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Automating CTC Tea Processing for Greater Efficiency and Consistent Quality

Home - Automating CTC Tea Processing for Greater Efficiency and Consistent Quality
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Client Location:

Assam & Bangladesh

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Industry:

Tea Manufacturing

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Project:

CTC Tea Online Processing Machinery

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Project Type:

New Greenfield Project

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Solutions Deployed:

WIZARD CCW & CPW, Rotorvane, KAIZEN Nova/Super, MATRIX CFM
& VIBRANT Dryer

Key Outcomes:
  • Reduced dependence on manual operations across the CTC tea processing line
  • Reduced electricity consumption and processing time through integrated online processing
  • Improved the quality and consistency of the finished black tea through controlled, integrated processing
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The Challenge

Tea processing at scale requires precise control across multiple stages, from green leaf handling and withering to CTC manufacture, fermentation, drying, sorting, and packing. As production volumes increase, maintaining consistent processing conditions while controlling manpower, energy consumption, and processing time becomes increasingly important.

Before the implementation of the automated processing solution, the customer’s operations involved higher manpower requirements, higher electricity consumption, longer processing times, and fully manual processing.

These operational challenges created a need for a more efficient and integrated approach to CTC tea production, one that could support high-volume processing while improving process consistency and reducing dependence on manual operations.

The Solution

To address these challenges, T&I Global Limited supplied a complete CTC Tea Online Processing Machinery solution as part of a new greenfield project.

Designed for an input capacity of 1,800 kg/hr of green leaf and an output of approximately 400 kg/hr of made tea, the integrated line brings together automated equipment across the major stages of CTC tea processing.

The system was designed to provide continuous material movement through the processing line, reduce manual intervention, and improve overall process efficiency.

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Automated Withering

The processing line incorporates the WIZARD Continuous Physical and Chemical Withering System (CCW and CPW) to provide controlled withering of the green leaf before CTC processing. Integrating continuous withering equipment helps establish consistent processing conditions and prepares the leaf for subsequent production stages.

Controlled Leaf Conditioning

Following withering, the leaf passes through the TIVANE Rotorvane for controlled conditioning before entering the CTC processing stage. This prepares the withered leaf
for efficient CTC manufacture and supports consistent downstream processing.

Precision CTC Processing

The KAIZEN NOVA/SUPER CTC Machine forms the core of the CTC manufacturing stage. The system processes the tea through the crushing, tearing, and curling stages required to produce CTC tea. Its integration into the online processing line enables continuous material flow and reduces the need for manual handling between processing stages.

Granulation and Continuous Fermentation

Following CTC manufacture, the GOOGHIE Granulator and MATRIX Continuous Fermentation Machinery (CFM) support the subsequent processing stages. The MATRIX CFM enables continuous fermentation as part of the integrated production process, helping maintain consistency as the processed tea moves towards drying.

Controlled Drying

The processed tea then enters the VIBRANT Dryer 285 for controlled drying. Drying is a critical stage in tea manufacturing, as the moisture level of the finished tea directly affects its stability and quality. The system is designed to achieve the required final moisture level, with the project specifying an output moisture range of 2.5%–3.2%.

Sorting, Screening and Packing

After drying, the made tea proceeds through the SUPREX Sorter and SUPREX Fibre Extractor, followed by the Vibro Screen Sorter for further separation and grading. The processed tea is then transferred to the Packing Machine, completing the integrated production line.

The complete conveyor system connects the individual processing stages, enabling
continuous material movement throughout the operation.

The Results

The implementation of TIGL’s integrated CTC tea processing solution resulted in improvements across automation, manpower requirements, energy consumption, processing time, and tea quality.

Reduced Manual Intervention

The fully automated processing system significantly reduced dependence on manual operations across the production line, addressing the customer’s previous requirement for higher manpower.

Lower Electricity Consumption

The integrated processing solution reduced electricity consumption compared with the customer’s previous operating approach, contributing to improved operational efficiency.

Improved Processing Efficiency

Automation and continuous material movement helped reduce processing time and improve the overall efficiency of tea production.

Improved Tea Quality

The project has contributed to improved tea quality, with the integrated processing system supporting more consistent processing from green leaf handling through CTC manufacture, fermentation, drying, sorting, and packing.

The system processes approximately 1,800 kg/hr of green leaf to produce around 400 kg/hr of made tea, with a specified final moisture range of 2.5%–3.2%.

The Business Impact

The implementation of a fully integrated CTC tea processing line enabled the customer to move towards a more automated and efficient production model.

By connecting withering, leaf conditioning, CTC manufacture, granulation, fermentation, drying, sorting, screening, and packing into a coordinated processing system, the project reduced reliance on manual operations while supporting high-volume tea production.

With an input capacity of 1,800 kg/hr of green leaf and approximately 400 kg/hr of made tea output, the system provides the production infrastructure required for continuous CTC tea manufacturing.

Backed by T&I Global’s in-house manufacturing expertise and DSIR-certified R&D facility, the project demonstrates how integrated tea processing automation can help manufacturers improve operational efficiency, reduce manual intervention, manage processing time and electricity consumption, and achieve more consistent tea quality

Contact Details

Corporate Office