In today’s competitive environment Tea Manufacturers are in the lookout and keen
to implement methods/improvements to produce better quality of product with
higher shelf life. Methods of improvisation in tea processing includes reduction
in processing durations and enhance production, improvement in microbiological
quality of product and lesser micro-contaminations in the environment to produce
better quality of the product. Major tea processing steps consist of collection
of tea leaves from the garden, withering them over a period of time, cutting
them into suitable size, fermentation (spreading it on the floor or conveyer for
a suitable duration so that the green color converts into brown), Drying, Size
Gradation, Sorting and Packing.
Problem associated with tea processing
Certain amounts of micro-organisms are always associated with any food product
and the same holds good for tea also. The Micro-Organisms grow at faster rate
and deteriorates the product quality, with respect to preserving freshness and
shelf life. The problem lies in the area of CTC machine, where small particles
of Tea Leaves entangle into machine component and spread around. These particles
in the due course are a source of Micro-Biological contamination.
Tea fermentation is primarily an Oxidation Process and to promote the process
during fermentation, lot of air is available around the product. Fresh air is
again a source of contamination and increase the microbial load on the product.
Concentration of ozone inside processing unit.
• An Air blower is normally installed closer to the CTC machine, blowing air
near the rotary portions and closer to the entangled particles of Tea into the
machine. To control the Microbial contaminations, process of blowing steam and
disinfectant chemicals are utilized. Both these options are a recurring
expenditure and reduce product quality.
• During fermentation, to promote the process, lot of fresh air is blown, which
although enhances the fermentation process, however increases the microbial load
onto the product.
How ozone will help in the above problems
Ozone being tri-atomic oxygen is a very strong oxidizer, efficient
Broad-Spectrum Microbiological Control Substance, having powerful Oxidizing and
Disinfecting Property. It destroys any bacteria, viruses, cysts and pathogens in
the air or any food product in a very short duration. Ozone is very effective in
the moist environment, thus Tea processing is an effective area for Ozone
Growth of spoilage Micro-organism can be retarded to a great extent in the
presence of Ozone. If a controlled environment of ozone is maintained in the
fermentation area or CTC machine, the fermentation process will accelerate and
the bacterial growth in the area can be retarded to a great extent.
As a result the Fermentation duration can be reduced. In actual practice, our
clients have reported a reduction of 33% duration. In addition, Microbial load
is also substantially lower, making a superior product with an enhanced aroma,
appearance and infusion.
Ozone System suitable for Tea Processing
• Ozone Environmental Sterilization Closer to CTC machine
An Online Ozonation System can be installed at the inlet of the blower from
which the air will be passing, and the oxygen of the air will be converted into
Ozone. Ozone mixed air will be blown close to the CTC Machine. Ozone will
disinfect the environment and subsequently the component of the machine.
As a result of the sterile environment, microbiological load on the air and the
machine component will get drastically reduced ultimately providing improved
hygienic environment for the processing of the tea. Use of ozone is approved by
FDA, USA and agencies of other countries.
• Improvement of oxidizing and sterilized Environment at tea Fermentation floor
For improving the oxidized and disinfecting environment controlled amount of
ozone is spread into the area. This is done through the spraying of special
Ozone showers, suspended in the effective area. By virtue of controlled ozone
environment enhanced oxidation reduces the fermentation duration. In addition
microbiological load is also reduced providing a improved quality product in
shorter duration. The productivity can be increased by 30% to 40% by reduction
of fermentation duration.
Concentration of Ozone, required to be maintained in the area
A very small Ozone concentration of .05 to .08PPM is adequate for sterilization
of the affected area.
Maintenance and Control of Ozone concentration in cold
Concentration of ozone in the air is monitored by Ozone Monitor. For Automatic
regulation feed back loop can be used. The Monitoring System is equipped with
high and low level outputs, which are used for providing warnings or control
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