Anaerobic Incubation and Shear Processing for Tea Polyphenol Extraction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing black tea products do not effectively deliver a liquor with enhanced red color and high polyphenol and theaflavin content, leading to suboptimal sensorial experience and polyphenol utilization.
Innovation Solution
A process involving anaerobic incubation of fresh tea leaves followed by comminution and mechanical shear, which increases the red color and polyphenol delivery in the final tea product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional fermentation and drying processes are used, then black tea products are produced, but the red color intensity and polyphenol delivery in the liquor are insufficient
Solution Approach 1:
The patent applies preliminary action by conducting anaerobic incubation of fresh tea leaves before traditional fermentation. This pre-treatment step prepares the leaves by accumulating polyphenols and modifying their chemical composition, which then enhances polyphenol delivery during subsequent brewing. The incubation phase (4-48 hours at controlled temperature) creates optimal conditions for enhanced extraction without complicating the overall manufacturing process.
Solution Approach 2:
The patent utilizes parameter changes by controlling temperature, oxygen levels, and time during the anaerobic incubation phase. By maintaining specific temperature ranges (4-40°C) and anaerobic conditions, the process optimizes polyphenol accumulation and theaflavin formation. These controlled parameter changes during incubation directly improve polyphenol content and red color intensity in the final product.
2Quantity of substance
If anaerobic incubation is performed for extended periods, then polyphenol content increases, but production time increases
Solution Approach 1:
The patent applies continuity of useful action by maintaining controlled anaerobic conditions throughout the incubation period without interruption. The continuous presence of polyphenol precursors and enzymes under optimized temperature and oxygen-excluded conditions ensures steady accumulation of polyphenols and theaflavins. This continuous process maximizes polyphenol content within the 4-48 hour window, achieving high extraction potential without unnecessary time extension.
3Quantity of substance
If traditional fermentation processes are used, then black tea is produced, but theaflavin content and red color delivery are limited
Solution Approach 1:
The patent applies preliminary action by conducting anaerobic incubation to accumulate theaflavins and polyphenols before traditional fermentation. This pre-treatment creates a reservoir of extraction-ready compounds in the leaf material, which then delivers enhanced theaflavin content and red color intensity during brewing. The incubation phase (4-48 hours) prepares the leaves to maximize theaflavin delivery without requiring changes to subsequent processing steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process significantly enhances the red color and polyphenol delivery in the tea product, improving the overall sensorial experience and polyphenol extraction.
Implementation Method 1
b. subjecting the incubated leaf to comminution to produce comminuted dhool
Implementation Method 2
c. subjecting the comminuted dhool to a step of shear for 30 seconds to 15 minutes by passing the dhool though an instrument with shear rate in the range of 5000 /s to 25000 /s
Implementation Method 3
The term fermentation is traditionally used in the tea processing to refer to enzymatic oxidation. The characteristic colour, flavour and aroma of black tea are produced during fermentation.
Implementation Method 4
The tea is dried at high temperature after fermentation to arrest the enzyme action and to bring down the moisture to a low level
Data Source
AI summary
The present invention provides a process of producing a tea product comprising the steps of: a. incubating fresh leaf at a temperature in the range 4 °C to 60 °C under anaerobic conditions for a period of 4-36 hours; b. subjecting the incubated leaf to comminution to produce comminuted dhool; and c. subjecting the comminuted dhool to a step of shear for 30 seconds to 15 minutes by passing the dhool though an instrument with shear rate in the range of 5000/s to 25000/s wherein the shear rate is defined as (I) wherein D is the shaft diameter, H is the channel depth and Ν is the rotational speed.