Survey on black tea production process at ssoe phu tho tea company limited

THAI NGUYEN UNIVERSITY OF AGRICULTURE AND FORESTRY ADVANCED EDUCATION PROGRAM TRUONG THI NGOC HUYEN TOPIC TITLE: SURVEY ON BLACK TEA PRODUCTION PROCESS AT SSOE PHU THO TEA COMPANY LIMITED BACHELOR THESIS Study Mode : Full-time Major : Food Technology Faculty : Advanced Education Program Office Batch : 2018 – 2022 Type : On-the-Job Training (OJT) Supervisor(s) : Dr Dinh Thi Kim Hoa Thai Nguyen, December 2022 DOCUMENTATION PAGE WITH ABSTRACT Thai Nguyen University of Agriculture and Forestry Degree Program Bachelor of Food Technology Student name Truong Thi Ngoc Huyen Student ID DTN1854190005 Thesis Title Survey On Black Tea Production Process At SSOE Phu Tho Tea Company Limited Supervisor Dr Dinh Thi Kim Hoa Supervisor’s signature Abstract: The processed Camellia sinensis leaves used to make tea, the world's most popular refreshing beverage, are assessed organoleptically Although the biological potentials are fixed in the leaves, processing makes it edible Tea wouldn't have existed as a beverage if not for its abundant polyphenols and caffeine About two-thirds of polyphenols, or catechins, are converted to polyphenolic pigments like theaflavins (TF), thearubigins (TR), and other polymerization compounds when they are oxidized in the presence of polyphenol oxidase The quantity and balance of these substances in the tea fluid affect the quality of black tea Keywords Tea, , processing, quality Number of Pages 66 Date of Submission 11th November,2022 ii ACKNOWLEDGEMENT First of all, I would like to express my gratitude to the lecturers in the Advanced Education Program and at the Thai Nguyen University of Agriculture and Forestry, who have provided me with in-depth knowledge not only of my subjects but also of my soft skills, as well as the opportunity to complete my thesis It has been a delight to work with a profound supervisor, Dr Dinh Thi Kim Hoa who has always been willing to assist me at any time She also provided me with the best possible conditions, supported all of my study materials, and discussed any issues I had anytime I conducted surveys or analyzed data Thank the directorate and departments of SSOE company without your support, during my internship, and providing me with relevant information and data, I wouldn’t have been able to carry out my thesis Especially, Ms Nguyen Thi Hoa, who wholeheartedly taught and helped me with the knowledge and skills to well in research during internships and company surveys Although many attempts have been made to implement the topic in the most comprehensive manner possible, owing to the lack of early familiarity with the real production technique as well as limited expertise and experience, flaws are unavoidable I sincerely appreciate your comments and recommendations on how to be better in my thesis Sincerely thanks! Truong Thi Ngoc Huyen iii TABLE OF CONTENTS DOCUMENTATION PAGE WITH ABSTRACT ii ACKNOWLEDGEMENT iii TABLE OF CONTENTS iv LIST OF FIGURES LIST OF TABLES CHAPER I INTRODUCTION 1.1 Rational research 1.2 Research’s objectives 1.3 Detailed schedule 1.4 Timeline CHAPER II LITERATURE REVIEW 2.1 General information about SSOE Phu Tho Tea Company Limited 2.1.1 Introduction of company 2.1.3 Infrastructure 2.2 Overview of Black tea 2.2.1 Definition of Black tea 2.2.2 Introduce some technological processes of black tea production 2.2.3 Raw materials for black tea production 2.2.4 Classification 2.2.4 Situation of tea production and consumption in the world and in Vietnam 10 2.3 Brief introduction about tea plant 17 2.3.1 General characteristics of tea plants 17 2.3.2 Original of tea 19 iv 2.3.4 Tea growing areas in Vietnam 20 2.4 The importance of the tea industry to human life and the economy 21 2.4.1 For human life 21 2.4.2 For economy 22 2.5 Chemical composition of tea plant 22 2.5.1 Phenolic compounds 22 2.5.2 Alkaloids 23 2.5.3 Group of nitrogen-containing compounds (Protein and amino acids) 24 2.5.4 Glucose and pectin 24 2.5.5 Pigments in tea 25 2.5.6 Vitamins 25 2.5.8 Water 26 2.5.9 Fragrance Oil 26 2.5.10 Ashes 27 CHAPTER RESEARCH SUBJECTS AND RESEARCH METHODS 28 3.1 Survey object 28 3.2 Place and time of study 28 3.2.1 Survey location 28 3.2.2 Survey time 28 3.3 Survey content 28 3.3.1 Survey on black tea production process by OTD method 28 3.3.2 Survey of standards applied at SSOE for black tea products 28 3.4 Survey Methods 29 3.4.1 Methods of information collection 29 v 3.4.2 The method of data collection 29 CHAPTER RESULTS AND DISCUSSION 30 4.1 Production process of black tea by OTD method 30 4.2 Process explanation 31 4.2.1 Materials 31 4.2.3 Preliminary wilt 31 4.2.4 Rolling turn 34 4.2.5 Rolling turn 35 4.2.6 Sifting 35 4.2.7 Fermentation 36 4.2.8 Drying 37 4.2.9 To sieve, sort 38 4.2.10 Mixing and preserving 40 4.2.11 Packaging 41 4.2.12 Markers 42 4.3 Equipment used to produce black tea production 42 4.3.1 Wilted furnace 42 4.3.2 Rolling equipment 43 4.3.3 The equipment of unfold ferment 43 4.3.4 Dryer 43 4.4 Regulations in the license to discharge wastewater into the water source of SSOE Phu Tho Tea Co., Ltd and to survey of standards applied at SSOE Phu Tho Tea Company Limited 44 4.3.1 Collection, treatment and discharge of wastewater into water sources 44 vi 4.5 Final production 46 CHAPTER DISCUSSION AND LESSON LEARNED 47 5.1 Discussion 47 5.2 Learned 47 CHAPTER CONCLUSION 48 REFERENCES 49 APPENDICES 51 vii LIST OF FIGURES Figure 2.1 FAO Composite Price 11 Figure 2.2 Actual and Projected Production of Black Tea 14 Figure 2.3 Actual and Projected Consumption of Black Tea 14 Figure 2.4 Actual and Projected Exports of Black Tea 15 LIST OF TABLES Table 2.2 Classification of black tea product at SSOE Phu Tho Tea Company Limited .9 CHAPER I INTRODUCTION 1.1 Rational research Tea, which is processed by the tender shoots or leaves of tea plant (Camellia sinensis (L.) O Kuntze), is the second most popular beverage worldwide after water (Rietveld and Wiseman 2003) Drinking tea and enjoying tea is a very popular culture in the life of Vietnamese people Tea is a very healthy drink, thanks to its biomedical properties, and the presence of groups of vitamins and tannins that help clear heat, detoxify, reduce blood fat, high blood pressure, and dysentery due to bacterial infection However, due to the purpose of profit, many tea production areas have abused pesticides, plant protection products, and herbicides beyond the allowable threshold, affecting food safety for consumers and at the same time adversely affect the image of Vietnamese tea in general and tea products in the Phu Tho region in particular In fact, the demand for safe organic products for human health is being concerned and OTD black tea is one of such product lines Tea has rapidly gained popularity in more than 60 nations, making it one of the three most popular non-alcoholic beverages on the planet The scientific connotations of tea are directly tied to the reasons why its usage has steadily grown over the world Tea has a cult following due to its distinctive health benefits and distinct flavor Tea's unique characteristics are mostly dictated by the secondary metabolites it contains (Wan and Xia 2015) Tea leaves are mostly utilized as a beverage plant because they contain the required secondary metabolites, which give a variety of distinct properties Different portions of the plant are principally employed for manufacturing the end product in tea and other beverage plants, such as coffee, grape, and cocoa, with secondary metabolites residing in the same or unique Phu Tho has many advantages in terms of natural and human conditions with concentrated tea growing and production areas with high yields There are many businesses that have been oriented towards the trend of organic tea production, serving the needs of organic food and food safety, and at the same time directing their products to the export market in order to affirm and enhance their trade Vietnamese tea brand Stemming from that practice, we carried out the topic: "Survey on OTD black tea production process at SSOE Phu Tho company" 1.2 Research’s objectives The main objective of this paper is to survey on process of manufacturing black tea at the SSOE Phu Tho tea company Specific objectives include: To find out the history of formation and development, production situation and business development strategy of SSOE Phu Tho Tea Company To survey on process of manufacturing black tea by Orthodox method at the SSOE Phu Tho Tea Company To survey the standards applied at the SSOE Phu Tho Tea Company Evaluate of the existing process on manufacturing the black tea at the SSOE Phu Tho Tea Company And give recommendation for the improvement 4.3.1.3.1 Process of collecting, treating and discharging wastewater Industrial sanitary waste water Wastewater from the workers' cafeteria Domestic wastewater in the factory area Sedimentation tank, oil separator Collection system Ecological pond 600m3 compartment septic tank Wastewater generated by the operator Collection system compartment septic tank Settling tank, sterilization Rainwater flowing over the surface Garbage barrier Pits Factory's rainwater drainage system Drainage system along Provincial Road 316C After being treated, wastewater from the operator's house and shift house is treated by a septic tank with a capacity of 12m3 and then continues to flow through a 3-compartment settling tank with a capacity of 27m3 located in the northwest of the factory to settle and disinfect wastewater when connected to the common drainage system along provincial road 316C Domestic wastewater from the factory's toilet area, after being treated through a septic tank with a capacity of 15m3, is collected to a centralized wastewater treatment system and then discharged into the common drainage system along provincial road 316C After going through the settling tank, open separation with a capacity of 22,5m3, the wastewater from the canteen is collected into the ecological pond in the factory premises 45 4.5 Final production 46 CHAPTER DISCUSSION AND LESSON LEARNED 5.1 Discussion Black tea also offers a variety of health benefits because it contains antioxidants and compounds that may help reduce inflammation in the body The production process is strictly followed according to regulations, at each stage, there is a team leader, deputy team leader, technical staff, and QC staff to monitor workers, supervise production activities and check product quality Possessing advanced production technology, using modern equipment and machinery for production, improving product quality The process complies with ISO and HACCP standards, hygienic production conditions are ensured Black tea is also used to create blends that are flavored with fruit, flowers, and spices, and exhibit a wide range of flavor profiles depending on their ingredients Therefore, customer can rest assured to use it 5.2 Learned Learn more about the modern industrial-scale black tea production process from input materials, processing to finished products How to operate, manage and organize the factory This is also an apprenticeship period to better understand what will in the future It is a time to learn and a great opportunity ability, practice soft skills, the ability to handle situations and communicate in real work, helping to quickly see knowledge gaps and promptly fix them At the same time, it is a good opportunity to step by step plan for the future 47 CHAPTER CONCLUSION During survey on SSOE tea company obtained the following results: - Product Quality Management Process - Learn the flow chart of technological production of black tea products - Investigate some main stages in the production line: + Surveying the stage of receiving raw materials + Surveying the tea rolling process + Surveying the tea fermentation process + Surveying the tea drying process + Survey the process of mixing and packaging products + Preservation 48 REFERENCES I Internet resources Peng, Z., H R Tong, G L Liang, Y Q Shi, and L Y Yuan 2018 Protoplast isolation and fusion induced by PEG with leaves and roots of tea plant (Camellia sinensis L O Kuntze) Acta Agronomica Sin 44:463–70 (in Chinese) Rietveld, A., and S Wiseman 2003 Antioxidant effects of tea: evidence from human clinical trials The Journal of Nutrition Gardner EJ, Ruxton CHS, & Leed AR 2007 Black tea – Helpful or harmful? A review of the evidence European J Clin Nutr 61: 3–18 Luczaj W & Skrzydlewska E 2005 Antioxidative properties of black tea Prev Med 40: 910–918 Baruah MA & Mahanta KP 2003 Fermentation characteristics of some Assamica clones and process optimization of Black Tea Manufacturing J Agric Food Chem 51(22): 6578–6588 Balentine AD, Wiseman AS & Bouwens MCL 1997 The chemistry of tea flavonoids Crit Rev Food Sci Nutr37(8), 693–704 Tokuşoğlu Ö, Ünal MK & Yıldırım Z 2003.HPLC–UV and GC–MS characterization of the flavonol Aglycons Myricetin in quercetin, Kaempferol, and tomato pastes and other tomato-based products Acta Chromatographica 13: 196–207 Samy RP & Gopalakrishnakone P 2010 Therapeutic potential of plants as anti-microbials for drug discovery.Evid Based Complement Alternat Med 7(3): 283–294 49 Halder B, Das Gupta S, & Gomes A 2012 Black tea polyphenols induce human leukemic cell cycle arrest by inhibiting Akt signaling: Possible involvement of Hsp90, Wnt/β-catenin signaling and FOXO1 FEBS J279: 2876–2891 10 Kimura K, Ozeki M, Juneja LR & Ohira H 2007 l-Theanine reduces psychological and physiological stress responses Biol Psychol 74(1): 39–45 II Vietnamese resources Djemukhatde K.M Cây chè miền Bắc Việt Nam Nhà xuất Nông nghiệp 1982 TCVN 5609:2007 (ISO 1839: 1980), National standard for tea - sampling III Internet resources https://vietnamcredit.com.vn/news/vietnams-top-tea-exporters-in-the-firstten-months-of-2021_14563 https://vietnamcredit.com.vn/news/overview-of-vietnams-tea-industry_14207 50 Receive material Possibility Stage Potential hazards Biological : - Pathogenic microorganisms: E Coli, Coliform Severity level APPENDICES Is there a significant food safety hazard? (Y/N) L L N Explain Justify your decision for column Pathogenic microorganisms can infect raw tea buds from the air, from workers, from harvesting, storage and transportation of harvesters, however, tea is an unfavorable environment for the growth of microorganisms cause disease - Raw tea may itself carry diseases caused by fungus or mold, but because the raw materials are grown, cared for and harvested according to GG and applied according to GMP, receiving raw materials, it is possible that the materials used in tea production can carry their own disease is low, GG harvested ingredients and teas are dried at 125℃ so the severity of this hazard is low, and not a significant food safety hazard - VSV can infect tea from the air, workers' hands and containers, but the environment for growing, caring for and harvesting tea is cool, clean, not a favorable environment for microorganisms SSOP use of direct and indirect product contact surfaces, personal hygiene SSOP What preventive measure(s) can be applied for the significant hazards - GMP receives raw materials Apply SSOP Personal Hygiene - SSOP Sanitize direct and indirect product contact surfaces - GMP dried Critical Control Point determine (Decision tree) Q1 (Y/N) Q2 (Y/N) Q3 (Y/N) Q4 (Y/N) CCP? (Y/N) 10 Y N N N 51 - Parasites, insects Chemistry : - Residues of pesticides L H N - Parasites can infect tea buds from workers, can infect tea leaves from farm care Dry tea is an unfavorable environment for the growth of parasites - GMP receives raw materials - Apply SSOP Personal Hygiene - Because gardeners not properly apply regulations on spraying pesticides: the preharvest isolation period is not correct or the use of drugs is not in the list prescribed by the state that the company provides - Pesticide residues can affect consumers' health - Purchase procedure and supplier evaluation: - suppliers are on the list - List of suppliers participating in the Sustainable Agriculture project Y Y - - Y 52 Physics : External objects: Gravel, soil, glass, metal pieces, tree branches, grass, etc M M Y - Due to the factory, workers can contaminate the raw materials Consumers will make tea and drink water, so foreign objects will not harm the digestive system - Particularly for small metal fragments present in finished tea can enter the user's body and affect consumers' health - Apply SSOP Prevent cross contamination - SSOP- Protect products from infectious agents - GMP Receiving raw materials - GMP classification - GMP metal detector - Pathogenic VSV can infect tea semifinished products from the air, from workers, from floors, from tools and machines, from insects Tea leaves are not a favorable environment for the growth of pathogens - While waiting for the tea to wilt, animals can fly into the wither area - GMP wilts - Apply SSOP Personal Hygiene - SSOP Prevents cross-contamination - SSOP Protect the product from infectious agents - GMP wilts Y N N N 53 Wilting Biological : - Pathogenic microorganisms: Ecoli, Colifoms - Parasites, insects M M Y L L N - Chemistry : - None Physics : External objects: Gravel, earth, glass, metal pieces ) M M Y - - Pathogenic microorganisms can infect tea semi-finished products from the air, from workers, from floors, from tools and machines, from insects Tea leaves are not a favorable environment for the growth of pathogens While waiting for the tea to wilt, animals can fly into the wither area Because the factory and drying yard are not clean, workers can contaminate foreign objects Consumers will make tea and drink water, so foreign objects will not harm the digestive system Particularly for small metal fragments present in finished tea can enter the user's body and affect consumers' health - Apply the rules of the processing factory - SSOP Personal hygiene - SSOP Prevents cross-contamination - SSOP Protect products from infectious agents - Applying procedures TT Maintenance of machinery and equipment - GMP Wither - GMP classification - GMP metal detector Y N N N Y N N N Chemistry : None 54 Fermentation Biological : - Pathogenic microorganisms, molds - Insect L L N L L N M M Y - Pathogenic microorganisms can infect tea semi-finished products from the air, from workers, tools and machines Tea leaves are not a favorable environment for the growth of pathogenic microorganisms - Lack of control over the fermentation process can cause mold in the tea - Insects of ginseng entering the yeast room affect the taste and quality of tea - GMP Fermentation - Apply SSOP Personal Hygiene - SSOP Prevents cross-contamination - SSOP Protect the product from infectious agents - Due to the factory, damaged rotating tube may contaminate foreign objects Consumers will make tea and drink water, so foreign objects will not harm the digestive system - Particularly for small metal fragments present in finished tea can enter the user's body and affect consumers' health - Apply SSOP to Prevent Crossing - SSOP Protect products from infectious agents - GMP Spinning fragrant - GMP classified GMP metal detector - Applying procedures TT Maintenance of machinery and equipment - GMP metal detector - GMP Fermentation - Apply SSOP Personal Hygiene - SSOP Prevents cross-contamination - SSOP Protect products from infectious agents Y N N Y N N Y Y - Chemistry : - No Physics : - External objects (Dust, shards of rotating tubes, metal shards ) Drying Biological : - Pathogenic microorganisms, molds M M Y Pathogenic microorganisms can infect tea semi-finished products from the air, from workers, tools, and machines Tea leaves are not a favorable environment for the growth of pathogenic microorganisms N - Y Chemistry : - No 55 Physics : - External objects (Dust, shards of rotating tubes, metal shards ) Sieve Biological : - Pathogenic microorganisms: Ecoli, Colifoms - Parasites, insects Chemistry : - Oils, lubricants, etc M M Y M M Y M L N - Due to the factory, the equipment may contaminate the tea semi-finished products Consumers will make tea and drink water, so foreign objects will not harm the digestive system - Particularly for small metal fragments present in finished tea can enter the user's body and affect consumers' health - Applying equipment maintenance procedures - Apply SSOP Personal Hygiene - SSOP Prevents cross-contamination - SSOP Protect products from infectious agents - GMP drying - GMP classification - GMP metal detector Pathogenic microorganisms can infect tea semi-finished products from the air, from workers, tools, and machines Dry tea is an unfavorable environment for the growth of pathogenic microorganisms - Apply SSOP Personal Hygiene - SSOP Prevents cross-contamination SSOP Protect products from infectious agents - GMP sieve - Applying maintenance procedures, maintaining machinery and equipment - SSOP Sanitize direct and indirect product contact surfaces - SSOP Prevents cross-contamination - SSOP Protect products from infectious agents - GMP sieve The likelihood of this hazard occurring is moderate, however due to hygienic manufacturing processes: Use cooking oil (or food grade grease) to lubricate the tightening shafts On the other hand, there are maintenance, maintenance and cleaning plans for machines made and implemented by the mechanical department, so this risk does not affect the health of consumers Y N Y Y N N N Y Y N N Y N 56 M M Y Physics : External object (Dust, worker's hair, metal shards ) Packaging Biological : - Pathogenic microorganisms Chemistry : - Heavy metal Physics : - External object (Dust) From workers or factories can contaminate foreign objects Consumers will make tea and drink water, so foreign objects will not harm the digestive system Particularly for small metal fragments present in finished tea can enter the user's body and affect consumers' health VSV can get into the packaging from the environment L L N L H N L M N - There may be heavy metal residues in the packaging that can contaminate the product However, the packaging used at the enterprise is provided by the suppliers on the list, and ensures that the supplier has the packaging quality that meets the TCCS in accordance with the requirements of the relevant authorities From the environment contaminates the packaging - Applying equipment maintenance procedures - SSOP Sanitize direct and indirect product contact surfaces - SSOP Prevents cross-contamination - SSOP Protect products from infectious agents - GMP sieve - GMP classification - GMP metal detector - Apply SSOP Protect products from infectious agents GMP 11-01 receives and preserves packages - Only receive packaging from suppliers listed in the list of packaging suppliers at the enterprise - Fully update the packaging supplier's documents certifying that the supplier's products meet the standards - Apply SSOP Protect products from infectious agents - GMP receives and preserves packages Y N Y Y N Y N N N Y Y N N 57 Metal Detector Biological : - Pathogenic microorganisms: Ecoli, Colifoms M M Y Pathogenic microorganisms can infect tea products from the air, workers, equipment, and machinery Finished tea is not a favorable environment for the growth of pathogenic microorganisms - Apply SSOP Personal Hygiene - SSOP Prevents cross-contamination - SSOP Protect products from infectious agents - - Apply SSOP Personal Hygiene - SSOP Prevents cross-contamination - SSOP Protect products from infectious agents - Applying equipment maintenance procedures - GMP metal detector - Monitoring form: “CHECKING TABLE OF EASY METAL MACHINE” - Apply SSOP Personal Hygiene - SSOP Prevents cross-contamination - SSOP Protect products from infectious agents - SSOP Preventing harmful animals Y N N N Y Y CCP Y N N Y Y Chemistry : - None Physics : - External objects: dust, sand, workers' hair, metal pieces M M Y - External objects: can be mixed in products from machines, factories, workers… through processing stages Consumers will make tea and drink water, so foreign objects will not harm the digestive system Particularly for small metal fragments present in finished tea can enter the user's body and affect consumers' health Inventory for export Biological : - Viruses, bacteria cross-contaminated by workers - Rodents L L N M M N Workers with infectious diseases can crosscontaminate tea during packing The process of preserving tea is susceptible to insects and rodents, affecting the quality of tea N N Chemistry : - No Physics : - No 58 Receiving and preserving packaging Biological : - Pathogenic microorganisms VSV can get into the packaging from the environment L L N Chemistry : - Heavy metal L H N - There may be heavy metal residues in the packaging that can contaminate the product However, the packaging used at the enterprise is provided by the suppliers on the list, and ensures that the supplier has the quality of the packaging to meet the basic standards in accordance with the requirements of the authorities relate to Physics : - External object (Dust,) L M N From the environment contaminates the packaging - Apply SSOP Protect products from infectious agents GMP 11-01 receives and preserves packages - Only receive packaging from suppliers listed in the list of packaging suppliers at the enterprise - Fully update the packaging supplier's documents certifying that the supplier's products meet the standards - Apply SSOP Protect products from infectious agents - GMP receives and preserves packages Y N N N Y N N N Y N N N 59