CTC (cut-tear-curl) teas-what they are and how they are made

The Tea Detective
Uncovering and Exploring the Facts About Tea

CTC Teas-From Field to Cup
How They Are Made

There are basically two manufacturing methods for black tea, CTC or cut-tear-curl, and traditional
orthodox leaf manufacture. Most likely you have been drinking CTC teas for years without
even knowing it as they are primarily used to fill tea bags.

to orthodox tea manufacture. This is a smart move as today's tea drinkers are becoming more
knowledgeable and savvy about tea, driving the demand for more specialty orthodox teas.

The production method for CTC black tea differs somewhat from
traditional orthodox black tea manufacture. After withering, the
fresh leaf needs to be chopped into smaller pieces.

The blades used to chop the tea are extremely sharp and fast
moving so it's important that any extraneous materials, such as
sticks or small rocks be removed before the leaf goes into the
machine.

This initial step is called preconditioning and is a combination of sifting and shredding. A machine
called a green leaf sifter with a perforated, vibrating tray, feeds a continuous flow of withered
leaf through while separating out any sticks, stones, or sand.

The sifted leaf then goes into the green leaf shredder, a cylinder to which very sharp, light, and
well balanced knives are attached. Rotating at 2,500 rpm's the knives shred the leaf as it goes
through.

To ensure uniform particle size the cylinder decreases in diameter along the length of the shaft
so all pieces are the same size when they emerge. This step completes the preconditioning.
Next comes a series of two rotorvanes for final conditioning.

The rotorvane was developed in 1957 by Ian McTear of the Experimental Tea Research Station
at Tocklain in Assam, India. The rotorvane is basically a combination tumbler-barrel-drum rang-
ing in diameter from 8 to 18 inches. A central shaft acts as an auger pulling the leaf through as
it crushes, tears, and mixes the leaf. This process generates heat that continues the enzyme
activity inside the leaf, spreading the juices to the surface, which begins the oxidation process.

For final conditioning the leaf is passed through the first rotorvane with an open end and only 8
inch diameter, crushing and compacting the leaf. The diameter of the second rotorvane drum is
15 inches with a sieve plate or screen on the end, further squeezing and mincing the leaf into
what is called chutney.

With final conditioning finished, the CTC leaf is on to rolling, where the chutney will be passed
through a series of four to five CTC rollers. The mechanical rolling machine was invented by a
man named A. Holle, and was first introduced, again in Assam, India, in 1872, at Jorhat. Today,
the mechanical rolling machines are still in use worldwide.

The rolling machine used for CTC production has two identical stainless steel rollers with sharp
cutting teeth mounted parallel to one another and attached horizontally. The rollers rotate at
different speeds, one fast, one slow, and in opposite directions from one another.

The chutney is fed from the rear, drawn between the rollers and chopped and cut into uniformly
sized particles. Because the particles are so small there is no clumping, so the step of roll-break-
ing, needed for orthodox teas, isn't needed for CTC.

Depending on the climate and location it is at this stage where the tea is spread out in thin lay-
ers in cool, humid air and left to oxidize for 20 to 30 minutes or more. It's at this point that the
tea begins to develop the recognizable aroma and flavor of black tea, darkening in color and de-
veloping the tea chemicals, theaflavins and thearubigins.

The next step is to stop oxidation of the leaf with firing. There are several different methods
used for firing CTC teas. The first method, drum oxidation is commonly used in southern India.
The chutney is placed inside the drum (think clothes dryer) for 60 to 90 minutes. The continuous
revolving motion of the drum guarantees that every bit of the internal juices are evenly spread
over every bit of leaf.

Drum oxidation also increases leaf density and creates a darker leaf, and even granulation of
the pieces.

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With the next method, continuous oxidation machines, the chutney is fed into the automatic dryer and carried on a
conveyor belt where it passes beneath ultraviolet lamps, which activate the polyphenol oxidase and stimulates
oxidation. The ultraviolet light also kills bacteria and microbial contaminants. This method is used in areas with high
humidity and for fast, high volume production of average grade CTC tea leaf.

The most efficient firing method, though, is with the Fluid Bed Dryer, which blows the tea parti-
cles on a stream of hot air (240-250F), reducing the moisture content to just 2-3%. This
method ensures that all the pieces of leaf, no matter the size, are evenly dried.

After finishing the oxidation stage the leaf is cooled, sorted one last time, graded, and then
packaged for storage or sale.

Now that you know the steps involved in making the black tea in your favorite bagged tea
brand, it helps you to appreciate even more the handy, tasty little tea bag you slip into your
mug, when sitting down for a quick cup of tea. Enjoy.

The CTC processing method began in the 1950's
because of the increasing popularity of tea bags.
Designed to produce a less bulky tea that would
brew more quickly and with an even, robust flavor,
CTC teas are directly opposite of traditional ortho-
dox teas, that concentrate on drawing out unique
flavor and style from the leaf.

CTC teas are less costly to produce, yet many of
the growers producing them are actually losing
money. That's because 95% of tea produced to-
day is CTC and there is a glut of tea in the market,
driving down prices for everyone.

The prices have fallen so low, in fact, that many
producers can no longer afford to stay in business
any longer and are either closing or switching over

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