From Plucking to Packaging: The Art of Tea Processing
Tea, that ancient elixir, transforms from tender leaves to aromatic brews through a meticulous journey. Join us as we unravel the art of tea processing, step by step. From plucking fresh leaves to the final packaging, each stage plays a crucial role in shaping the flavor, color, and aroma of your favorite cup.
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Harvesting: The Delicate Beginning
Plucking Fresh Leaves
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Importance:
- Quality Starts Here: The plucking stage determines the quality of the tea.
- Timing Matters: Leaves are harvested starting early spring and each season produces tea of various flavor profile.
- Hand-Picked Precision: Manual plucking ensures the best leaves are selected.
- Plucking Time: Best green leaves are collected early morning when leaves are dew-kissed.
Chemistry Connection:
- Enzymatic Activity: Fresh leaves contain enzymes that initiate oxidation.
- Polyphenol Transformation: Oxidation begins, altering polyphenols and flavor compounds.
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Withering: Softening the Leaves
Wilting and Reducing Moisture
- Importance:
- Moisture Reduction: Leaves are spread out to lose excess water.
- Enzyme Activation: Withering activates enzymes, initiating oxidation.
- Flavor Development: A crucial step for developing tea’s taste.
Time and Temperature:
- Withering Time: 12 to 36 hours (varies by tea type).
- Temperature: Controlled environment (around 20°C to 25°C).
Chemistry Connection:
- Enzyme Inactivation: Enzymes break down chlorophyll, affecting color and flavor.
- Aroma Precursors: Volatile compounds develop during withering.
Picture : Green Tea Leaves being Withered on a trough
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Rolling: Shaping the Leaves
Bruising for Flavor
- Importance:
- Leaf Bruising: Rolling breaks cell walls, releasing juices.
- Oxidation Control: Rolling influences oxidation levels.
- Forming Tea Shapes: Different rolling techniques create various tea styles.
Time and Temperature:
- Rolling Time: From 10-15 minutes to multiple hours depending upon tea to be produced.
- Temperature: Controlled (around 25°C to 30°C).
Chemistry Connection:
- Cell Rupture: Cell membranes break, allowing enzymes to interact with polyphenols.
- Oxidation Initiation: Juice exposure to oxygen starts oxidation.
Picture: Tea Rolling Machine for small batch Production
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Oxidation: The Flavor Alchemy
Transforming Tea Leaves
- Importance:
- Chemical Changes: Enzymes interact with oxygen.
- Color and Taste: Oxidation determines tea color (green, oolong, black).
- Aroma Development: Flavors evolve during this stage.
Time and Temperature:
- Oxidation Time:
- Green Tea: Minimal (2 to 4 hours).
- Oolong Tea: Moderate (30 minutes to 2 hours).
- Black Tea: Extensive (4 to 18 hours).
- Temperature: Controlled (around 20°C to 25°C).
Chemistry Connection:
- Polyphenol Changes: Enzymes convert catechins to theaflavins and thearubigins.
- Flavor Complexity: Oxidation impacts taste, color, and aroma.
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Drying: Locking in Flavor
Preserving Tea Leaves
- Importance:
- Halting Oxidation: Drying stops enzymatic activity.
- Preserving Quality: Proper drying ensures long shelf life.
- Final Flavor: Drying sets the tea’s taste profile.
Time and Temperature:
- Drying Time: Varies (around 30 minutes to 2 hours).
- Temperature: Controlled (around 80°C to 90°C).
Chemistry Connection:
- Enzyme Denaturation: Heat deactivates enzymes, preserving flavor.
- Maillard Reaction: Amino acids and sugars interact, enhancing taste and color.
Fig: Artisan using Cabinet electric dryer for drying teas
6. Sorting : Grading of Tea
There are two methods of Tea sorting:
Commercial Sorting:
One commonly used sorting method for commercial production is machine sorting where an electro mechanical device uses vibration and sieve filtration method to create the different grades of teas by sizes.
Hand Sorting:
Hand Sorting is used commonly for artisanal loose leaf teas. In this process workers (usually women), meticulously sort out any stalks or impurities present in the tea by hand. This is a very time consuming process but yields excellent output at the end. All products that Nepal Hills Tea showcases are hand sorted.
Picture: A worker hand sorting White Loose Leaf Tea
7 . Packaging: The Last Touch
Preserving Freshness
- Importance:
- Freshness Preservation: Proper packaging keeps tea aromatic.
- Protection from Light and Moisture: Packaging shields tea from external factors.
- Consumer Experience: Packaging impacts how you enjoy your tea.
Authored By:
Bhaskar Dahal
2nd Generation Tea Entrepreneur
Founder and C.E.O, Nepal Hills Tea Inc.
