Processing 199

five in normal practice, depending on such factors as degree of wither, type of tea
required, roller charge and speed, rolling conditions, and temperature
(Nagalakshmi et al., 2003).

Leaf Distortion for Non wither Teas

In the case of non-wither teas, a number of leaf distorting machines are used.
Versatile modern machines (Legg-cut, CTC [crushing, tearing, curling], and
Rotorvane) are used singly or in combination. The object is intensive maceration
of the tea leaf to ensure rapid and complete fermentation. The soft withered leaf
is cut, torn, or rolled in the small gap between the serrated surfaces of the rollers.
The machines used for leaf distortion include the Triturator, Ceylon continuous
tea processing machine, Tocklai continuous roller (TCR), Barbora leaf
conditioner (BLC), and USSR continuous rolling expresser (Anonymous, 1974;
Srikantayya, 2003; Nagalakshmi et al., 2003).

Fermentation
It is the most crucial step while processing black tea and is necessary for
certainchemical and biochemical changes. It varies from 45 minutes to 3 hours.
The green leaf after rolling and sifting in the case of orthodox tea or macerated
leaf (CTC type) is spread in thin layers 5–8 cm deep on the factory floor or on
racked trays in a fermentation room. Temperature varies between 24°C and 27°C
and is controlled by using humidifiers or cool air. The leaf colour changes from
green to coppery red along with development of a pleasant characteristic aroma
at the end of fermentation process. The ratio of theaflavin and thearubigin
content is 1:10 (under ideal conditions) which serves to be an aid for measuring
the rate of fermentation. Also the tannin content declines during this process
from 20% to 10-12% which is another useful method to assess fermentation rate.
Modern developments in fermentation technology such as skip, trough, and drum
continuous fermenting systems have merits such as controlled optimal
temperatures, reduced cost, lowered floor space requirement, and improved
briskness in tea liquor (Srikantayya, 2003; Nagalakshmi et al., 2003). Monomeric
flavonoids (flavan 3-ols or tea catechins) are oxidized to polymeric theaflavin
and thearubigin during tea fermentation. Fermentation process gives a distinctive
colour, decreased bitterness and astringency, and characteristic flavor. Flavanols
of tea in the group of catechins constitute 25%–30% of the dry matter of the tea
leaf. Tea quality is mainly related to the flavanol concentration of the fresh leaf.

Grading and Storage

Tea is often winnowed to remove the stalky material and is sieved to obtain
different grades based upon the particle size. Chemical changes take place during
the storage of finished tea products, which tend to lose all residual greenness and
harshness within a few weeks. Tea remains sound and full of flavor for more than
1 year, if kept in a cool place and protected from moisture and oxygen
(Anonymous, 1974; Nagalakshmi et al., 2003).
200 Beverages: Processing & Technology

5.1.2 Orthodox Tea

The primary step involved in the manufacture of orthodox tea is plucking in
which the shoots are harvested from the fields and later exported to the factory.
The leaves harvested in the first step are spread in thin layers on troughs for the
aim of achieving 60-65% moisture content and the process is known as
withering. This step depends upon factors like moisture content of tea leaves, leaf
size as well as temperature. This step is followed by rolling and twisting of
withered leaves in orthodox rolling machine for a time period varying between
20 to 120 minutes. Then the leaves are fermented at 30ºC, pH 4.5-5.0 and relative
humidity 75-80% until sufficient colour and aroma develops. The fermented
leaves are then subjected to drying/firing followed by sorting and grading.
Finally, packing is done in paper sacks to maintain quality and avoid any
moisture loss (Jayasundara, 2011; Sarkar et al., 2016). A brief overview of the
various processing steps involved in manufacturing orthodox tea is given in
Figure 2.

Fig. 2. An overview of processing and preparation of black tea and orthodox tea

5.1.3 Oolong Tea

Oolong tea is a type of oxidized tea. Both spontaneous as well as controlled
oxidation takes place during the manufacturing process of tea (at withering
phase). Spontaneous oxidation at the withering step of the production of white,
oolong and black tea. Moreover, controlled oxidation is a very important
component while manufacturing oolong and black tea (Heiss, 2007). The
different steps involved in processing oolong tea are picking, withering, rolling,
oxidation, drying and finally grading (Anonymous, 2012).

5.1.4 Green Tea

Green tea is a type of non-fermented tea. The various steps involved in the
production of Japanese style green tea are harvesting, withering, steaming,
Tea Processing 201

rolling/shaping and drying. Similarly, Chinese style green tea is produced by pan
firing after the withering phase while rest of the steps are similar in both the
varieties. The withering process is carried out for at least twice as long as
compared to that in case of white tea (4-5 hours). The method of drying also
varies in case of both Japanese and Chinese style green tea. The former is
generally dry heated for the purpose of deactivating enzymes (oxidases) while
the latter is subjected to steaming (Kosińska and Andlauer, 2014). A brief outline
of the steps involved in the production of green tea is given in Figure 3.

Fig. 3. An overview of processing and preparation of green tea

5.1.5 White Tea

White tea is a type of non-fermented tea, the others being yellow and green tea.
Initially, the fresh tea leaves are harvested from the gardens followed by
withering for 4 to 5 hours which is preferably done in the sun. The withered
leaves are further subjected to drying to obtain the final product i.e., white tea
(Kosińska and Andlauer, 2014). The steps involved are presented in Figure 4.
Also, a complete overview of processing and preparation of different types of tea
is given in Figure 5.

Fig. 4. An overview of processing and preparation of black tea and orthodox tea
202 Beverages: Processing & Technology

Fig. 5. An overview of processing and preparation of different types of tea

(Anonymous, 2018)

5.1.6 New Manufacturing Technology

Certain disadvantages of traditional methods of tea manufacture are known
including undamaged tea leaf tissues (20%–25%) while rolling or CTC method,
which in turn results in high losses of polyphenols; loss of 70% to 80% of
essential oil in the firing stage leading to loss of aroma as well as its high quality.
In order to overcome these damages, in countries like India and China; under
fermented teas are subjected to thermal treatment upto 40°C to eliminate the
grassy odour and coarse taste owing to the presence of high proportions of
polyphenols, catechins, and other constituents. Thermal treatment results in
isomerization and epimerization of catechins, degradation of chlorophyll, and
synthesis of aldehydes and essential oils and improves the flavor quality of
finally manufactured tea (Yamanishi, 1978).

5.2 Nonconventional and New Tea Products

5.2.1 Flavored Teas

For the production of flavored teas, various natural and nature-identical flavors
are incorporated during the processing. Different tea’s that are present in the
market such as flavored black tea, green tea, oolong tea, instant tea, decaffeinated
black tea and decaffeinated instant tea are highly profitable in generating
economy.
Tea Processing 203

The superiority of low grade tea is enhanced by the addition of certain

chemicals such as aldehydes, alcohols, ketones, esters, geraniol, citronellol,
phenylethylalcohol, cinnamaldehyde, phydroxybenzaldehyde, acetophenone,
cyclohexanes, benzyl acetate, methylsalicylate, 8-oxo-1,3,6,6-tetramethyl, 1,3-
dihydroxy-2- propane, 5,6,7,8- tetrahydroisoquinolene, 2,6,6-trimethyl-cyclohex-
2-ene-4-ol-1-one and any others.
Different amino acids such as phenylalanine, norleucine, glutamic acid,
alanine and threonine produce different aromas (rose like, spicy, flowery, wine
like odor respectively). These flavor enhancers impart fresh tea flavor and aroma
to hot and cold–water-soluble teas. Some of the major flavoring agents are made
up by the blend of hexanol (1.25%), 1-penten-3-ol (10.55%), linalool oxide
(11.92%), geraniol (0.52%), cis-3- hexen-1-ol (10.55%), linalool (55-66%),
isobutanol (5%) alongwith the essence of banana, apricot, prune, apple, currant,
raisin, date and fig.

5.2.2 Herbal Teas or Tisanes or Tea Substitutes

Herbal tea, also known as tisanes, constitutes a blend of leaves, seeds, nuts,
barks, fruits, flowers, grasses as well as roots of certain plants. A plethora of
beneficial botanical plants, herbs, spices are traditionally being used over many
decades for the production of herbal teas. These tisanes are well known to
possess numerous medicinal properties which help to curb gastrointestinal
problems, support heart health and strengthen the immune system. It also aids in
energizing our body by inducing relaxation. The various types of herbal teas
available in the market are black tea, green tea, cinnamon tea, chamomile tea,
ginger tea, ginseng tea, peppermint tea etc. (Ravikumar, 2014).

5.2.3 Decaffeinated Teas

Caffeine has been reported to stimulate the central nervous system, increase
vigilance, alleviate mood as well as promote psychomotor and cognitive
performance of humans. But its over consumption has been linked to cause
addiction, anxiety, insomnia, gastrointestinal disturbances, increased blood
pressure, affect respiratory and reproductive health. Intoxication can also lead to
cancers and further death of human being (Kumar et al., 2018). Caffeine is
consumed in various forms either natural or synthetic, via foods and beverages
like coffee, tea etc. Therefore, manufacture of decaffeinated tea is highly
desirable in order to regulate the levels of caffeine intake. It is produced by the
removal of 60-90% of caffeine from black tea by the process of solvent
extraction. Decaffeinated green tea extracts are also available in the market
which is 100:1 herbal extract consisting of high amount of EGCG content and is
also known to prevent free radical oxidation and thus acts as antioxidant. This
extract contains ample amount of catechins (EGCG) amd contains <0.42%
caffeine (Anonymous, 1997).
204 Beverages: Processing & Technology

5.2.4 Instant Teas

Instant tea is obtained by drying out of tea imbuement of dark tea or green tea is
a dry powder that is esteemed for its benefit. The item is exceptionally hygro-
scopic and consequently requires appropriate packaging. Distinctive kinds of
instant tea, viz., hot-soluble and cold soluble, are accessible, reliant upon end
utilization. These two kinds are extensively used in machines. Different forms
present in market are, flavored instant teas, decaffeinated soluble tea either plain
or with added flavors. Preparation of instant tea is done using different raw
materials-crude tea leaves collected after pruning of tea plantations, green tea
leaves after fermentation, low grade teas, black tea and tea waste. A series of
events takes place for the preparation of instant tea such as quality control of raw
material, withering, leaf distortion, and optimal fermentation to produce the best
body of liquor. However, flavor losses cannot be completely abolished at the
time of processing.

5.2.5 Tea Concentrates

Tea leaves are extracted with hot water at 80°C–90°C. Citric acid and sodium
bicarbonate are the additives which help in better extraction. The extract is
elucidated and concentrated either by evaporation or through freeze-concent-
ration method. To the concentrated brew, sugar, stabilizers (xanthan, CMC, or
carrageen), emulsifiers (mono- and diglycerides, lecithin, or ethoxy fatty
alcohols), preservatives (sodium benzoate, potassium sorbate) and flavorings
(lemon oil or orange oil) are added. Shelf life of the same is 6 months at 60°F
without deterioration and is then used for the formulation of liquid tea based
beverage.

5.2.6 Tea Beverages

Ready-to-Serve Beverages
Fresh tea brew which is commonly known as brown tea is consumed hot across
the globe; except in India and in Britain where it is consumed along with milk
and sugar. Currently, ready to serve (RTS) products based on tea, e.g., TehBotole
and its products are quite famous in Indonesia and these also represent a major/
noteworthy portion of the soft drink market. TehBotole is a noncarbonated
bottled tea beverage which is prepared from The Wangi (processed green tea
with jasmine flavor). Transparency and shelf life of the beverage are well
retained. Tea beverages can also be stored for a longer period of time in various
other forms. Tea extracts can also undergo the process of vinification. The extract
is fermented by Saccharomyces cerevisiae var. Montachet and by S. bayanus,
after sweetening with sugar to 20°Brix. The levels of caffeine, theaflavin and
theobromine should show a progressive decline at the time of fermentation over a
span of 15 weeks. By the addition of ammonium phosphate, the soluble amino
acids are reduced by more than 90% by S. bayanus in 1 week.
Tea Processing 205

Carbonated Tea Beverages

Black tea or decaffeinated black tea is extracted with water to introduce the
required solubles into the water medium and then filtered through fine filters.
Sugar syrup, a preservative (sodium benzoate) and an acidulant (citric acid) are
prepared separately and later incorporated in the beverage so prepared. Certain
chemicals are also added to solubilize the cream formed in the beverage and
prevent turbidity. But this in turn causes turbidity and undesirable taste.
However, usage of decaffeinated tea helps in the elimination of turbidity to some
extent. The final product consisting of tea solids (0.3-0.4%), sugar (10%), citric
acid (0.1-0.5%); is cooled and carbonated.

Fig. 6. Schematic description of Kombucha manufacture (Kumar and Joshi, 2016).

Kombucha
Kochumba, which is a traditional fermented tea is known as tea cider and is
usually drunk for various medicinal purposes. It is produced at home by using tea
fungus (Acetobacter xylinum, Acetobacter aceti, Acetobacter pasteurianus,
Gluconobacter oxydans) (Greenwalt et al., 2000) and yeast (Saccharomyces sp.,
Zygosaccharomyces sp., Torulopsis sp., Pichia sp., Brettanomyces sp.) and tastes
206 Beverages: Processing & Technology

like sparkling apple tea. Different factors such as geographic, climatic and
cultural conditions, types of wild yeast and bacteria result into variation in the
composition of tea. The sugar present in cultivation medium is fermented to
ethanol which is then oxidized to produce acetic acid by acetic acid bacteria.
Also the fermented liquid contains gluconic, glucuronic and lactic acid other than
acetic acid. The different components present in Kombucha are organic acids,
enzymes, amino acids, polyphenols, alcohols, vitamins. It is considered as a non-
alcoholic beverage as it contains <0.5% alcohol. It is well known for its
detoxifying and energizing properties and also aids in curing gastric problems. Its
other beneficial health effects include treatment of insomnia, arthritis, hemorr-
hoids, heart diseases, respiratory problems (allergies, asthama) and prevention of
cancer (Kumar and Joshi, 2016).

6. SUMMARY AND FUTURE PERSPECTIVE

Tea is a refreshing, thirst-quenching beverage next to water, consumed in a
number of different ways by most of the people all across the world. Owing to
the presence of numerous compounds, it plays an important role in the health
food/functional food industry. Different types of tea and tea based products are
now-a-days in market to cater the need of the consumers. Still there is a strong
need to develop or modify the existing processing methods, for the better
retention of the phytochemicals as well as tea-based products. On another hand,
consumer awareness regarding the same is highly required for their wide
acceptability. High impact value addition can expand the export market of India
dramatically and it is emerging as a new research scope in this era.

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