"From Leaf to Cup: An Overview of Orthodox Tea Production and Manufacturing Process"
Orthodox Tea Production and Manufacturing
Orthodox tea refers to the traditional method of producing tea leaves, rather than a specific type of tea. The term is typically used in contrast to "CTC" (crush, tear, curl) tea, which is a newer method of processing tea that produces smaller, more uniform tea leaves.
Orthodox tea is a type of black tea that is hand-processed using traditional methods. The process involves several steps, including withering, rolling, oxidation, and drying. Here are the basic steps for manufacturing orthodox tea:
Orthodox tea can be made from a variety of tea clones and cultivars, and the choice of clone or seed can have an impact on the final product. Here are some tea clones and cultivars that are commonly used for producing orthodox tea:
1. Camellia Sinensis var. Assamica: This tea variety is native to the Assam region of India and is known for its large leaves and strong flavor. It is commonly used to produce black teas such as Darjeeling and Assam.
2. Camellia Sinensis var. Sinensis: This tea variety is native to China and is known for its small leaves and delicate flavor. It is commonly used to produce green, white, and oolong teas.
3. Darjeeling clonal tea: Darjeeling tea is a high-quality tea grown in the Darjeeling district of West Bengal, India. Darjeeling tea is made from the Camellia Sinensis var. Sinensis plant, but there are also several clonal varieties of Darjeeling tea that have been developed for their unique flavors and aromas.
4. China clonal tea: China clonal tea is a type of tea grown in the Darjeeling district of West Bengal, India, and is made from the Camellia Sinensis var. Sinensis plant. This tea variety is known for its floral aroma and delicate flavor.
5. Taiwan Oolong tea cultivars: Taiwan is known for producing high-quality oolong teas, and there are several cultivars of the Camellia Sinensis plant that are commonly used to produce these teas. Some popular Taiwan oolong cultivars include Jin Xuan, Qing Xin, and Si Ji Chun.
It's worth noting that the final product of orthodox tea depends on several factors, including the processing method, the climate, and the soil conditions, in addition to the tea clone or seed used. A skilled tea maker can produce high-quality orthodox tea from a variety of tea clones and cultivars, but the specific choice may depend on the desired flavor and aroma profile of the final product.
1. Withering:
Freshly plucked tea leaves are spread out on large trays or racks and left to wilt and lose moisture for several hours. This process makes the leaves more pliable and easier to roll.
The orthodox withering method is a crucial step in the production of high-quality tea, as it can greatly affect the flavor and aroma of the final product. Here is a general overview of the orthodox withering method:
- Harvesting: Fresh tea leaves are harvested by hand, typically early in the morning to ensure the highest quality.
- Spreading: The freshly picked tea leaves are spread out in a thin layer on large trays or bamboo mats, allowing them to wilt and lose moisture. The thickness of the layer and the duration of the withering process can vary depending on the type of tea and the desired outcome.
- Monitoring: During the withering process, the tea leaves are carefully monitored to ensure that they are not over-withered or under-withered. Over-withered leaves may become too brittle and lose their aroma and flavor, while under-withered leaves may not release their full flavor potential during subsequent processing steps.
- Tossing: In some cases, the tea leaves may be gently tossed or rotated during the withering process to ensure even withering.
- Testing: After the withering process is complete, the tea leaves may be tested for moisture content and other factors to determine the next steps in the processing.
The orthodox withering method typically takes several hours, but the exact duration can vary depending on the climate, humidity, and other factors. The goal is to achieve a balanced wither that allows the tea leaves to release their full flavor potential during subsequent processing steps.
2. Rolling:
After withering, the leaves are rolled, usually by hand, to break down the cell walls and release the juices inside. This step helps to initiate the oxidation process.
The rolling process is a critical step in the production of orthodox tea, as it helps to release the enzymes and flavor compounds that are necessary for the tea's unique flavor and aroma. Here's a general overview of the orthodox tea rolling process with a rolling table:
- Preparing the leaves: The withered tea leaves are first spread out on a flat surface, where they are inspected and sorted to remove any stems or unwanted material.
- Loading the leaves: The leaves are then loaded onto the rolling table, which is a large table with a rotating drum in the center. The leaves are placed on top of the drum, and a cover is placed over the top to keep them in place.
- Starting the rolling: The rolling table is turned on, and the drum begins to rotate, causing the leaves to roll and twist against each other. The rolling motion is typically gentle and slow at first, gradually increasing in speed as the rolling process continues.
- Monitoring the rolling: During the rolling process, the tea maker must monitor the leaves closely to ensure that they are being rolled evenly and not over-rolled. Over-rolling can cause the leaves to become too small and lose their flavor and aroma.
- Adjusting the pressure: Depending on the type of tea being produced, the tea maker may adjust the pressure on the rolling table to achieve the desired level of oxidation. Higher pressure can lead to more bruising of the leaves and greater oxidation, while lower pressure can result in a lighter flavor and aroma.
- Stopping the rolling: Once the tea maker is satisfied with the degree of rolling, the rolling table is stopped, and the tea leaves are removed and spread out to continue the oxidation process.
The rolling process is a critical step in the production of high-quality orthodox tea, and a skilled tea maker can adjust the rolling method to achieve the desired flavor and aroma profile of the final product.
3. Oxidation:
The rolled leaves are spread out on trays or racks and left to oxidize for several hours, during which time the juices inside the leaves react with the air and turn the leaves from green to brown.
The oxidation process is a critical step in the production of orthodox tea, as it allows the tea leaves to develop their unique flavors and aromas. Here's a general overview of the orthodox tea oxidation process:
- Spreading the leaves: After the rolling process, the tea leaves are spread out in a thin layer and left to rest in a cool and humid environment. This step is called withering or wilting, and it allows the tea leaves to lose some of their moisture content.
- Bruising the leaves: The tea leaves are then bruised or crushed to break down the cell walls and release enzymes that trigger the oxidation process. This is typically done by tossing the leaves or shaking them in baskets.
- Spreading the leaves again: The tea leaves are then spread out in a thin layer and left to rest for a period of time, usually several hours. During this time, the enzymes released during bruising interact with the oxygen in the air, causing the leaves to turn darker in color and develop new flavors and aromas.
- Checking the oxidation level: The tea maker must check the oxidation level of the tea leaves regularly to ensure that they are not over-oxidized or under-oxidized. Over-oxidized leaves can become bitter and astringent, while under-oxidized leaves may not develop their full flavor potential.
- Stopping the oxidation: Once the tea maker is satisfied with the level of oxidation, the oxidation process is stopped by heating the tea leaves in an oven or a pan. This step, called firing or fixing, also helps to dry the leaves and preserve their flavor and aroma.
The exact duration and conditions of the oxidation process can vary depending on the type of tea being produced and the desired flavor and aroma profile. A skilled tea maker can adjust the oxidation process to achieve the desired level of oxidation and produce high-quality orthodox tea.
4. Drying:
The oxidized leaves are then dried, either by exposure to the sun or by using a machine. This step stops the oxidation process and removes any remaining moisture from the leaves.
The drying process, also known as firing or fixing, is a critical step in the production of orthodox tea, as it helps to remove any remaining moisture from the leaves and lock in their flavor and aroma. Here's a general overview of the orthodox tea drying process:
- Preparing the leaves: After the oxidation process, the tea leaves are spread out in a thin layer and left to rest for a period of time, usually several hours. This allows the leaves to develop their unique flavors and aromas.
- Heating the leaves: Once the tea maker is satisfied with the oxidation level of the leaves, the leaves are heated to stop the oxidation process and remove any remaining moisture. This is typically done by heating the leaves in an oven or a pan.
- Monitoring the temperature and time: The temperature and time of the drying process can vary depending on the type of tea being produced and the desired flavor and aroma profile. Generally, the drying temperature is around 100-120°C (212-248°F), and the drying time is between 20-30 minutes.
- Checking the moisture level: During the drying process, the tea maker must check the moisture level of the leaves regularly to ensure that they are not over-dried or under-dried. Over-dried leaves can become brittle and lose their flavor and aroma, while under-dried leaves may not be preserved properly.
- Cooling the leaves: Once the drying process is complete, the tea leaves are cooled down to room temperature to stop any further chemical reactions and to allow the leaves to stabilize.
The exact duration and conditions of the drying process can vary depending on the type of tea being produced and the desired flavor and aroma profile. A skilled tea maker can adjust the drying process to achieve the desired moisture level and produce high-quality orthodox tea.
5. Sorting and grading:
The dried tea leaves are sorted and graded based on their size and quality. The highest quality leaves are typically reserved for loose-leaf tea, while lower-quality leaves may be used for tea bags.
Orthodox tea is typically sorted into grades based on the size and shape of the leaves. Sorting is an important step in the production process, as it helps to ensure consistency and quality in the final product. Here's an overview of the orthodox tea grade sorting process:
- Separation by size: The first step in sorting is to separate the tea leaves by size. This is typically done using a series of mesh screens or sieves with different sized holes. The leaves are passed through the screens several times, with each pass separating the leaves into different size grades.
- Separation by weight: Once the leaves are separated by size, they may also be separated by weight. This is typically done using a machine called a gravity table, which uses air currents to separate the leaves based on their density.
- Sorting by quality: After the leaves are sorted by size and weight, they may also be sorted by quality. This is typically done by hand, with experienced tea tasters examining the leaves for color, texture, and aroma. The leaves are sorted into different grades based on their overall quality.
Mach number, or the maximum speed of sound in a medium, is not typically used in the orthodox tea grade sorting process. Instead, sorting is generally done based on size, weight, and quality, using manual or mechanical methods.
6. Packaging:
The sorted and graded tea leaves are packaged and prepared for shipping.
Orthodox tea is typically packaged in a variety of grades, depending on the size, shape, and quality of the tea leaves. Here's an overview of some of the common orthodox tea packaging grades and their names:
- 1. Whole Leaf Grades: These grades contain whole, unbroken tea leaves and are considered to be of the highest quality. Some common whole leaf grades include:
- Orange Pekoe (OP): This grade contains long, wiry tea leaves that are unbroken and relatively thin. OP is one of the most common grades of orthodox tea.
- Flowery Orange Pekoe (FOP): This grade contains long, wiry tea leaves that have been carefully handpicked to include a bud and two leaves. FOP is considered to be a higher grade than OP.
- Golden Flowery Orange Pekoe (GFOP): This grade contains young tea leaves that are picked early in the growing season, along with the bud. GFOP is considered to be a premium grade of orthodox tea.
- Broken Leaf Grades: These grades contain tea leaves that have been broken into smaller pieces. They are typically less expensive than whole leaf grades and may be used for tea bags or blending. Some common broken leaf grades include:
- Broken Orange Pekoe (BOP): This grade contains broken tea leaves that are larger than those in the Fannings grade.
- Fannings (F): This grade contains small, broken tea leaves that are used for tea bags.
- Dust (D): This grade contains very fine tea particles that are used for tea bags or instant tea.
The exact grading system for orthodox tea can vary depending on the country of origin and the individual tea estate. However, the above grades are commonly used in many tea-producing regions around the world.
It's important to note that the specific process for manufacturing orthodox tea may vary depending on the region, the type of tea, and the individual tea producer's preferences. However, the basic steps outlined above are typical for orthodox tea production.
In conclusion, orthodox tea production is a traditional and meticulous process that involves several steps to create high-quality tea leaves. The process starts with handpicking and sorting the leaves, followed by withering, rolling, oxidation, and drying. The oxidation step is a crucial stage that determines the flavor, aroma, and color of the final product. The drying process removes any remaining moisture from the leaves and locks in their flavor and aroma. Finally, the leaves are sorted into different grades based on size, weight, and quality before being packaged for sale.
Orthodox tea is known for its high quality and unique flavor profile, and is produced in several regions around the world, including India, Sri Lanka, China, and Taiwan. The production of orthodox tea requires skilled workers who have a deep understanding of the tea-making process, as well as access to high-quality tea leaves and specialized equipment. While the production process may be time-consuming and labor-intensive, the end result is a delicious and satisfying cup of tea that has been enjoyed for centuries.