History of Malawian tea

Malawi boasts of being the pioneer for tea growing in the African continent. The industry dates
back to as far ago as 1890 when Europeans still had abodes in Africa. Jonathan Duncan is
attributed with consistently trying out a variety of tea seeds in Malawian soils which he obtained
from Edinburg. After many futile efforts, he successfully planted two tea trees in 1878 at the
Blantyre Mission grounds. However, the true diversification of tea growing in the country’s
fertile regions is pin-pointed back to one Henry Brown; a Scottish farmer who was in Malawi
courtesy of Scottish Missionaries. The Missionaries had received the seeds from Edinburg’s
Royal Botanic Gardens. Brown was eager to revive his passion in plantation farming after his
coffee succumbed to disease in Sri Lanka. He went on to erect tea gardens at his estate and the
climate only propelled the crop’s successful growth.
Mulanje lowlands and the Thyolo highlands were the first recipients of the newly introduced
cash crop. The tea gardens in the aforementioned areas acquired the seeds from South Africa’s
Natal which were originally transplanted and cultivated in Sri Lanka’s region of Ceylan.

Processing of tea
Introduction
The most widely consumed ancient beverage is the Tea. Camelia sinensis is the botanical name
of the tea plant. Processing of tea involves various steps like plucking, withering, crushing,
drying, rolling and shaping of tea leaves through which the leaves are made ready for brewing.
Tea consumption was originated in ancient China and reached the European continent in the 16th
century. In India, tea was cultivated in Assam in the 19th century. Chinese variety (C. s.
Sinensis), and Assamese variety (C. s. Assamica) are the two basic varieties of tea from ancient
time. The practice of steaming fresh tea leaves and drying them for further storage and
consuming it by decocting with other herbs was followed in China.
Tea Plant Generally, the tea plant grows to height of 35 feet in tropical and subtropical climates.
The plantations are cultivated at altitudes at 2460 m above sea level. For the ease of plucking and
pruning the bushes are maintained at two to two and half feet height, so that the bush spreads and
grows widely.
Processing of Tea
There are different types of tea, varying in colour, smell, taste and appearance due to the minor
changes in the processing steps.
Types of Products from Tea Products from tea are broadly classified into i. Conventional teas
and ii. Nonconventional tea products
i. Conventional teas comprise of (a) Completely fermented black tea, (b) Unfermented green tea
(c) Partially fermented Oolong (red and yellow) tea,
ii. Nonconventional tea products include
(a) Cold- and hot-soluble Instant tea
(b) Flavored tea and decaffeinated tea. Canned or bottled teas, soluble tea mixes, tea beverages,
frozen tea liquid, and tea tablets termed as convenience products. Liquid tea concentrates, tea
mixes, iced tea mixes, and fruit tea mixes are the recent products that has shown tremendous
increase in the global market.
Conventional Teas
Harvesting or Plucking
This operation is a significant step in the final quality of the tea. Usually, tender and uniform
terminal bud and two shooting leaves or only shoots with three leaves are picked from the tea
plant twice a year. Manual picking is done for high quality tea and it highly depends on the skill
of the picker but this is a costly method. Mechanical picking of tea flushes and leaves are also
practiced but it results in large quantities of broken leaves and partial flushes. However,
mechanical harvesting at right time can yield high quality teas. Plucking of coarse leaves is
strictly avoided since it interferes in the quality of the tea.
Withering
The plucked tea leaves are subjected to withering for initial removal of moisture content. Two
methods of withering are generally practiced.
Natural method of Withering
The freshly picked tea leaves are spread out in very thin layers on wire meshed racks that are
arranged one above the other and further subjected to drying in natural air for a minimum period
of 20 to 24 hours.
Artificial Withering
The plucked tea leaves are widely laid in 18 to 20cm layers in tables with wire meshes that are
placed in a tunnel in which forced circulation of warm air mixed with fresh air takes place. This
method of withering significantly causes a reduced withering time, resulting in approximately
60-62% residual moisture reduction rendering the withered tea leaves suitable for tea processing.
Breaking Up
Breaking up is the process of rolling the withered tea leaves which is a pre-preparation step. This
is done with the use of a circular table with a central cone with lateral slat like arrangement
called battens. The top of the table is fitted with a circular jacket with a pressure cap. The table
and jacket are made to rotate in opposite directions eccentrically, thereby causing the withered
leaves placed in the jacket to twist and roll on the surface of the cone and battens which is almost
similar to manual rolling.
CTC Method (Crushing, Tearing and Curling)
CTC machine comprises of two metal rollers that are separated but placed with minimum
distance between each other that revolves at unequal speeds. This movement cuts, tears and
twists the withered and broken up tea leaves. As a result, the juice from the tea leaves are pressed
to the surface of the leaves, which initiates the fermentation process.
Fermentation 3
During fermentation, the oxidation process which had begun during rolling is continued.
Fermentation takes place in separate fermentation rooms, which need to be kept extremely clean
to avoid bacterial infection of the tea. The tea leaves are placed in 3.5 –7.5 cm. layers on
aluminum trays. The thickness of the layers depends on the room temperature. As soon as the tea
has acquired a copper red color, the correct degree of fermentation has been reached, and the
process must be halted by drying. The tannin content decreases during fermentation, from 20%
in fresh tea leaf to 10%–12% after fermentation. The formation of aroma compounds is caused
due to oxidation of amino acids, carotenes, and unsaturated lipids during the fermentation period.
Drying or Firing
The drying process carried on a 4 plates system drier. Hot air up to 90 °C, is blown against the
leaves, which should have reached 80 °C, by the time has been completed, I order for the
polyphenol oxidize enzyme to be properly inactivated. The moisture content should be reduced
to 3.5% whereby the aroma becomes established and the leaves take on their typical black
coloration.
Flowchart 1
Tea Processing
Grading and Storage of Fermented Tea 4 Winnowing is practiced to separate the stalky matter
and grading is done by sieving, where from different grades of tea are obtained based on particle
size. During the storage of finished tea products various chemical changes take place, leading to
the loss of the remaining residual greenness and roughness in 10 to 15 days period. Tea should
be stored in moisture and oxygen proof area to retain the flavor and aroma developed in
fermented tea. Flavor retention is possible for more than 1 year, under such storage conditions.
Green Tea
A bud and two to three leaves of tea shrubs are harvested for Green tea production. Green tea
consumption sums to around 21% of total tea production due to larger amounts of catechins and
vitamins. Green tea possesses a pleasant taste and aroma, and has light olive-green shade color.
Since green tea is unfermented, the inactivation of browning enzymes is regarded as a crucial
factor. The enzyme is inactivated either by steaming or by roasting the green leaves in a pan. The
steps of manufacturing of green tea are similar to fermented tea except for the fermentation step.
The steps include are plucking, steaming/roasting, primary heating and rolling, rolling,
secondary rolling, drying, refining, firing, sorting, and packing. There are 18 different types of
green tea worldwide.
Flowchart 2
Green Tea Processing
Yellow Tea
Yellow tea is much similar to green tea but lies in between black and green tea. It belongs to the
unfermented tea variety that is brighter in color on infusion than that of green tea. Yellow tea,
yields a milder taste and is highly refreshing with a stronger aroma when compared to green tea.
It contains a higher quantity of catechins and vitamins than black tea and therefore is highly
stimulative.
A bud and two or three young leaves and tender shoots of the tea plant are used for the
production of Yellow tea. Withering should be uniform right from the tender parts of the shoots,
the bud, and first leaf to the third leaf and stalk. Withering, roasting, rolling, sorting, and firing
are the steps in manufacturing yellow tea.
Red Tea
Red tea is a less fermented tea with a delayed enzymatic reaction and chemical processes with a
mild taste and a stimulating aroma. Withering, rolling, roasting, firing, sorting, and final firing
the steps involved in the production of red tea.
Dark Tea
An unfermented tea traded only in Chinese internal market is known as Dark tea. It is brownish
yellow or brownish red after infusion. It yields a mild aroma and it is highly vulnerable to
fermentation by microbes. One bud leaf, and four to six leaves united with stalks are subjected to
withering and rolling followed by piling and drying continued by steaming, and then further
compressed to obtain the Dark tea. Piling is an important quality determining factor; because of
this fact the tea leaves are kept at high process temperatures and humidity for long periods of
time to enable the natural growth of microorganisms such as Aspergillus glaucus,
Saccharomyces etc. Piling causes oxidation of polyphenols due to the combined action of
moisture, heat, and the microbes. When compared to yellow tea, dark tea contains no
chlorophyll, and the concentrations of catechins and free amino acid are much lower thus
resulting in a mellowed flavor of dark tea.
White Tea
A fermented type of Chinese tea meant only for export is White tea that gives light orange-
yellow tea when infused. One fresh bud with one to two leaves with intense hairs or only buds
containing moderate content of polyphenols undergoes the process of withering and firing. Thus,
obtained white tea is sorted, and packed. Withering is done for a period of three days during
which amino acids content increases, and decrease in sugar and polyphenolic components levels
is seen.
Nonconventional Tea Products
Instant Tea
The process of dehydrating the infusions of either black tea or green tea yields a highly
hygroscopic product called Instant tea. Instant teas are available in different types namely hot
soluble and cold-soluble depending on consumer preferences.
Technology
6 Different raw materials which are used for Instant tea preparation are Green tea, black tea etc.
Apart from processed tea, the low-grade tea, crude tea leaves and dust tea waste are also used as
raw material. Quality control of ingredients for Instant tea preparation is mandatory to produce
best quality Instant tea.
Extraction Extremely good quality water is used for infusing tea for extraction. Generally co-
current or counter-current methods of extraction are followed by continuous removal of moisture
by dewatering. The combination of leaves used for extraction is mixed with hot water in varying
ratios of tea leaves and water. As an alternate method the tea leaves are consecutively subjected
to extraction in different stages and the resulting extracts so obtained are received in a tank and
mixed thoroughly immediately before the final stage of concentration. In the countercurrent
method, the tea leaves and the concentrated extracts are in opposite directions causing a gradual
accumulation of solids in continuous extractions, up to nearly 10% level. To obtain a quality
product it is usual to add a portion of the first extract finally before spray drying that makes up
the flavor loss.
Decreaming and Cream Solubilization at room temperature,
The tea brew is cooled and forms a hazy layer termed as cream. This is due to a caffeine-
polyphenol-protein complex formation which affects the organoleptic characteristics of tea
beverages that are both hot-soluble and cold-soluble. Hence, a step called decreaming is
practiced to remove the cream, by subjecting the extract to centrifugation or passing it through
filtration membranes. Tea cream may also be solubilized by chemical methods or enzymatic
methods.
Aroma Stripping and Aromatization Steam or inert gases are used for the aroma stripping
process immediately after extraction and just prior to concentration. The concentration is carried
out at low temperature and pressure conditions and they are added again in the final tea
concentrate.
Concentration
The tea extract is concentrated from 10% to 30% of solids either in a vacuum concentrator or in
other evaporators like falling film evaporator or rising film or thin film evaporator. This is a
crucial step for aroma retention. Usually the process is employed at very low temperatures and
short entraining times of the tea extract in the concentrators. Permitted fillers are added to
increase the solids concentration to 30%, to enhance the speed of the drying operation.
Drying 7 Spray driers, freeze driers or vacuum driers are used to dry the extract.
The commonly used method is spray drying because the other methods involve high processing
temperatures which causes high flavor losses. In order to increase the bulk density of the product
either carbon dioxide or ammonium carbonate is added or the extract is subjected to
agglomeration which is followed by spray drying. Anti-caking agents are added to the product
since it is highly hygroscopic in nature.
Chemical Composition The chemical composition of instant tea ranges as follows in percentages
of: 40.5–49.0% of tannins, 55.2–89.4% of total catechins, 3.5–5.1% of caffeine. The total amino
acids ranges from 7.0–8.0% with total nitrogen from 2.9 to 4.0%. The total protein nitrogen of
the instant tea varies from 0.14–0.40
Blending
Blending of instant tea is done to enrich other teas varieties. Instant tea is added to regular tea to
improve the constituents of extract from 40% to 70% which includes polyphenols, caffeine etc,
thereby increasing the nutritive value. Since low-cost tea is used for the manufacture of instant
tea, addition of 15% instant tea to any grade of regular tea does not affect its taste or flavor but
yields high profit.
Flavored Teas
Flavoured teas are produced by incorporation of various natural or nature-identical flavors in
processed teas. Flavored black tea, green tea, Oolong tea, instant tea, decaffeinated black tea, and
decaffeinated instant tea are available worldwide. Incorporation of natural flowers or flower
petals or skin peels of citrus fruits is done after the firing step in factories. Spiced teas with
ginger, cardamon, clove, cinnamon or scented teas with lemon, orange, mint, bergamot, and rose
are popular and consumed widely in all parts of the world. Essence of apricot, banana, apple,
raisin, currant, date, prune, and fig is also added to impart the fruity flavor to tea.
Flavour Incorporation Techniques in Tea Alternate layers of tea leaves and fragrant flowers are
spread in a chamber to incorporate natural fragrance to tea. This chamber is subjected to heating
in baskets for nearly 2 hours, which render the flowers crisp. The flowers are removed by sieving
and the tea thus separated is packed. This tea is mixed with unscented teas in the ratio of 1:20.
Concentration of extract of liquid teas with spices like ginger, cardamom, clove, cinnamon,
coriander, and cumin are done by adding them at the brewing stage itself. There are two
standardized diffusion methods that are generally practiced. The first direct method involves the
mixing of flavor component in a small quantity to the desired grade of tea directly and then this
blend is remixed with the bulk stored tea. In the second indirect method, 8 the flavor is sprayed
on a ball of cotton or paper that comes into indirect contact with blend, where only vapors are in
contact with tea. In the third spraying method, tea is spread in layers of uniform thickness in
trays, placed in specially constructed rooms. Automatic spraying devices are used for flavor
incorporation on these layers. Flavor losses can be reduced by adding encapsulated flavours.
Decaffeinated Teas For consumers who are concerned about the health effects of caffeine intake,
decaffeinated teas are produced. About 60% to 90% of the caffeine is separated from the black
tea by a process of solvent extraction, which is called decaffeination. This step reduces the
caffeine content from 0.2%to 0.8%. Chemical or enzymatic treatment is employed to remove
bound caffeine. The involved in the process are:
(a) Increasing the initial moisture content from 10% to 40%;
(b) organic solvent treatment for 12 to 18 hours which extracts 97% of the caffeine;
(c) live steam treatment for the removal of all residual solvents;
(d) final drying for the excess moisture removal.

QUALITY STANDARDS AND SPECIFICATIONS

Physical, chemical, sensory, and microbiological specifications are the parameters assessed for
the quality of black tea, decaffeinated black tea, and flavored tea. In physical characteristics
grades, particle size, bulk density, color, and appearance are assessed. For chemical quality
polyphenols, total soluble, and extraneous matter are checked within the ISI and PFA standards.
Microbiological parameters are important in speciality liquid tea products like carbonated
beverages, canned or frozen tea concentrates.
Physical Characteristics
Stalks, fiber, and foreign matter are removed from processed teas. They are graded into, leaf
grade, brokens, fannings, and dust, based on the colour, particle size, and infusion qualities.
Chemical Quality of Tea
The quality of tea is governed by the presence of chemical substances like polyphenols including
tannins, caffeine, pectins, theaflavins [TFs] and thearubigins [TRs], noncaffeine nitrogenous
compounds, sugars, minerals, and lipids. Tannins are present upto 10% levels only in processed
black tea in comparison to green tea that possesses 18%–20% of tannins.
Blending of Teas,
The final moisture content of the graded teas is less than 3% moisture level. This graded tea is
packed in tea chests, lined with aluminum foil in controlled humidity conditions. Tea with
different characteristics are blended together to produce best satisfying quality product in the 9-
consumer market on the basis of parameters like quality, flavor, strength, body, size and style of
leaf.
Tea Tasting and Sensory Quality of Tea
The combined effects of nonvolatile solids extractable from tea leaf to about 0.30% to 0.45%
solids concentration under normal brewing temperature determines the quality of tea. Infusion is
made by adding boiling water of 0.142-L capacity in which a graded or blended tea sample of
2.83g is kept. After 5–6 minutes the brew containing 2% solids is assessed by a specialist
characteristic like color, quality, strength, briskness, flavor etc.
Storage and Packaging
Aspects Different storage conditions are used to store manufactured black teas for a time period
of 3 to 6 months before they reach the consumer market. Black tea is stored for 300 days, with
flavor retention at 32% relative humidity,
Suitable packing materials, both unit and bulk packing, is essential to protect tea from moisture
and oxygen. To conclude this session let us recall the concepts of tea processing right from
harvesting, withering, CTC Processing of tea leaves, fermentation, drying and packaging. Apart
from conventional tea products, currently there is continued research in new product
development, value-added products, convenience products, and development of compatible
flavors to satisfy customer requirements.

Agronomical practices in tea plantation,

Agronomic practices include water supply, nutrient management, canopy establishment, and tea
garden ecology management not only directly affect the yield, but also influence the metabolism
of quality-related components in tea.