The processing of tea is carried out as soon as possible after the harvest and nearly always on the
estate in an elongated four story building called a factory. This process is comprised of five steps:
Withering, Rolling, Fermentation, Firing and Sifting.
Withering reduces the dark, glossy leaves to a soft, limp condition with forty percent
less weight due to moisture loss. The leaves are brought fresh from the estate fields
and spread over shelves of nylon netting called "tats". These are stretched over a
trough with warm air being forced through from below for a period of six to eight
hours. When a leaf can be folded in half, from point to stem without snapping the
mid-rib, it is ready to be sent on for rolling.
Rolling is the step of applying pressure to the withered leaves in order to release the
essential oils and enzymes responsible for giving tea its characteristic flavor. Rolling
also gives the leaf the twist or curled shape that you can see in some packets of tea.
This is done in a tea roller which is a round table equipped with battens (curved
wood slats) radiating from its center where an inverted cone is situated. A metal
housing, called the jacket, rotates over the table crushing the leaves against the battens and the
cone. The leaves emerge in sticky lumps which then have to be broken apart by a separate machine
called the roll-breaker which sieves the leaves through a mesh to separate them before they are
carried away for the next step.
Fermentation is the single most crucial step in the processing of tea, imparting the distinctive flavor
characteristics that will define a particular tea. The rolled tea leaves are spread evenly and thinly
on a concrete floor in a cool, airy, and humid room. The tea then is allowed to naturally ferment
by oxidizing. Through enzymic action, the juices have been squeezed from the leaves. It is during
this step that the leaves change from a greenish color to a bright, coppery shade. Careful monitoring
is required and the time needed will depend on the condition and type of leaf, but it will usually
take 1.5 to 2 hours to achieve the desired level of fermentation.
Firing stops the fermentation process and dries the leaves to about two percent moisture. This is
done by placing the leaves on trays that circulate through a dryer while the temperature is gradually
increased to about 190 degrees fahrenheit. Very careful monitoring is once again needed throughout
this 30 minute step to ensure that the tea is neither under-fired nor over-fired and burnt. The proper
result will ensure that new black looking leaves will keep their flavor locked-in as it is finally
brewed for drinking.
Sifting, or Grading, is the final step before the tea is packeted for marketing.
This first involves the removal of the mid-ribs and veins from the leaves and the subsequent
sorting of the leaves into a number of different grades according to the size of each leaf.
The basic grades are "leaf", "broken" and "dust". The tea is then packed and shipped off the estate to auction.