Our Production

Black Tea Process

From fresh leaf to finished cup: the six key stages that shape Tsara’s clean, bright, and aromatic Ceylon black teas.

Fresh leaf and finished black tea

The Appearance of Black Tea

Traditional Ceylon black teas present as wiry, well-twisted strands or even granular shapes depending on the grade. A clean, even leaf with a lively copper liquor signals careful handling from field to factory.

  • Wiry grades (OP, OP1, etc.): long, elegant strands; bright, brisk cups.
  • Broken grades (BOP, BOPF, etc.): faster infusion; stronger colour & body.
  • Tippy lots: golden buds adding honeyed aromatics and depth.

Every decision—from leaf handling to airflow and time—protects aromatics and builds cup clarity.

Step 1: Withering

Withering gently lowers leaf moisture to make leaves pliable for rolling while preserving natural enzymes and fresh-leaf character.

  • Sun wither in mild conditions for soft, floral high notes.
  • Indoor trough wither for precise airflow & temperature control.
  • Warm-air wither when weather varies—keeps results consistent.

Target: flexible leaves that bend—not break—when rolled.

Tea leaves withering in troughs
Rolling tea leaves

Step 2: Rolling

Rolling shapes the leaf and ruptures cell walls to release juices—priming polyphenols and setting up the tea’s structure.

  • Light, even rolls protect aroma in whole-leaf grades.
  • Wiry roll for OP/OP1 elegance and bright liquor.
  • Controlled pressure avoids bitterness and keeps cups clean.

Outcome: leaf is shaped, cell juices exposed, aromatics protected.

Step 3: Fermentation (Oxidation)

Enzymes in the ruptured leaf react with oxygen, turning green leaf to coppery-brown and building signature black-tea aroma, colour, and body.

  • Cool, humid rooms maintain steady oxidation.
  • Careful timing—under- or over-oxidation dulls the cup.
  • Aroma monitoring (fruity, malty, floral) guides the decision to fire.

Key control: temperature, humidity, and time to hit the flavour “sweet spot”.

Tea oxidation room
Tea firing and drying lines

Step 4: Firing / Drying

Warm, clean air halts oxidation, locks aroma, and reduces moisture to safe shelf-stable levels without scorching the leaf.

  • Staged temperatures finish evenly from tip to stem.
  • Low odour air preserves delicate aromatics.
  • Target moisture typically 2–3% for stability.

Result: a beautifully finished black tea with bright colour and clean aroma.

Step 5: Sifting & Grading

Dried leaf passes through sifters and graders to separate consistent sizes—ensuring predictable infusion and colour.

  • Whole-leaf grades (OP, OP1, OPA) for refined, bright cups.
  • Broken grades (BOP, BOPF) for strength and quick brew.
  • Tippy selections where golden buds amplify sweetness.

Each grade is cupped to confirm liquor colour, aroma, and balance.

Tea grading screens
Sorting and packing black tea

Step 6: Sorting & Packing

Final sort removes stems and dust from premium grades. Teas are then packed in oxygen-barrier, food-safe material to preserve freshness.

  • Batch codes & COAs keep lots fully traceable.
  • Oxygen barrier + freshness seals protect aroma in transit.
  • Clean, audit-ready lines meet export standards.

Retail pouches, tins, and bulk formats available.

2–3%

Target final moisture for black tea stability

100%

Every batch is cupped before release

6 Stages

Clear, repeatable process from field to pack

Traceable

Lot coding & certificates available on request

On the Floor

Receiving fresh leaf
Fresh leaf arrives cool, weighed, and logged by lot.
Cupping black tea
Every stage is verified by daily cuppings for colour & aroma.
Packed tea
Oxygen-barrier packs and date codes lock in freshness.

Frequently Asked

Why do some grades brew faster than others?
Smaller particle sizes (e.g., BOPF) extract quicker and produce stronger colour. Whole-leaf grades (e.g., OP1) brew slower but show more clarity and layered aroma.
Do you blend grades after grading?
For house styles we may blend compatible grades to balance colour, body, and aroma. Single-grade, single-estate lots are kept pure and packed separately.
What keeps the cup so clean and bright?
Gentle wither and roll, precise oxidation, and low-odour drying air protect aromatics. Immediate barrier packing prevents staling and taint.

Questions About Our Process?

We’re happy to walk you through specs, grades, and packing options—so you get the exact cup you want.

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