First, microwave fixation:
(a) The principle of microwave heating:
Microwave heating works by using microwaves as an energy source. When microwaves interact with the molecules in a material, they cause molecular polarization, orientation, friction, and collisions, which result in the absorption of microwave energy and the generation of heat. This process allows objects to heat themselves from the inside out, rather than relying on external conduction. This internal heating method is efficient and effective for various applications, including tea processing.
(b) Advantages of microwave fixation:
1. During microwave fixation, the surface temperature of the tea leaves remains relatively low, reducing the need for cooling after processing. This helps preserve chlorophyll and aromatic compounds, resulting in a vibrant green color and a mellow aroma.
2. Fresh leaves are exposed to the microwave heating chamber for a short duration, eliminating the need for air or steam-based heat transfer. This minimizes nutrient loss, ensuring the tea retains its rich texture and natural qualities.
3. Microwave fixation has sterilizing properties, and since the entire process takes place within a closed system, the risk of secondary contamination is significantly reduced. This makes the final product both safe and hygienic.
4. The simultaneous internal and external heating of the tea prevents issues such as burnt edges or uneven drying. It also helps reduce the bitterness and astringency commonly found in summer and autumn teas, enhancing their commercial value.
5. Microwave fixation accelerates moisture evaporation, creating a porous structure that improves the rehydration of the finished product. This makes it easier for the tea’s nutrients and flavors to be released during brewing.
(c) Operation essentials of the microwave cleaning machine:
1. Turn on the power supply and ensure the machine is running smoothly.
2. Perform initial calibration and adjust the rotation speed as needed.
3. Make sure the fan is operating properly to ensure adequate heat dissipation.
4. Place a damp towel on the conveyor belt to maintain optimal working conditions.
5. Apply high pressure, distribute the leaves evenly, open the exhaust port, and start the fan.
6. After processing is complete, continue spreading wet towels, close the pressure valve, and allow the machine to cool for 10 minutes before cutting off the power.
(d) Precautions:
1. Do not run the equipment under empty load, and ensure no metal materials enter the heating chamber during operation.
2. Never open the power or heating box doors while the machine is in operation.
3. Regularly lubricate the moving parts of the equipment to maintain smooth performance.
4. In case of a sudden power failure, all switches should be turned to the "off" position to prevent damage.
Second, the full mechanical production process for flat tea:
The process includes: Spreading - Fixation - Multi-purpose Machine - Titian - Grading - Packaging - Storage.
After harvesting, fresh leaves lose about 30% of their moisture. The fixing machine is preheated, and the seals are checked. Leaves are evenly distributed at the feeding point and transported via the conveyor belt for two minutes to achieve the desired fixation level. After 20 minutes of fixation, the leaves are transferred to the multi-purpose machine. The pot is heated to 100°C. Once the oil vapor evaporates, 0.3 kg of leaves are placed in each tank, and the speed is increased to 50 rpm. After one minute of warming up, the speed is reduced to 30 rpm, a light pressure bar is applied, and the process continues for two minutes until the color and shape are set. Then, decompression is done for one minute, followed by pressing for another minute. A half-minute decompression or gentle pressing for two minutes is performed, then decompression for one minute before removing the pan. The foam head is removed, and the leaves are sent to the Titian machine.
Titian also serves a drying function. Adjust the time and temperature settings as required. Place the Titian tea on the tray, ensuring even thickness. Insert it into the machine, close the door, start the fan, and activate the heating switch. The system will automatically control the temperature and time. After the set time is reached, the machine stops automatically. Remove the tray, turn off the heating switch, and let the fan run for 10 more minutes. Once cooled, the tea is graded, packaged, and stored.
Third, semi-mechanical production process for flat tea:
Different from the fully automated process, this method involves releasing the pan after applying pressure in the multi-purpose machine. The pan is heated to 80°C using an electric fryer. After manual grinding, the leaves are further processed to reach 90% dryness, then moved to the Titian stage.
Fourth, the manufacturing process for Maojian tea:
The steps include: Fixing - Rubbing - Unblocking - Shaping - Sorting - Titian - Packaging - Storage.
After the leaves are fixed, they are fed into the kneading machine. Before starting, clean the machine and turn it on to check for any issues. Load 10 kg of leaves and knead for 10–20 minutes, adjusting the pressure based on the principle of “light, light, light, light.†After the pressure is released, continue kneading for one more minute to expel the leaves. The deblocker is used to separate the leaves, ensuring even distribution. The leaves are then sent through the shaping mechanism. The pot temperature should be between 80–100°C, with 2.5 kg of leaves per tank. After about four minutes, the leaves are panned. After cooling, they are placed in a 80°C tank for two minutes. When 90% dryness is achieved, the leaves are panned, sieved, and sent to the Titian machine. The process is similar to that of fully mechanized flat tea production.
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