Black Tea Sorting And Quality Control Techniques Training

Objectives:
• Understand the global importance of black tea and its market segments.
• Identify key quality attributes: appearance, aroma, taste, and liquor colour.
• Explain the tea manufacturing process and its impact on quality.
• Recognise the role of sorting and grading in quality control.
• Familiarise with SAQA unit standards and training outcomes.

Topics:
• Overview of black tea production: plucking, withering, rolling, fermentation, firing.
• Quality parameters: leaf appearance, infusion colour, flavour, and mouthfeel.
• Introduction to tea grading systems: whole leaf, broken, fannings, dust.
• Importance of sorting and quality control in value chain.
• Tea tasting basics: sensory evaluation principles.
• Overview of SAQA unit standard 115839 and learning pathways.
• Hygiene and safety in tea handling.
• Course structure and assessment expectations.

Objectives:
• Distinguish between different black tea grades based on leaf size and shape.
• Describe the mechanical and manual sorting processes.
• Identify common sorting equipment and their functions.
• Explain the relationship between leaf grade and cup quality.
• Apply standard terminology for grading black tea.

Topics:
• Grading categories: OP, BOP, FOP, TGFOP, CTC, orthodox.
• Sorting methods: sieving, air classification, colour sorting, hand picking.
• Equipment: graders, vibratory sieves, gravity separators, electronic sorters.
• Impact of sorting on consistency and market value.
• Practical demonstration: sorting by size and visual inspection.
• Recording and documentation of grade yields.
• Quality defects related to poor sorting: stems, fibres, foreign matter.
• Workflow integration: sorting line layout and material flow.

Objectives:
• Set up a professional tea tasting station following industry standards.
• Evaluate black tea using the ISO 3103 cupping method.
• Describe sensory attributes: dry leaf, infused leaf, liquor, and flavour.
• Identify common off-flavours and their causes.
• Record and interpret sensory scores using standardised forms.

Topics:
• Cupping protocol: sample preparation, water quality, brewing time.
• Sensory analysis: appearance, aroma, taste, mouthfeel, aftertaste.
• Scoring systems: 100-point scale, descriptive analysis.
• Common defects: over-fired, under-fermented, smoky, musty, woody.
• Practical cupping session: evaluating 5-6 different grades.
• Developing a sensory vocabulary for black tea.
• Calibration of panelists: consistency and bias reduction.
• Linking sensory data to sorting and processing adjustments.

Objectives:
• Explain key chemical components affecting tea quality: polyphenols, caffeine, amino acids.
• Perform basic physical tests: moisture content, particle size distribution.
• Understand the role of fermentation in flavour development.
• Interpret laboratory reports for quality assurance.
• Apply limits for chemical residues and contaminants.

Topics:
• Chemistry of black tea: theaflavins, thearubigins, caffeine, L-theanine.
• Moisture analysis: oven-drying method and acceptable ranges.
• Particle size analysis: sieving and laser diffraction.
• Colour measurement: liquor brightness and clarity (e.g., using spectrophotometer).
• Fermentation index and its correlation with quality.
• Pesticide residue limits and food safety standards.
• Practical: conduct moisture test on a tea sample.
• Interpreting quality control data sheets.

Objectives:
• Describe a comprehensive quality control (QC) system for black tea.
• Identify critical control points in the sorting and grading process.
• Apply international and local standards: ISO, SABS, HACCP.
• Develop checklists and standard operating procedures (SOPs).
• Understand traceability and lot management.

Topics:
• Elements of a QC system: incoming inspection, in-process control, final testing.
• HACCP principles in tea processing: hazard identification and control.
• ISO 3720: black tea specification.
• SABS standards for tea grading and packaging.
• Developing SOPs for sorting, grading, and cupping.
• Traceability systems: batch codes, records, and recall procedures.
• Practical: create a QC checklist for a sorting line.
• Auditing and corrective actions.

Objectives:
• Operate sorting equipment safely and efficiently.
• Perform hands-on grading of black tea samples.
• Identify and segregate off-grade material.
• Document sorting outcomes and yield percentages.
• Troubleshoot common sorting issues.

Topics:
• Hands-on sorting: using sieves and gravity separators.
• Visual inspection: removing stalks, fibres, and foreign matter.
• Operating colour sorters: settings and calibration.
• Yield calculation: weight of each grade vs. total input.
• Practical grading exercise: sort 5 kg of bulk tea into grades.
• Identifying defects: over-fermented, under-fermented, burnt.
• Safety protocols: lockout/tagout, PPE, dust control.
• Recording data: grade weights, defect percentages, and observations.

Objectives:
• Explain the principles of tea blending for consistency and flavour.
• Develop a blend formula based on sensory and physical data.
• Evaluate blend uniformity and stability.
• Apply statistical process control (SPC) to sorting lines.
• Manage inventory and shelf-life considerations.

Topics:
• Blending objectives: consistent flavour, colour, and price point.
• Blending methods: batch blending, continuous blending.
• Practical: create a blend from three base grades to match a target profile.
• Statistical process control: control charts for particle size and moisture.
• Sampling plans for quality verification.
• Shelf-life testing: accelerated ageing and sensory changes.
• Inventory management: FIFO, stock rotation, and lot tracking.
• Practical: evaluate blend consistency through cupping.

Objectives:
• Prepare comprehensive quality reports for management and clients.
• Maintain accurate records of sorting, grading, and testing.
• Understand certification requirements: organic, Fair Trade, Rainforest Alliance.
• Communicate quality issues effectively with production teams.
• Implement corrective actions and continuous improvement.

Topics:
• Quality report structure: summary, data, analysis, recommendations.
• Record-keeping: batch records, sensory scores, lab results.
• Certification standards: organic, Fair Trade, UTZ, Rainforest Alliance.
• Non-conformance reports (NCR) and root cause analysis.
• Practical: write a quality report for a batch of tea.
• Communication skills: feedback to sorters and processors.
• Continuous improvement: PDCA cycle (Plan-Do-Check-Act).
• Legal and regulatory compliance in South Africa.

Objectives:
• Integrate all skills in a simulated sorting and QC scenario.
• Complete a practical assessment: sort, grade, cup, and report.
• Demonstrate competency in all unit standard outcomes.
• Develop a personal action plan for workplace implementation.
• Receive feedback and certification.

Topics:
• Simulated production run: from bulk tea to graded, quality-assured product.
• Practical assessment: sorting, grading, cupping, and report writing.
• Oral questioning to verify understanding.
• Review of unit standard 115839 outcomes.
• Feedback session: strengths, areas for improvement.
• Certification ceremony and issuing of certificates.
• Action planning: applying learning in the workplace.
• Course evaluation and closing.