“Chai banayi kya?” (Did you make the tea?) is a question that echoes in homes across India, often followed by the aroma of freshly brewed tea filling the air. But have you ever wondered how that perfect cup of chai gets from the plant to your glass? The journey is nothing short of magical.
Imagine a lush, green tea garden high in the hills, where the first tender leaves are plucked with precision. These leaves, rich in flavour and promise, begin their transformation through a delicate process of withering, drying, and sometimes fermenting. It’s a process that requires patience, skill, and years of tradition, passed down from one generation to the next. From the fields to the factory, and finally into your cup, each step in the making of tea plays a vital role in creating the perfect brew.
In this blog, let’s take a journey together, exploring how your everyday chai goes from the tea plant to the steaming cup that makes everything feel just right.
From Seed to Leaf
Every cup of tea begins its journey with a remarkable plant—Camellia sinensis. Found in lush tea gardens across India, from the misty hills of Darjeeling to the sprawling plains of Assam and the serene Nilgiris, this plant thrives in specific conditions. It requires the perfect balance of altitude, temperature, and rainfall to grow, making tea cultivation as much an art as it is a science.
The process starts with planting either seeds or saplings in carefully prepared soil. Tea plants take about 4 to 5 years to mature, demanding constant care and attention during this time. Farmers work tirelessly, pruning the bushes to waist height to encourage the growth of new, tender shoots. These fresh shoots, called "flushes," are where the magic of tea truly begins. The leaves and buds are hand-plucked with incredible precision, as only the youngest and most delicate parts of the plant produce high-quality tea.
Timing plays a crucial role in this stage. Early morning harvests are often preferred, as the leaves are at their freshest, brimming with natural oils and flavour. The geography and climate of the region also lend unique characteristics to the tea—Assam’s bold and malty notes, Darjeeling’s floral and musky undertones, and Nilgiri’s brisk and aromatic flavour.
From Leaf to Tea Powder and Tea Bags
Once the fresh tea leaves are plucked, their journey takes a transformative turn through traditional and modern processing methods. These processes are crucial in shaping the tea's final flavour, aroma, and texture. Let’s explore how these delicate leaves are turned into the familiar tea powder or packed neatly into tea bags, focusing on both the traditional orthodox method and the contemporary CTC (Crush, Tear, Curl) process.
What’s the Traditional Orthodox Method?
This method follows age-old techniques to process tea. It emphasizes preserving the natural integrity of the leaves, resulting in whole-leaf tea known for its complex flavours. The steps include:
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Withering: The freshly plucked leaves are spread out in thin layers and left to wither, reducing their moisture content and making them pliable for further processing.
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Rolling: The withered leaves are gently rolled to break their cell walls and release essential oils. This step is crucial in developing the tea's signature aroma and flavour.
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Oxidation: Rolled leaves are left to oxidize in a controlled environment. This chemical reaction, triggered by exposure to oxygen, determines the tea's colour and flavour profile. For instance, black tea is fully oxidized, while green tea skips this step.
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Drying: Finally, the leaves are dried using heated air or pans to halt oxidation and lock in the flavours. The result is whole-leaf tea, often used in loose-leaf tea blends or premium tea bags.
The orthodox method is time-intensive but produces teas with rich, layered flavours—ideal for discerning tea drinkers who savour every note in their cup.
What is The CTC (Crush, Tear, Curl) Method?
The CTC method, developed during the British colonial era, is a modern, mechanised approach designed for efficiency and consistency. It’s widely used to produce tea powder and tea for bags, particularly for Indian chai.
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Withering: Similar to the orthodox method, the process begins with withering to reduce the moisture in the leaves.
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Crushing, Tearing, Curling: The withered leaves are passed through CTC machines, where they are crushed, torn, and curled into uniform granules. This process increases the surface area of the leaves, making them brew faster and release bold, strong flavours—perfect for milk-based teas.
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Oxidation: The granulated tea undergoes rapid oxidation, which enhances its robust flavour and dark colour.
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Drying and Grading: The oxidized tea is dried in large ovens and then graded based on size. The finer particles are used for tea powder, while larger granules may be packed for strong brews.
The CTC method is ideal for producing economical, mass-market teas with a strong and brisk flavour, often used in tea bags or instant blends.
From Factory to Your Cup
After processing, tea leaves begin the final leg of their journey to become the comforting brew we know and love. This stage involves careful sorting, quality checks, packaging, and distribution to ensure the tea reaches your cup in its freshest and most flavourful form.
Sorting and Grading
Tea leaves are first sorted and graded based on their size and quality:
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Orthodox Tea: Graded into whole leaves, broken leaves, fannings, and dust. Whole leaves are prized for their rich, complex flavours, while fannings and dust are typically used in tea bags.
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CTC Tea: Granules are sorted into uniform sizes, with finer particles reserved for quick-brewing tea powders.
This classification ensures that every type of tea meets its intended use, whether for premium loose-leaf blends or mass-market tea bags.
Packaging
Packaging is a crucial step in preserving tea’s flavour and aroma. Depending on the tea type loose-leaf tea is packed in airtight containers or foil-lined bags to prevent oxidation. Tea powder or granules are sealed in moisture-resistant pouches to retain their bold flavours. Tea bags are filled with precise portions of fannings or dust and sealed for convenience. Advanced machinery ensures hygiene and consistency in every pack.
Distribution
Once packaged, tea is distributed locally or exported worldwide. Premium varieties, like Darjeeling or Assam, often arrive in speciality stores or gourmet markets, while everyday blends are widely available in supermarkets or online.
Brewing the Perfect Cup
At last, the tea reaches your hands. Whether it’s steeping loose leaves, dipping a tea bag, or brewing a robust chai with milk and spices, every method highlights the tea’s unique journey.
So the next time you pour yourself a cup of chai, pause for a moment. Remember the lush gardens, the skilled hands, and the centuries-old legacy that make this humble drink a source of comfort and joy for millions. After all, a cup of tea is more than a beverage—it’s an experience, steeped in culture and love.