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Streamlining CTC Tea Production with an Integrated Processing Line

Home - Streamlining CTC Tea Production with an Integrated Processing Line
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Client Location:

Assam, India

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Industry:

Tea Manufacturing

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Project:

CTC Tea Processing Machinery

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Project Type:

New Greenfield Project

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Solutions Deployed:

GL Shifter, Smart Feed, Rotorvane, KAIZEN Nova/Super, MATRIX CFM, VIBRANT Dryer, & SHOLA Heater

Key Outcomes:
  • Integrated online processing reduced manual intervention while supporting smoother material movement and shorter processing cycles.
  • Optimised energy use and controlled processing stages supported improved production efficiency and more consistent finished tea quality
  • Enabled smoother material movement from green leaf handling through drying
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The Challenge

Processing large volumes of green leaves into quality made tea requires a well-coordinated production system. As tea manufacturing operations expand, individual processing stages must work together to maintain a steady flow of material and avoid unnecessary interruptions between operations.

For Tea Q Tea’s new greenfield project in Assam, the requirement was to establish an integrated CTC tea processing line capable of handling a substantial quantity of green leaves and converting them into made tea efficiently. The system needed to bring together green leaf handling, feeding, leaf conditioning, CTC manufacture, continuous fermentation and drying within one connected process.

The focus was therefore on developing a processing arrangement that could support high-volume production while maintaining continuity across the major stages of tea manufacture.

The Solution

T&I Global supplied an integrated CTC tea processing line designed to connect the key stages of production, from green leaf handling to final drying and heating.

Green Leaf Handling and Feeding

The process begins with the Green Leaf Shifter, which supports the initial movement and handling of incoming green leaves. The Smart Feed then facilitates a more organised and continuous feed of material into the subsequent processing stages.

Together, these systems help establish a steady starting point for the tea processing line.

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Green Leaf Handling and Feeding

The process begins with the Green Leaf Shifter, which supports the initial movement and handling of incoming green leaves. The Smart Feed then facilitates a more organised and continuous feed of material into the subsequent processing stages.

Together, these systems help establish a steady starting point for the tea processing line.

Leaf Conditioning

The green leaves are passed through the TIVANE Rotorvane, which prepares and conditions the leaf material before CTC processing. This stage forms an important link between leaf handling and mechanical tea manufacture.

CTC Processing

The conditioned leaf is then processed through the CTC machine, where the tea is manufactured into the required CTC form. This stage is central to producing the desired particle structure and preparing the material for fermentation.

Continuous Fermentation

Following CTC processing, the material moves into the Continuous Fermentation System (CFM). The continuous arrangement supports the onward movement of processed tea through the fermentation stage as part of the integrated production line.

Drying and Heating

The fermented tea is transferred to the VIBRANT Dryer for moisture reduction and drying. The Shola Heater forms part of the heating arrangement supporting the drying process.

This connected drying and heating setup helps bring the processed tea toward its final made-tea form.

The Results

High-Volume Processing Capability

The integrated line was designed to handle 26 lakh kg of green leaves and produce approximately 6 lakh kg of made tea, supporting the production requirements of a large-scale tea manufacturing operation.
 

Streamlined Operations

The integrated online processing system reduced manual intervention across the production line while supporting smoother material movement and shorter processing cycles. By connecting key stages from feeding to drying, the system helped create a more coordinated and efficient workflow.
 

Improved Production Efficiency and Tea Quality

Optimised energy use, combined with controlled processing stages, supported improved production efficiency. The coordinated handling of conditioning, CTC processing, fermentation, and drying also contributed to greater consistency in the finished tea.

The Business Impact

For Tea Q Tea, the project established an integrated CTC tea processing setup capable of supporting high-volume production in a new greenfield facility. By connecting the principal stages of tea manufacture, the solution provided a structured processing flow from green leaf intake to made tea.

The line’s capacity to process 26 lakh kg of green leaves into 6 lakh kg of made tea demonstrates its suitability for large-scale tea manufacturing. More importantly, the integration of feeding, conditioning, CTC processing, continuous fermentation, and drying created a coordinated production system that can support operational continuity and consistent process management.

The project highlights how integrated tea-processing automation can streamline operations, minimise manual intervention, improve control over processing time and energy consumption, and support consistent tea quality.

Contact Details

Corporate Office