CTC Machine

 

 
 

 

CTC Machine

Mechanism and Objectives

  • The Fermentation process, is a chemical re-action involving oxidation of the oxidisable soluble matters in the macerated tea particles with the oxygen, artificially brought into the action, in presence of the existent moisture and PPO enzymes, a natural ferment within the particles. The “tea-polyphenol oxidase (PPO)”, are natural ferments and plays the role of catalytic agent in fermentation process.
  • The Oxidisable matters are largely responsible for the color and strength of the tea liquors with possibly a substantial contribution to it’s pungency and some other qualities also. Un-invited gate crashers like raw moisture or water born bacteria would only jeopardize the quality of the fermentation.
  • In Black CTC tea manufacture, the oxidation rate and simultaneously the leaf temperature starts increasing from the 1st. Maceration unit, i.e. Rotorvane, would reach it’s peak rate & temperature possibly by about 25-35% into the fermenting process and the next stage of Condensation would be finally completed leading to the desired level of chemical changes at gradually reducing rate from peak at the end of planned residence period of the fermenting process. Rates of both the Oxidation and Condensation periods need to be controlled.
  • Physically, the particle’s color would slowly first become yellow, then change to reddish yellow and finally to dark brown or coppery. The smell of processed leaf also would start changing from grassy to a sweet odor to the nose.
  • The enzyme’s activity is dependent on the leaf temperature. It becomes most active between 80–90 °F but, acts very slowly below 60 °F. Hence warmth is needed for fermentation activity during cooler days or in cooler climatic areas. It starts getting destroyed at accelerated rate as temperature increases and hardly survives at temperatures beyond 120 °F.
  • Ambient air would need conditioning to attain and proper humidification systems with auto control system should be provided for the air to maintain the desired dry bulb temperature and RH%.
  • The temperature profile of the leaf during the fermentation period is a good indicator for accessing the attainment of the levels of chemical changes and the provided electronically controlled fermentation system, this profile graph is used as a control logic.

From the above the following design objectives for construction of the CFU had been considered

  1. Use of Food grade Hygienic moving leaf carrying surface
  2. Incorporate facility for varying the speed of the leaf carrying surface as infinitely as possible
  3. Ensure that the leaf from the up-stream equipment is spread full width of the leaf carrying surface at desired thickness uniformly
  4. Ensure uniform oxidation facility to almost all the leaf particles on the surface through out the layers.
  5. Incorporate facility through a suitable air humidification system to auto control of the condition of the applied air to the leaf w.r.t. it’s dry bulb temperature and RH% to control the leaf temperature profile throughout the bed length as desired
 
 
 
 
 
 
 
 
Salient Features & Advantages
 
 

Magic Mesh:
The heart of TIG’s Matrix PVB CFM is the specially imported Magic Mesh with 46% open area. This Magic Mesh provides several advantages: Open area nearly 80% more than SS trays/belts, which ensures even fermentation across the tea bed, improved cup characteristics and infusions. Availability of the Magic Mesh in up to 10ft,width,which is space saving and enables wider machines and shorter lengths. Specially designed idlers and SS skid plates are provided to support the Magic Mesh conveyor.

Modular Air Control Arrangement:
Each module is fitted with an Individual Damper to draw only the required quantum of humidified air. The common duct runs parellel to the machine and specially designed air chambers with perforated pressure plates are used to feed humidified air to each module. This design eliminates accumulation of tea in ducts.

Construction:
The machine is designed for maintaining the highest standards of hygiene and uses stainless steel Aerodynamic Hoppers. All parts of the machine coming in contact with tea are also made of stainless steel. The heavy duty rectangular tube section framework adds to the strength of the machine. The matrix is low in height making it convenient to monitor and easy to clean.

Stainless Steel Air Ducts:
Circular SS Tapered Air supply Ducts are provided to maintain uniform air pressure throughout the length of the machine. The circular design improves hygiene and air flow into the machine.

Compact Shaft-Mounted Drive:
This advanced mechanism has following benefits :
1. Eliminates the needs for a drive pedestal.
2. No obstruction in floor space.
3. Low power consumption.
4. Longer,trouble-free life.
5. No V-Belts used.

Centralised Operating Control Console:
This console has an in-built AC Variable Speed Drive, Temperature Inductors, busbar arrangement with MCBs, Ammeter, Voltmeters and push button motor on/off switches. These are all enclosed in dust proof, powder coated, two-door panel.

Humidfication:
For continuous supply of fresh humid air into each module, a Centrifugal Blower is connected to the Mist Chamber or Y-Duct to suit the site conditions. Two humidifiers are provided with the humidification system.

Feed Conveyor:
A full width(10’/8’/6’/4′) PVC Feed Conveyor with Spiral Spreader ensures regulated feed and even spreading of ‘dhool’ on the machine. An extended belt can be provided to reduce feed height and enable direct feed from the CTC or Googhie.

Nylon Cleaning Brush:
Unique simple detachable design which allows changing and cleaning brush even when machine is in use.

OPTIONAL ACCESSORIES:

Oscillating Conveyor:
This is a new feeding device.This helps to spread the tea uniformly at the feed end of the CFM and eliminates use of the full width feed conveyor and spreader. This is also more suitable and convenient for online processing.

Effective Upturner:
To ensure even fermentation through the cross section of the bed, a slow speed, specially designed ensures that grades are not disturbed in the process.

Discharge Conveyors:
These can be the standard type or twin type, which are used to discharge teas at either end of the machine or in the centre, to suit factory layout.

Bail Breakers:
Stainless steel full width ball breakers can be provided with independent drive arrangement and easy cleaning system.


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