The most time consuming stage in the preparation of Ivan tea is the process of preparation for fermentation, namely, the destruction of the fiber of the tea leaf.

The option with an electric meat grinder does not suit everyone. Especially picky fans of this drink, try to avoid the interaction of the sheet with metal objects (meat grinder).

Maybe it's in the old traditions, maybe in the opinion that the interaction of the willow-herb leaf with the metal triggers the oxidative process. I will not guess, I will just describe the process of making a small device for another version of twisting a leaf of willow tea.

If there are no problems with twisting a well-dried willow-tea leaf, then you will have to tinker with the leaves of fruit trees (apple, pear, etc.) and raspberries. And without freezing-thawing the leaves, most likely, you will not be able to do it.

Materials and tools

For work, you will need a wide board (pine, linden, etc.), an angle grinder (aka angle grinder) with a disc diameter of 125 mm., A flap end circle and a skin.

Work process

Draw a circle with a compass.

We sketch the future convolutions.

If it is convenient for you to do circular rotations clockwise, then we do the convexity of the convolutions as in the photo. If it is counterclockwise, then the direction of the convexity is changed to the opposite.

Now, using the petal circle, we make indentations along the contour. First from the inside,
then from the outside.

If possible, choose the interval between the "waves".
Smooth out irregularities with a sandpaper.

The do-it-yourself rollerball is ready. You can start rolling the tea.

PS. Subsequently, for convenience, the board had to be made wider and more massive, for which a 36 mm thick grooved floorboard was used. The diameter of the cup has also increased.

After some experiments with this device, I was once again convinced that proper withering is a very important component of the process of rolling a willow-tea leaf. It depends on the correctness of withering whether the leaf will curl or break.

We all constantly hear advertisements for tea with bergamot flavor, not with bergamot, but with taste !!! The taste is achieved with the help of various additives. At the same time, a large number of various herbs grow in Russia, which can, how to tone up, or vice versa, calm the nervous system, help with various diseases, and improve the general well-being of the body.

Here are a few types of plants that are traditionally used as tea additives.

• mint,
• Melissa,
• yarrow,
• raspberries,
• currant,
• chamomile,
• calendula,
• the Rose,

1. Organizational issues

To start an activity, you need to register with the tax inspectorate; to start an activity, the organizational form “Individual entrepreneur” is optimal, as well as to choose the form of taxation, the most suitable form is “Simplified taxation system, income minus expenses”.

1.1. Obtaining permits

To start tea production, you need to obtain the following documents from SanEpidemStanatsiya and RosPotrebNadzor:

1. Technical conditions agreed and registered (TU)
2. Technical instruction (TI)
3. Recipe
4. Veterinary Authority
5. hygienic conclusion of SES for production
6. Others (according to the individual characteristics of the project)

The list of documents is large and the collection of all documents takes considerable time, you can either do everything yourself (for a long time), or contact specialized firms that will do everything themselves and relatively quickly, but for a fee.

2.

Opening of a tea-making workshop

2.1. Equipment

There are many offers on the Internet for the sale of equipment for the production of tea bags, the most popular are automatic equipment Constanta (productivity 130-150 bags per minute) and automatic equipment EC-12 (productivity 120 bags per minute).

This equipment can produce leaf or herbal tea as well as fruit teas.

The cost of equipment differs from the brand of the machine, the year of manufacture and modification. So the prices for new equipment start from 100,000 euros, used equipment can be bought for 35,000 - 40,000 euros.

View other tea filling machines.

2.2. Room selection

Room requirement:

The room in which the organization of production is planned must comply with the requirements of the SES.

The premises should be in several rooms, in one warehouse for raw materials, a warehouse for finished products, a production site, staff rooms.

The premises must have electricity and water supply.

2.3. Staff

To service a small tea production workshop, the following employees should be on staff:

• Director (general management, product sales),
• Technologist (makes a recipe, controls the quality of raw materials, and finished products),
• Workers 3 people (engaged in the production and packaging of products).

2.4. Raw material suppliers

To produce a quality and competitive product, you need to choose good suppliers. There should not be any problems with suppliers, there are many offers on the Internet about the sale of both tea by weight and various medicinal herbs.

You can arrange reception of various field herbs from local people in the countryside by announcing this in advance.

2.5. Sales markets

Finished products can be sold through several distribution channels:

• Federal and regional grocery chains
• Specialty tea shops
• Internet shop
• Pharmacy chains

3. Feasibility study

3.1. Capital expenditures:

• Filling equipment ES-2 (used from 1996) - 1,700,000 rubles
• Obtaining permits - 150,000 rubles
• Repair of the premises (according to SES standards) - 500,000 rubles.
• Advertising campaign: 500,000 rubles.
• Inventory creation, other RUB 500,000
• Total 3 350 000 rubles

The productivity of the automatic equipment EC-12 is 120 bags per minute or 6 packs of 20 filter bags. For a month (22 days) at 8 hours, this equipment can produce 63,360 packs of tea, with a selling price of 30 rubles per pack, monthly earnings (with 100% sales of manufactured products) will amount to 1.9 million rubles.

The cost of tea production includes the cost of raw materials and electricity, the margin depends on the type of product, but on average somewhere around 50%

3.2. Economy

7.3. Payback

The recoupment of the workshop for the production of tea bags is 14 months.

Victor Stepanov, 2012-05-23

Questions and answers on the topic

No questions have been asked about the material yet, you have the opportunity to do it first

Below are the characteristics equipment for drying tea leaves, offered for delivery by our company.

The price is indicated in US dollars, so that you can calculate the price for today as quickly as possible.

Internal rate of companies: Central Bank rate + 1.5%.

You can order tea leaf drying equipment, at a bargain price, in our company.

Tea Leaf Drying Equipment

Specifications

This position is included in the section Equipment for the production of tea Buy a roller for rolling a tea leaf

Tea is a visiting card of Sri Lanka. The island produces 9-11% of the world's tea. More than half a million people work on the plantations. Almost all tea produced on the island is exported. It turns out that getting to the factory to make a report is not so easy. All the factories where I went without an agreement, they kicked me out, and they didn't let me take pictures.

There are several "tourist factories" on the island, where anyone can go, but the show was not interesting to me, I needed a real tea factory. Thanks to the acquaintances of our chef, we managed to find such a factory, and even shoot a little, until the bosses of a familiar manager arrived.

"The tea plantations of Ceylon are as monuments to the courage and bravery of the planters, like the statue of a lion in a field near Waterloo." Arthur Conan Doyle

In the central highlands of Sri Lanka, there are plantations of the famous Ceylon tea. Tea was first brought to the island in 1824 from China, and in 1839 from Assam (India). It turned out that the Chinese variety adapted better to the highlands, while the Indian variety adapted well to the plains of the island. In 1867, Scottish planter James Taylor pioneered the commercial cultivation of tea, planting 80 hectares of seedlings in the Nuwara Eliya area.

Sri Lanka now ranks third in the world in tea production and first in export. For its unique characteristics, Ceylon tea is recognized as the best in the world. Due to the climatic conditions, the local tea has a delicate taste and aroma. Tea is cultivated all year round and is grown at three levels: up to 600 m above sea level in the regions of Balangoda, Ratnapura, Kelaniya and Galle river valleys; from 600 to 1200 m and above 1200 m in areas around Nuwara Eliya.

01. The raw material for making tea is the leaves of the tea bush, which is grown in large quantities on special plantations. For the growth of a tea bush, a warm climate with a sufficient amount of moisture is necessary, which does not stagnate, however, at the roots. In Sri Lanka, the collection is carried out up to four times a year. The teas of the first two harvests are most appreciated.

02. The best quality is considered to be tea from the highland plantations of the southern part of the island (2000 m above sea level and above). Teas from other plantations are of average quality.

03. Tea leaves are collected and sorted by hand: for teas of the highest grade (and value), unblown buds and the youngest leaves are used, only the first-second flush (the first-second group of leaves on the shoot, counting from the end); coarser teas are made from mature leaves. The work of the pickers is quite heavy and monotonous: the ratio of the mass of finished black tea and raw leaf is about ¼, that is, to make a kilogram of tea, it is required to collect four kilograms of a leaf.

04. The production rate for collectors is 30-35 kg of leaves per day, despite the fact that it is necessary to comply with quality standards and take only the necessary leaves from the bushes. The raw material for high-quality teas is often grown on small plantations scattered on mountain slopes, so that the need to move from one plantation to another is added to the collection of the leaf.

05. The need for manual assembly limits the possibilities of tea cultivation. Attempts were repeatedly made to mechanize the collection and sorting of tea leaves, in particular, in the USSR, back in 1958, a mechanized tea harvesting unit was created, but the technology of mechanized assembly has not yet been completed.

06. Depending on the location, new shoots are harvested once a month or every few weeks.

07. Women collect tea.

08. A kilo of green leaves costs 150 rupees. This is about 50 rubles.

09. Anyone can collect tea. But for each kilogram, the collector must give 100 rupees to the owner of the bush and land.

10. After assembling the women, they bring tea to the control point, where the owner checks what has been collected, whether there are any foreign objects in the bags.

11.

13.

14. In total, a tea picker earns up to 500 rubles per day.

15.

16. Sacks of tea are brought here.

17. There are few men at the factory. They do only the most difficult jobs, such as chopping wood for stoves or fixing machines.

18. The temperature in the oven is maintained at 120 degrees, and the leaves are dried with this air. Deviations greater than 5 degrees are not allowed.

19.

20. The factory has an ideal organization, there are markings for employees on the paths, there are signs and diagrams everywhere, people are robots.

21. Stairs markings.

22. The first stage in tea production is drying. Tea leaves are laid out on nets and blown with warm air at a temperature of 32-40 ° C for 4-8 hours. The tea leaf loses some of its moisture and softens.

23.

24. The leaves are turned over by hand.

25. The most expensive tea is white. It is made from tips (unblown tea buds) and young leaves, which have passed the minimum number of processing stages during the production process, usually only withering and drying. Despite the name, white tea has a higher oxidation state (up to 12%) than most green teas. Among the white teas there are pure tips and teas made from a mixture of tips and leaves. When dry, it has a light, yellowish color.

26.

27.

28.

29. Further whose sheet is rolled on special machines, rollers. When curled, part of the juice is released. The blades of the tea leaf rolling machine are made of Kitul wood.

30. Rolling the tea leaves, on the one hand, preserves the best qualities of the tea, significantly increasing the storage time, on the other hand, it allows you to regulate the extraction of essential oils and other active ingredients that the tea "gives up" during the brewing process.

31. Depending on the intensity, time and temperature of curling, a different taste of the tea is obtained. The richest and strongest teas are obtained from strongly twisted leaves, and softer and more fragrant ones from slightly twisted tea leaves.

32.

33. After twisting, Fermentation occurs - the process of oxidation and fermentation of cell juice. Tea leaves are laid out on a flat surface and placed in cool, damp, dark rooms. During fermentation, the tea leaves turn dark brown and give off a characteristic spicy aroma. Ideal conditions for high-quality fermentation are a combination of an air temperature of about 15 C with a humidity of about 90 percent. Fermentation can last from 45 minutes to several hours.

34. Many of the machines are from the British, they are more than 100 years old.

35. Next, the tea is dried at a temperature of 90-95 ° C for black tea and 105 ° C for green tea. This stops oxidation and reduces the moisture content of the tea to 3-5%. 5. Drying the tea leaf at high temperature stops the fermentation process. At the same time, it is very important to catch the stage when the tea leaves begin to give off their aroma, otherwise you can get an over-fermented product, the taste of which will be much worse, and the infusion will be less transparent. This moment is very delicate: if the tea is not dried, it will simply mold and rot. And if you dry it, the leaves will char and the drink from them will acquire a burnt aftertaste.

36.

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41.

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43.

44.

45. Here tea is sorted according to the size of the tea leaves

46.

47.

48.

49.

50.

51.

52.

53. Already prepared tea is passed through this machine. She catches tea leaves of the wrong color and weeds them out.

54.

55.

56.

57. And that machine sorts the tea by size.

58.

59.

60.

61.

62.

63. Ready, sifted tea is packed in paper bags.

64.

65. Labeling - an important point when buying tea - information on the label. It must be marked on it: the place of collection, information about the manufacturer, weight, expiration date, type of tea, variety and international marking of the tea leaf.

66. Women, factory workers, load bags of tea into a truck that will take him to the port.

67.

68.

“The second process in black tea production is rolling the withered leaf. The purpose of the curling is to give the tea leaf the shape characteristic of a high quality finished product; dismemberment of the shoot into its constituent elements; destruction of the integrity of the parenchyma; squeezing out and even distribution of juice over the surface of the leaves; changing the course and direction of biochemical processes occurring in a living tea leaf. When twisting, the necessary conditions are created for the rapid development of oxidative processes. This is achieved by crushing the tissues of the tea leaf in special machines - rollers. " Quote from "Chemistry and Technology of Tea" Tsotsiashvili I.I. and Bokuchava M.A.

In this article, I do not describe the methods that break, cut the tea leaf. That is, as a result of all the procedures described here, FOP (whole) tea is obtained, not BOP (cut) tea. At our factory in Abkhazia, we only make whole leaf tea.

There are many different types of tea leaf curling. When I traveled to the villages of Abkhazia and studied the principles of curling, I saw how tea can be elegantly curled with a simple operation. The tea leaf is placed on the palm and with the edge of the other hand (moving away from you) is folded into a kind of tube. Sometimes (with a rougher approach) a wad of withered tea leaves rubs against a wooden table until the leaves crumple and crumple. Even less often, a sheet is placed on the palm and with the other hand, with the help of a circular motion, a ball-ball is made from it. Once I was lucky to see a specific device consisting of 2 sheets of plywood and round sticks attached to it, cut lengthwise. Such a corrugated leaf on top and bottom, and tea leaves in between. An uncomplicated movement, reminiscent of washing on an old washboard - and the leaves are crumpled and curled.

These methods are very laborious and with their use it is difficult to make more than 10-25 kg of ready-made tea per family per year. The prime cost of such tea is high, and the quality can be very different (the human factor is triggered). Therefore, for the mass production of tea, special machines are used - rollers. There are different types of rollers. In Abkhazia, I have so far met with two principal types: a vertical roller of the Marshal CHRO-2 system and a tape roller. The tape type is quite simple - the two rubber bands on the drums run in opposite directions. Withered tea leaves are poured between them, which curl up into a kind of tubes.

The vertical roller is more difficult. A vertical cylinder (open type), into which tea leaves are poured from above, walks along a special frame in a circle. The frame (made of stainless steel or galvanized) has a complex pattern of bronze arcs. Tea leaves, under the pressure of the entire mass of cylinder leaves, roll from above through arcs and acquire a spiral shape. They move along the conductor of the drawing of arcs to another place of the cylinder. The process stops when all the tea leaves have acquired one or another curled shape. Industrial rollers of this type are available for 200, 500, 1000, and 2000 kg loads. Perhaps there are others. There are advantages and disadvantages to this batch mechanism. Often the leaves are broken and then pounded into a mushy mass by the large weight of the leaves in the top cylinder. And, above all, the tea must be well dried, which is a rarity in large Caucasian factories.

We use a small vertical closed roller with a load of 7 kg of withered tea leaves. It has many advantages and flexibility in approach to raw materials. Above is a small press, the pressure of which can be easily adjusted. It also has 3 rotation speeds and a neat unloading system through a special cuvette. Such a small laboratory roller was made to order. It was with him that my experiments with twisting were connected.

Prerequisites for experiments
1. The tea leaves must be intact (not frayed) and evenly curled.
2. Internal veins and petiole should be crumpled and tannin-containing juice should be extracted from them (otherwise the tea will be bitter).
3. Leaves should be evenly wetted with their own juice.
4. Due to friction and moisture, the roller (tea mass in the cylinder) should not be heated to avoid uncontrolled rapid fermentation.
5. Respect for raw materials.

The essence of experiments
1. Regulation of the pressure of the press and the speed of rotation of the roller.
2. Pauses during roller operation to allow the raw material to cool down.
3. Manual turning of tea leaves inside the roller.
4. Try roasting uncoiled tea leaves in a kettle to set the green tea.

The control
1. Leaves during brewing are complete and even, the teeth are neat.
2. Tea has no bitter taste when brewed.
3. Absence of fines.
4. Nuances of taste and aroma (organoleptic research).

Result
Experimentally, it was found that 45 minute twisting is optimal for a 3-sheet Colchis flush. The first 10 minutes without pressure, then with light pressure for 15 minutes. Then in small cycles of 10 minutes with spontaneous pressure (one of the additional capabilities of our roller), in which the piston pressure does not reverse.

Additional roasting improved the curl shape (harvest) and flavor by 0.25 points. This is not economically feasible and we have refused this additional option.

In a practical study of this process, many nuances were discovered that were not described in this article and that affect the quality of the finished tea. They are the know how of our factory.

Nikolay Monakhov

The purpose of rolling is to squeeze as much tea juice out of the tea leaves as possible. In addition, it was found that when curling, tea polyphenols are mixed with tea enzymes, which is a prerequisite for normal fermentation.

Twisting can be done manually, and such tea is called "ortodox tea". Hand twisting, very time consuming process. Leaves, about a centimeter thick, are taken into the hands, twisted into a tube, and its rolling begins. Rolling is rarely carried out by weight, more often on the walls of vats-baskets, or on special tables or boards that resemble wavy washboards. The curling should continue until the leaves turn from green to dark green, i.e. do not get wet, do not soak in their own juice.

Twisting by machine. Rolling takes place in special machines that twist and squeeze the leaves, from which juice is released, which combines with oxygen in the air. The structure of the tea leaf is destroyed, breaking, and the fermentation process begins. There are traditional (eg Lipton Yellow Label (Orthodox) - loose leaf tea) and unconventional ("unorthodox") breaking methods. The first gives larger tea leaves, the second - smaller ones. To obtain teas "unorthodox", machines are used CTC ("cut, tear and curl" - "cut, tear and twist") or Rotovane. Both crumble the leaves into smaller pieces than the traditional method. This is more in line with the requirements of the modern market, as it speeds up the preparation of the final product. In this way, for example, Lipton Yellow Label CTC - granulated tea is obtained. This tea, with the same excellent aroma, has a more intense color when brewed.

Tea of ​​the CTC class goes through three stages of machine processing during the manufacturing process. The machines quickly press the tea leaves, squeezing out most of their juice; then they strongly grind the leaves and, at the final stage, roll them tightly into beads-granules, strongly resembling instant coffee in appearance. The tea granules are then dried in ovens or dehydrated (dehydrated) in any other way. CTC tea is a fully mechanized process that allows large quantities of tea to be produced very quickly and also allows the processing of raw materials that were previously discarded. In addition, the CTC technology has a certain advantage, allowing the production of the strongest teas with a high caffeine content, even from poor quality leaves. only black teas can be produced using STS technology, usually of medium and low quality.

THE UNION OF SOVIET SOCIALIST REPUBLICS OF BRETENIA WRITTEN Chagunava in the USSR 1969 in the USSR 2, 1978 (Proto STATE COMMITTEE OF THE USSR. with riffles on the inner surface, connected to each other by means of crankshafts and made with the possibility of rotation relative to each other, characterized in that, in order to more completely crush tea cells, improve the quality of twisting and increase productivity, the riffles are made along a helical line, 1 / 3 heights of each riffle from its base has a thickening, the width of which is twice the minimum thickness of the riffle, and the number of cuvette edges is equal to the number of riffles. The invention relates to equipment for the primary processing of tea, in particular to a device for rolling tea leaves, and can be used at tea factories of primary processing. there is a device for twisting, in which, to intensify the twisting process, the loading container is made in the form of a truncated cone, surrounded by a large base to the table 1. However, making the loading container in the form of a truncated cone reduces the volume of loading, therefore, the productivity of the device decreases. taper leads to abrasion of the sheet. 15 The closest to the invention in technical essence and the achieved result is a device for rolling a tea leaf, containing a table with a multifaceted cuvette and a loading container installed above it with grooves on the inner surface 20, connected to each other by means of crankshafts and made with the possibility of rotation relative to each other 2. However, the known device does not provide sufficient complete crushing of the tea cells, which leads to a deterioration in the quality of the tea rolling. The productivity of the device is not high. The aim of the invention is a more complete crushing of tea cells, improving the ZO quality of twisting and increasing productivity. The goal is achieved by the fact that in a device for rolling a sheet containing a table with a multifaceted cuvette and a loading Z 5 container with riffles on the inner surface, connected with each other by means of crankshafts and made with the possibility of rotation relative to each other, the riffles are made along a helical line, 1 (3 heights of each riffle from its base has a thickening, the width of which is twice the minimum thickness of the riffle, and the number of cuvette faces is equal to the number of grooves. FIG. 1 schematically shows the device. 45 tea leaf rolling device, front view; in Fig, 2 - the same, top view; in fig. 3 - section A - A in Fig. 1. The device contains a horseshoe-shaped frame 1 with three legs 2, a table 3 with a cuvette 4 and a loading container 5 installed above it with grooves 6 on its inner surface. The table 3 with the cuvette 4 and the loading container 5 are interconnected by means of crankshafts 7 and are made with the possibility of rotation one relative to the other using an electric drive (not shown), while the cuvette 4 is made hexagonal, and its surface has ribs (not shown) for increasing the crushing ability of leaf cells For intensive uniform twisting, mixing and circulation of the tea leaf, the riffles 6 of the containers 5 are made along a helical line, while 1/3 of the height H of each riffle 6 from its base has a thickening 8, the width of which is twice the minimum thickness Rifle 6., The device works in the following way. The declared tea leaf is loaded into container 5. Table 3 and container 5 are brought into rotation in opposite directions. The tea mass in the container 5 is subjected to additional pressure during rolling with the help of the riffle 6, thereby improving the mixing of the tea inside the container 5, as well as circulation, and eliminating overheating of the tea mass in local zones. Getting into the cuvette 4 cells of the tea leaf are crushed (destroyed), while the entire tea mass is rolled into a tubular form and the intensity of enzymatic oxidative processes increases. The proposed device for rolling the tea leaf allows, in comparison with the known ones, to increase the throughput of the roller at one time by 1, 6 / o, reduce the twisting time by 10 minutes, double the average daily processing of tea from one roller, double the productivity, increase the twisting intensity with 100th destruction of leaf cells and its uniform tubular shape and improved aeration. also intensify enzymatic final processes with mass circulation and increase the yield of the final product with an increased quality, 1103841 Fig gel T. Sokolov Veres Nikolaychuk EditedOrder 50 VNIIPpo 13035, M lial PPP Compile Techred I Circulation 58 States We are invented, F - 35 Patent, g .Corrector G. Reshetnik of the Signed SS Committee Wed and discoveries Raushskaya nab., 4/5 Uzhgorod, st. Project, 4

Application

2532019, 03.10.1977

TSINTSADZE GEORGY ILYICH, CHAGUNAVA SHOTA ELIZBAROVICH, PTOYAN GASPAR MIRONOVICH

IPC / Tags

Reference code

Tea leaf rolling device

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