What takes to make that delicious cuppa ?
Tea is not what it used to be, it’s neither palatable nor refreshing.
I have visited a few factories and I can vouch, that most factory
officers have not the knowledge about the chemical changes that takes
place once the leaf is plucked, nor have they been educated regarding
the basics in tea manufacture.
In olden times Ceylon produced some of the finest tea in the World
Market. I was privileged to join the tea industry in 1943 where the
European planters managed the estates, there were no toughs nor
improvised machinery, they followed the basic principles up to the
letter and the good old tea makers are no more.
Shortest cut to better tea is better plucking with a sound knowledge
in tea manufacture. In olden times the factories were equipped with jute
tats. Where the leaf is spread to a thickness of two inches the spacing
between one tat to another is 6” and aero 48” fans were used for
withering, the air could be reversed from one loft to another to produce
even withers.
Some of the finest tea were produced when tat withering was in
operation, Colombo & ECP dryers for firing of teas. With the
introduction of trough withering with little or no knowledge in
operating, Ceylon Tea lost its mark in world market and worldwide.
Trough withering is an improvised process of withering leaf, but
without the basic knowledge one can ruin the whole tea industry, this is
exactly what has happened and is happening now. One must take heed for a
even wither the spreading of leaf should be done systematically, at the
time of spreading all lumps should be dislodged, this usually happens
when the leaf is wet.
The pluckers usually hold the leaf in a tight grip this will not
dislodge unless separated at the time of spreading the leaf,it is
advisable to spread a bit thicker near the fan as the pressure of air
and warmth is noticeable.
In the process of withering the warm air pushes the moisture upwards
do not turn the leaf unless you are sure that the top surface is free of
water, if otherwise in the process of turning you will reverse the water
to the bottom of the trough, which will delay withering, it will be
preferable if the air is a bit warm when you commence, the temperature
should be reduced gradually if otherwise the leaf will get over
withered, when the leaf is wet one must reduce the spread of leaf by at
least 10% it is essential that surface moisture is removed within a
short period.
Bacteria is ever present in water, if not removed the quality will
suffer as the plucked leaf has no resistance to bacteria. Depending on
the weather you have to control your wither till manufacture proper
commences. Many factories adopt the practice of switching off the fans
to control wither and consumption of electricity. This practice will
have an adverse effect on the finished product, which is not noticeable,
but knowledge will provide the answer. When this happens the air does
not circulate between the leaf as the leaf has become flexible in the
process of wither which restricts circulation, that is the reason why
one must achieve at least 75% wither while the fans work in the forward
motion once the fans are reversed please avoid turning as the leaf is
flexible and would cause severe damage to the cells causing post
fermentation. When you switch on the thoughts see that all side windows
are kept open, so that the air flows freely inward and outward, well
withered leaf should look green. Any right thinking person will realise,
the importance in maintaining a technically sound wither, if you let the
leaf go into a state of decay to save consumption of electricity or any
other reason you will end up manufacturing decomposed leaf. The
withering staff should at all times check if the fans are switched on.
For the purpose of rolling the leaf should be flexible that’s why you
wither the leaf, this applies for any kind of manufacture. In the
process of rolling the leaf should get a twist, as to rupture the cells
and extract the juices, the juices extracted will be reabsorbed by the
dhools which will be the deciding factor in analysing the appearance of
fired teas, should the withered leaf be discoloured due to stoppage of
fans and handling this will have an adverse effect, on the quality of
the finished product.
Fermentation
Fermentation commences, once the leaf cells get ruptured and the
enzymes come in contact with air this happens when you commence rolling.
When you apply pressure, you will note that there is a build up of
temperature, when pressure is released it cools off, the heat generated
while rolling accelerate fermentation that’s the reason the third dhool
is removed to the dryer first when firing commences.
Depending on the type of manufacture you spread the dhool on the
fermenting table, orthodox and CTC teas usually is spread at a thickness
of 1 1/2” to 2” and low country manufacture at 4” in orthodox and low
country manufacture the percentage wither will not vary much, a little
harder wither is aimed, which reduces the moisture content in the dhools
and air circulates better while in the process of fermentation,
therefore, the need to dislodge the dhool particles does not arise.
During the process of fermentation the enzymes come in contact with the
air.
From the time leaf is plucked certain chemical changes takes place
this needs scientific approach, if one follows the basic principles as
stated in this article.
This technique had been formulated and approved by the tea industry
for more than a century, just follow the basics and you will make a
palatable tea and help the tea industry.
S.M. Ferdinands |
