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Instant tea extract production process
Instant tea extract production compliance managed by the farmsoft app delivers consistent quality tea extracts and easy business management

Instant tea & tea extract production compliance


Instant tea extract production process
Instant tea extract production process

INSTANT TEA AND
TEA EXTRACT
PRODUCTION

Centrifuges for the Production of Tea Extract and Instant Tea

Instant tea is a soluble tea that is used in various beverages. As a rule, it is tea extract in powder or granulate form - for example lemon tea from a shop or supermarket.

Flottweg separators and decanters are used in three applications in the tea area:

  • Producing tea extract
  • Manufacturing instant tea
  • Refining tea

Producing Tea Extract

In order to produce tea extract, it is necessary to extract the aqueous tea solution and concentrate the tea leaves. The decanter ensures optimum dewatering of the tea leaves and removes all residues, leaving none behind.
Your advantages in producing tea extract

  • Very gentle treatment of the tea
  • Maximum yield of tea extract

Manufacturing Instant Tea

The separator is used after tea extract has been obtained using a decanter. In order to manufacture instant tea, the separator separates off the fine and ultrafine solids. This produces a high-quality instant tea that meets all quality requirements.

Your Advantages In Manufacturing Instant Tea
  • Very gentle treatment of the tea
  • Maximum quality of the instant tea
Refining Tea

When consumers pour hot water on their tea, they do not want to find any residues or turbidity. The tea should be clear and develop the required flavour. Refining with the separator represents the best solution for optimum tea clarification.

Your Advantages In Refining Tea
  • Very gentle treatment of the product
  • Maximum clarification of the tea
Your Partner For Producing Instant Tea And Tea Extract

We know about the quality requirements when manufacturing tea extract and instant tea. As a result, we strive to meet the specific requirements of the tea industry with our decanters and separators as effectively as possible. See for yourself the personal support that can be provided by our in-house project planning team.

Flottweg is certified to ISO 9001 and builds its decanters according to the latest technical standards - Made in Germany. Flottweg decanters and separators have been used successfully in the tea industry for many years. We offer you sound technical knowledge, personal support and well known references.

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A novel technology for production of instant tea powder from the existing black tea manufacturing process

Soluble tea
Instant tea
Fermented tea
Vacuum drying
Pressed cake tea


Instant tea power and tea production process

Instant tea powder is the fully soluble solid of tea that has emerged as a new and fast growing product in every country. The various processes involved in the commercial production of instant tea include blending of tea leaves, hot water extraction, aroma recovery, soluble solids concentration, aroma restoration and dehydration. An envisaged process has been developed for the production of instant/soluble tea from the expressed juice of fermented tea leaves. Green tea leaves are subjected to withering, maceration, and fermentation process, which are similar to that of existing black tea production process. The fermented leaf is pressed to expel a part of juice containing soluble solids. The juice is then heated, centrifuged and vacuum dried to get soluble/instant tea powder. The pressed leaf residue is subjected to vacuum/hot air drying to obtain low grade conventional tea granules. About 20 ± 2 g of soluble tea and 220 ± 20 g of pressed cake tea are obtained from 1 kg of green tea leaves. The TF:TR ratio for soluble tea is 0.084 and that for pressed cake tea is 0.140.

Industrial relevance

The technology can be easily adopted by existing black tea manufacturers for simultaneous production of instant tea and black tea. The process is economical as both extracted juice and pressed cake are converted into value added products.

Highlights

► Production of instant tea from the expressed juice of fermented tea leaves. ► TF:TR ratios for soluble tea and pressed cake tea are 0.084 and 0.140. ► About 20 ± 2 g of instant tea is obtained from 1 kg of tea leaves. ► About 220 ± 20 g of pressed cake tea is obtained from 1 kg of tea leaves.

Scientists perfect instant tea processing

Tea, Green tea, Sri Lanka

Instant tea & tea extract production process
Instant tea & tea extract production process

Scientists have developed a new technology to process instant tea. The invention is said to cut processing time by 15 hours, making it considerably less labour intensive and reducing costs. Developed by the Indian Institute of Technology, Kharagpur, West Bengal, the technology uses green tea leaves and buds, instead of the usual process of using manufactured black tea.

The process is also said to produce a more distinct aroma as well a full flavour. The method involves extracting the liquor from the processed leaves, tea wastes, or undried fermented leaves, concentrating the extract under low pressure, and drying the concentrate to a powder by freeze-drying, spray-drying, or vacuum-drying it. The steps involve obtaining freshly plucked green tea, crushing the leaves, extracting the juice and subjecting it to oxidation for an hour in a controlled chamber at a temperature of 30-35°C. After the oxidization process new compounds are formed, and the green juice turns coppery brown. The fermented or oxidized juice is then steamed and centrifuged to arrest fermentation and to remove the colloidal and suspended materials. The next step is to dry it to obtain instant tea. The residue of the leaves can then be subjected to fermentation and drying for manufacturing black tea, minimising on waste and contributing to further cost savings.

Instant tea & tea extract production process
Instant tea & tea extract production process

Prof. H. N. Mishra, who headed the development of the technology, said, "Fresh tea leaves contain about 75 per cent moisture. This extra moisture means that the leaves are easier to process, which in turn helps to speed up the time and adds to the quality of the tea".​ The scientists estimate that the cost of the technology is just about Rs. 1,00,000/- (€20,000). The institution had already received a patent for the process and is about to implement the technology at two Banglore based tea companies. World tea production has been dominated by Asian countries with China, India, Sri Lanka, Indonesia and Bangladesh. China was the largest producer where output was about 861,000 million tonnes in 2004 followed by India and Sri Lanka with 850,500 and 303,000 million tonnes respectively.


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