Nilgiri tea is a type of tea that has a brisk, fragrant, and full-bodied flavor. It is also known for its bright color and floral aroma. Nilgiri tea is made using the CTC process, which stands for crush, tear, curl. The CTC process produces strong and uniform tea that is ideal for blending and making iced tea.
When I was young, I worked in a tea factory. I learned how the CTC tea production works. I will share with you how it is done in the tea factory.
Key Takeaways
- Nilgiri tea is a type of black tea that is grown and processed in the Nilgiris district in Tamil Nadu, India.
- It is made using the CTC process, which involves machines that crush, tear, and curl the tea leaves into small granules.
- The CTC process produces strong and brisk tea that is suitable for blending and making iced tea.
- The CTC process differs from the orthodox method, which involves hand-rolling the tea leaves to preserve their shape and flavor.
- It has a bright color, a floral aroma, and a full-bodied flavor. It is also rich in antioxidants and has many health benefits.
- Nilgiri tea can be brewed and enjoyed in various ways, such as with milk, sugar, lemon, or spices.
Step 1: Plucking
The first step of tea production is plucking, which is the harvesting of tea leaves from the tea bushes. Plucking is a crucial step that determines the quality and quantity of tea. Plucking is done by skilled workers who select the young and tender leaves from the tea bushes. The workers use a special tool called a shear to cut the leaves and collect them in a basket.
Where is Plucking done?
Plucking is done in Nilgiri tea plantations throughout the year, as the climate and soil of the region are favorable for tea cultivation. The Nilgiris district has a high altitude, a cool and moist weather, and a rich and fertile soil. These factors contribute to the growth and flavor of Nilgiri tea. The tea bushes in Nilgiri are of the Camellia sinensis var. sinensis variety, which is native to China and adapted to the Nilgiri conditions.
How is plucking done?
Frequency and timing of plucking
- The tea leaves are usually plucked every 7 to 10 days, depending on the growth of the bushes.Â
- The best time to pluck the tea leaves is in the morning, when the leaves are fresh and moist.Â
- The plucking method varies depending on the type of tea to be produced.Â
- For CTC tea, the plucking standard is two leaves and a bud, which means that the workers pluck the bud and the two adjacent leaves from the stem.Â
- For orthodox tea, the plucking standard is one leaf and a bud, which means that the workers pluck only the bud and the first leaf from the stem.
Plucking method and standard
The two leaves and a bud standard produces larger and coarser leaves that are suitable for the CTC process. The one leaf and a bud standard produces smaller and finer leaves that are suitable for the orthodox process.Â
Effects of plucking standard
The plucking standard affects the size, shape, and flavor of the tea leaves. The plucking standard affects the yield and cost of tea production. The two leaves and a bud standard produces more tea per hectare, but at a lower quality and price. The one leaf and a bud standard produces less tea per hectare, but at a higher quality and price.
| Plucking Standard | Size and Shape of Leaves | Type of Tea | Yield | Cost |
|---|---|---|---|---|
| Two leaves and a bud | Larger and coarser | CTC tea | Higher | Lower |
| One leaf and a bud | Smaller and finer | Orthodox tea | Lower | Higher |
After plucking, the tea leaves are weighed and transported to the tea factory for further processing. The tea leaves are usually transported in trucks or tractors, and covered with tarpaulin to protect them from sunlight and moisture. The tea leaves should reach the factory as soon as possible, preferably within 24 hours of plucking, to avoid deterioration and spoilage.
Step 2: Withering
The second step of tea production is withering, which is the process of reducing the moisture content of the tea leaves. Withering is necessary for tea production, as it prepares the tea leaves for further processing and enhances their flavor and aroma. Withering is done in Nilgiri tea factories using machines that blow hot and cold air over the tea leaves.
What are the effects of withering?
- The duration, temperature, and humidity of withering affect the quality and flavor of the tea leaves.Â
- The optimal conditions for withering depend on the type and variety of tea leaves, the weather, and the desired outcome.Â
- Generally, the longer and hotter the withering, the stronger and darker the tea. The shorter and cooler the withering, the lighter and greener the tea.
How is withering done?
Withering is done in two stages: primary withering and secondary withering.
Primary withering stage
In the primary withering stage, the tea leaves are spread on large trays or troughs and exposed to hot and cold air for about 10 to 12 hours. The primary withering stage reduces the moisture content of the tea leaves from about 75% to about 55%. The primary withering stage also activates the enzymes in the tea leaves, which are responsible for the oxidation process.
Secondary withering stage
In the secondary withering stage, the tea leaves are transferred to a rotating drum or a conveyor belt and exposed to hot and cold air for about 2 to 4 hours. The secondary withering stage reduces the moisture content of the tea leaves from about 55% to about 45%. The secondary withering stage also softens the tea leaves and makes them more pliable for rolling.
| Withering Stage | Moisture Content | Duration | Temperature | Humidity |
|---|---|---|---|---|
| Primary withering | 75% to 55% | 10 to 12 hours | 25°C to 35°C | 60% to 70% |
| Secondary withering | 55% to 45% | 2 to 4 hours | 30°C to 40°C | 50% to 60% |
After withering, the tea leaves are ready for rolling, which is the next step of tea production.
Step 3: Rolling
The third step of tea production is rolling, which is the process of breaking and shaping the tea leaves. Rolling is important for tea production, as it releases the juices and oils from the tea leaves and gives them their final form and appearance. Rolling is done in Nilgiri tea factories using machines that crush, tear, and curl the tea leaves into small granules. This is the CTC method of tea production, which is different from the orthodox method of tea production.
How is rolling done?
CTC method of rolling
The CTC method of tea production involves machines that have two sets of rollers with sharp teeth that cut, tear, and curl the tea leaves. The first set of rollers is called the cutter, which cuts the tea leaves into smaller pieces. The second set of rollers is called the curler, which tears and curls the tea leaves into tiny balls. The CTC method of tea production is fast and efficient, as it can process large quantities of tea leaves in a short time.
Orthodox method of rolling
The orthodox method of tea production involves machines that have smooth rollers that gently roll and twist the tea leaves, preserving their shape and flavor. The orthodox method of tea production is slow and labor-intensive, as it requires more time and skill to process the tea leaves.
Work in full swing. It’s a busy day at work at India’s largest cooperative Tea Federation @IndcoTeas Blending and packaging of ‘Ooty Tea’ supplied to about 30,000 ration shops in Tamil Nadu every month. #Tea #Nilgiris pic.twitter.com/YujKh88ISi
— Supriya Sahu IAS (@supriyasahuias) April 5, 2021
What are the effects of rolling?
The CTC method of tea production has some advantages and disadvantages over the orthodox method of tea production.
Advantages of CTC method
- The CTC method produces strong and uniform tea that is suitable for blending and making iced tea.Â
- It produces tea that has a longer shelf life and a lower price.
Disadvantages of CTC method
- The CTC method of tea production also compromises the quality and flavor of the tea, as it damages the natural structure and aroma of the tea leaves.Â
- It also produces tea that has more caffeine and tannins, which can cause bitterness and astringency.
Advantages of orthodox method
- The orthodox method produces mild and diverse tea that is suitable for enjoying as a single origin or a specialty tea.Â
- The method also preserves the quality and flavor of the tea, as it maintains the natural shape and aroma of the tea leaves.
Disadvantages of orthodox method
- The orthodox method of tea production also produces tea that has a shorter shelf life and a higher price.Â
- The orthodox method of tea production also produces tea that has less caffeine and tannins, which can cause smoothness and sweetness.
After rolling, the tea leaves are ready for oxidation, which is the next step of tea production.
Step 4: Oxidation
The fourth step of tea production is oxidation, which is the process of exposing the tea leaves to oxygen. Oxidation is the most crucial step of tea production, as it determines the color, aroma, and flavor of the tea. Oxidation is done in Nilgiri tea factories using machines that control the temperature, time, and airflow of the oxidation process.
How is oxidation done?
- Oxidation is done in large chambers or rooms that have fans and heaters that regulate the oxygen and heat levels.Â
- The tea leaves are spread on trays or racks and exposed to oxygen and heat for about 1 to 2 hours.Â
- The oxidation process causes the tea leaves to change their color from green to brown, as the enzymes in the tea leaves react with the oxygen and produce pigments called theaflavins and thearubigins.Â
- The oxidation process also causes the tea leaves to develop their aroma and flavor, as the enzymes in the tea leaves break down the proteins and sugars and produce volatile compounds.
What are the effects of oxidation?
The duration, temperature, and airflow of oxidation affect the quality and flavor of the tea leaves. The optimal conditions for oxidation depend on the type and variety of tea leaves, the weather, and the desired outcome. Generally, the longer and hotter the oxidation, the darker and stronger the tea. The shorter and cooler the oxidation, the lighter and milder the tea.
| Type of Tea | Oxidation Level | Color | Flavor |
|---|---|---|---|
| Black tea | Fully oxidized | Dark brown to black | Strong and brisk |
| Oolong tea | Partially oxidized | Light brown to amber | Smooth and floral |
| Green tea | Unoxidized | Green to yellow | Fresh and grassy |
| White tea | Slightly oxidized | Pale green to white | Delicate and sweet |
Step 5: Drying
The fifth and final step of tea production is drying, which is the process of reducing the moisture content of the tea leaves to make them shelf-stable and enhance their flavor. Drying is done in Nilgiri tea factories using machines that blow hot air over the tea leaves.
Drying is done in two stages: primary drying and secondary drying.
Primary Drying Stage
In the primary drying stage, the tea leaves are exposed to hot air at about 100°C for about 20 minutes. The primary drying stage reduces the moisture content of the tea leaves from about 45% to about 10%. The primary drying stage also stops the oxidation process and preserves the color, aroma, and flavor of the tea.
Secondary Drying Stage
In the secondary drying stage, the tea leaves are exposed to hot air at about 80°C for about 10 minutes. The secondary drying stage reduces the moisture content of the tea leaves from about 10% to about 3%. The secondary drying stage also enhances the flavor and aroma of the tea by further breaking down the compounds in the tea leaves.
What are the effects of drying?
The temperature, time, and method of drying affect the quality and flavor of the tea leaves. The optimal conditions for drying depend on the type and variety of tea leaves, the weather, and the desired outcome. Generally, the higher and longer the drying, the stronger and darker the tea. The lower and shorter the drying, the lighter and greener the tea.
| Drying Stage | Moisture Content | Duration | Temperature |
|---|---|---|---|
| Primary drying | 45% to 10% | 20 minutes | 100°C |
| Secondary drying | 10% to 3% | 10 minutes | 80°C |
After drying, the tea leaves are ready for grading and sorting, which are the processes of separating the tea leaves according to their size, shape, and quality. Grading and sorting are done using machines that have sieves, screens, or magnets that filter the tea leaves. Grading and sorting are important for tea production, as they determine the appearance, flavor, and price of the tea.
Common grades of Nilgiri CTC tea:
| Grade | Size and Shape | Quality and Flavor |
|---|---|---|
| BOP (Broken Orange Pekoe) | Small and even | Good and strong |
| BP (Broken Pekoe) | Smaller and uneven | Fair and brisk |
| BPS (Broken Pekoe Souchong) | Smallest and round | Best and smooth |
| Fannings | Tiny and flat | Fine and bright |
| Dust | Finest and dust-like | Inferior and dull |
After grading and sorting, the tea leaves are ready for packaging and selling, which are the processes of storing and transporting the tea leaves to the market. Packaging and selling are done using machines that pack the tea leaves in bags, boxes, or cans that protect them from moisture, light, and air. Packaging and selling are important for tea production, as they ensure the freshness, quality, and safety of the tea.
FAQs
Q. What is Nilgiri tea?
A. Nilgiri tea is a type of black tea that is grown and processed in the Nilgiris district in Tamil Nadu, India. Nilgiri tea has a brisk, fragrant, and full-bodied flavor. It is also known for its bright color and floral aroma. Nilgiri tea is made using the CTC process, which involves machines that crush, tear, and curl the tea leaves into small granules.
Q. What is CTC method of tea production?
A. CTC method of tea production is a method of tea production that involves machines that cut, tear, and curl the tea leaves into small granules. The CTC method of tea production is fast and efficient, as it can process large quantities of tea leaves in a short time. The CTC method of tea production produces strong and uniform tea that is suitable for blending and making iced tea.
Q. What are the benefits of Nilgiri tea?
A. Nilgiri tea has many benefits for health and well-being. Nilgiri tea is rich in antioxidants, which can protect the cells from damage and prevent diseases. Nilgiri tea also has anti-inflammatory and anti-microbial properties, which can reduce inflammation and infection. Nilgiri tea can also boost the immune system, lower the blood pressure, improve the digestion, and enhance the mood.
Q. How to differentiate between orthodox and CTC tea?
A. Orthodox and CTC tea are two different methods of tea production that result in different types of tea. Orthodox tea is made by hand-rolling the tea leaves to preserve their shape and flavor. CTC tea is made by machines that crush, tear, and curl the tea leaves into small granules. Orthodox tea has a mild and diverse flavor, while CTC tea has a strong and brisk flavor. Orthodox tea has a loose and curly appearance, while CTC tea has a granular and uniform appearance. Orthodox tea is more expensive and less available, while CTC tea is cheaper and more common.
Q. What is the price of Nilgiri tea?
A. The price of Nilgiri tea varies depending on the type, grade, quality, and packaging of the tea with an average range of ₹175 to ₹300 per 500 grams.