INTRODUCTION
Rationale
Tea tree cultivation has emerged as a vital food crop that contributes to health and plays a significant role in sustainable poverty alleviation for mountainous farmers This crop not only enhances the economic conditions of local communities but also supports the establishment and development of new rural areas Additionally, tea tree farming promotes tourism in various mountainous and midland regions.
Green tea is a globally popular beverage known for its numerous health benefits Modern research highlights that it is rich in beneficial compounds such as polyphenols, catechins, caffeine, and amino acids, which enhance immunity, promote overall health, alleviate stress, combat aging, and lower the risk of heart disease and cancer However, traditional brewing methods often leave valuable antioxidants and minerals in the residue, which are typically discarded Notably, a single cup of matcha provides the nutritional equivalent of about ten cups of regular brewed green tea.
Matcha is categorized into three main types: drinking matcha, cooking matcha, and cosmetic matcha Drinking matcha, sourced from young leaves, features a natural aroma and a mild acrid taste, making it the most premium and expensive option This type of matcha is also versatile for cosmetic applications In contrast, cooking matcha, derived from older leaves, has a stronger flavor and is more affordable, allowing for greater ingredient utilization The production of matcha has thus diversified to cater to various uses.
2 products from tea leaves and can be used in many products of the food and pharmaceutical industries
From the above reasons, I have chosen the topic:“Survey of Matcha green tea powder process at Ntea Viet Nam J.S.c in Dong Hy- Thai Nguyen”.
Objectives
- Surveyed matcha green tea powder production process at Ntea J.S.c in Dong Hy- Thai Nguyen
- Surveyed the standards applied for products system at Ntea Company: 5S process, ISO certification in manufacturing and product quality control, and Biocert-IFOAM certification.
Contents of work
- Survey of matcha green tea powder production process at Ntea J.S.c in Dong Hy- Thai Nguyen:
Gathering documents and information related to the company such as development history, development strategy, tea products are produced in the company and the documents related to matcha
- Survey of the standards applied for products system at Ntea Company: 5S process;
ISO certification in manufacturing and product quality control;
Profile of the cooperating agency
The company name: Ntea Viet Nam J.S.c in Dong Hy- Thai Nguyen
Legal representative: Nguyen Kim Cong
Address: Van Huu Village - Hoa Thuong Commune - Dong Hy District - Thai Nguyen Province
Figure 1: Certificate of Barcode Use Rights (MSMV) History and development of the company:
Founded in June 2012, Duc Thanh Trading and Import-Export Company Limited specializes in the commercial sector, while Ntea Vietnam J.S.C, located in Dong Hy, Thai Nguyen, focuses on sourcing raw materials, processing, and packaging.
In April 2014, the Company had an organic tea-making project, invited consulting scientists and Biocert organizations as well as calling for investors
Since then, this business has expanded its cultivation areas, developed and conducted experiment to cultivate and produce organic tea
In June 2015, the tea products of the company was awarded certificate of
IFOAM organic by the Biocert organization
In 2017, Ntea Thai Nguyen separated to form Ntea Vietnam J.S.C in Dong Hy, Thai Nguyen, located in Van Huu village, Hoa Thuong commune, Dong Hy district Additionally, Ntea Vietnam has expanded by developing various member units.
- Ntea Equipment Joint Stock Company;
- Ntea drink franchise Joint Stock Company;
- Ntea Media Joint Stock Company;
- Ninh Thuan Ntea Joint Stock Company
Figure 2: Administrative apparatus diagram of Ntea Thai Nguyen J.S.c
Ntea Viet Nam J.S.C, located in Dong Hy, Thai Nguyen, solidifies its presence in both domestic and international markets while actively promoting Vietnamese culinary culture to global audiences.
- For the market: Providing international quality products at reasonable prices, meeting the needs of consumers to enjoy selectively to improve the quality of life
- For partners: To take the lead in a competitive value, sustainable benefits for investors, and uphold the spirit of cooperation for mutual development
- For employees: To bring jobs, stable income, build a professional civilized, and friendly working environment
- For society: Accompanying with the common development of the community, actively contributing to social unions activities [1]
The main fields of activity of Ntea Viet Nam J.S.c in Dong Hy-Thai Nguyen:
- Planting, tending, manufacturing, processing, and trading in tea products;
- Producing and trading in fertilizers and organic products;
- Manufacturing and trading agricultural machines;
- Providing ecotourism and experience tourism services
- Expanding the domestic market and exporting tea products, affirming the standing position of Vietnamese branded tea in both quantity and quality, branch expansion with Ntea organic tea brand
- Creating raw material areas for production expansion and scaling up of organic tea production in Thai Nguyen province [1].
Description of your activities
Coming to the internship, visiting the production and processing model of the company, finding out documents related to the production and development of Ntea Thai Nguyen Company;
Finding out the machinery and equipment for Matcha production;
Research on documents related to green tea powder
Surveyed matcha green tea powder process;
Directly involved in the production of Matcha green tea powder
Continue to participate in the production of Matcha green tea powder;
Surveyed the standards applied for matcha products system at Ntea Company
Timeline
From 03/2020 to 06/2020: Survey of Matcha green tea powder process at Ntea Viet Nam J.S.c in Dong Hy- Thai Nguyen
LITERATURE REVIEW
Introduction to tea
Tea tree plants are composed of several key components, including stems, twigs, buds, leaves, flowers, fruits, and a root system For the production of matcha green tea powder, the primary focus is on the buds and leaves, specifically utilizing one bud and one leaf with a moisture content of less than 8%.
- Leaves grow from the buds, shoots grow from leaf axils
- Functionally, there are 2 types of shoots: shoots produce leaves
(nutritional buds) and shoots grow buds, flowers, and fruits (shoots reproduce)
- According to the position on the branch, there are 3 types of shoots:
Terminal buds (on the top), axillary buds and latent buds (in the branches)
+ Terminal buds: It grows on the ends of tea branches (top), thrives, buds sprout leaves, makes tops rise high, branches elongate
+ Axillary buds: It grows in leaf axils, is restrained by young shoots; only thrives when the terminal buds are picked
Latent buds, primarily found at the base of tea plants, do not have a fixed position and remain mostly dormant They only begin to sprout when stimulated by chemical growth enhancers or through mechanical methods such as bending or cutting branches.
Tea leaves have 3 types: scale leaf, fish leaf, and real leaf
Scales leaves are tiny, firm, and develop at the growth point of the plant They represent an incomplete stage of leaf development, characterized by their small size, oblong shape, and minimal serration along the margins Fish leaves, often used as a standard for tea picking, consist of one leaf blade and one tea stalk Newly grown leaves are considered young, followed by ordinary leaves and then older leaves, with varying margin characteristics such as serration, waviness, or flatness depending on the tea variety.
Leaf color in tea is influenced by various factors, including the tea variety, shelf life, nutritional content, and seasonal changes For optimal tea production, yellow leaves are ideal for crafting black tea, while green leaves are best suited for green tea.
- Leaf shape: Leaf shape is measured with formula R = length/width Tea leaves have pointed base, round to prison; pointed leaf tip
Types Ovoid Ovoid Ovoid(oblong) Oblong-lanceolate ( Source: Assoc Professor Do Ngoc Quy 2003 )
- Leaf size: Size of large and small tea leaves fluctuates according to variety, age, and nutrition; Large leaves often have high yields, small leaves have low yields
Table 2.2: Sort the leaves according to size
(Source: Assoc Professor Do Ngoc Quy 2003 )
Tea buds: tea buds are harvested by the producer, including 1 shrimp
+ 2 to 3 young leaves; The weight of 1 bud depends on the young age and tea variety:
Shan(Tuyet) tea varieties and India: 0.8 - 1.0 kg
Trung Du tea variety: 0.5 - 0.8 kg
Chinese tea varieties with small leaves: 0.3 - 0.5 kg
Introduction to Matcha
Matcha green tea powder is derived from Tencha, a specially cultivated tea that is shaded from sunlight for 2-3 weeks prior to harvesting This shading process enhances the color of the leaves, resulting in a vibrant dark green hue and promoting the secretion of beneficial compounds.
Types of leaf Large Medium Small
Matcha, a powdered form of green tea rich in chlorophyll and the amino acid theanine, has a history dating back nearly 1,000 years, originating during the Tang Dynasty in China Initially used in Buddhist ceremonies in the 13th century, it gained prominence in Kyoto in the 16th century when tea master Sen no Rikyu established the traditional tea ceremony known as "chanoyu." The preparation of matcha involved roasting and grinding tea leaves into a fine powder, which was then mixed with water and salt The introduction of tea to Japan is credited to Eisai, a Buddhist monk who brought tea seeds and knowledge of cultivation methods from China in 1191, promoting the benefits of green tea throughout the country.
According to Eisei's book "How to Stay Healthy by Drinking Tea," tea serves as a remarkable remedy that enhances the quality of life and has the extraordinary ability to extend human longevity Regions where tea trees are cultivated and consumed tend to enjoy longer lifespans Additionally, Buddhist monks have historically created matcha by grinding tea leaves into a powder, similar to their methods for preparing other medicinal plants.
2.2.2 The main chemical composition of Matcha and their value: a L-theanine:
L-theanine (γ -glutamyl-L-diethylamide) is an amino acid found in green tea and mushrooms; has molecular formula , Its molecular weight is 174,20g mol-1 which soluble in hot water [2]
L-Theanine reduces the negative effects of caffeine - commonly known as a stimulant found abundant in tea and coffee When taking high doses of caffeine (250mg, equivalent to 2.5 cups of coffee) there will be some negative effects such as increased anxiety, increased blood pressure The combination of caffeine and theanine will significantly improve alertness, reduce fatigue, and reduce the increase in blood pressure Moreover, the L-Theanine in tea also has an antioxidant effect It restores the antioxidant capacity of liver cells, helps prevent liver damage [2][7] b Tannin:
Tannins, a crucial component in assessing tea quality, are classified as polyphenols, with catechins making up 90% of this group Among these, epigallocatechin-3-gallate (EGCG) stands out as the primary polyphenol, representing approximately 12% of the dry weight of tea.
- For tea plants: regulating redox processes in tea plants, improving tea's resistance to tea pests and diseases
Tea quality and properties are determined by the oxidation process; unoxidized tea results in green tea, while tea that undergoes oxidation with yeast transforms into black tea Yellow tea is produced based on varying levels of oxidation.
Tannin, found in tea, boosts the body's resistance, promotes hemostatic effects, and enhances the absorption and storage of vitamins Additionally, tannin contributes to refreshing the body and may aid in treating certain intestinal diseases.
Catechin, a powerful antioxidant present in tea leaves, plays a crucial role in preventing cellular aging This colorless, water-soluble compound exhibits a varying degree of bitterness and comprises approximately 85-90% of the tannins found in tea.
Alkaloid is colorless compounds, bitter in taste, and slightly soluble in water In tea, there are many types of alkaloids but the most are caffeine
The caffeine content of Trung Du tea accounts for 3-5% of the dry matter
- For man: Caffeine has a stimulating effect on the central nervous system which stimulates the ability of the heart to function, has a diuretic effect
- For tea quality and properties: Caffeine has little variation during processing When caffeine combines with tannins, tea forms scum called Tannat- caffeine compounds, has a pleasant taste [6] d Chlorophyll:
Chlorophyll, a key pigment found in plant leaves, especially in tea leaves, plays a crucial role in photosynthesis It is synthesized through a metabolic process involving succinyl-CoA and glycine There are two primary forms of chlorophyll: Chlorophyll a (C55H72O5N4Mg) with a molecular weight of 893.48, and Chlorophyll b (C55H70O6N4Mg) with a molecular weight of 907.46.
Chlorophyll is commonly included in toothpaste and gum formulations to effectively combat bad breath and promote fresh breath Additionally, incorporating chlorophyll into your diet aids in detoxification and boosts resistance against cancer and various diseases Chlorophyllin is also utilized in numerous products aimed at weight loss and the prevention of degenerative diseases, including atherosclerosis, hypertension, diabetes, and Alzheimer's.
Production, consumption and exporting of green tea powder matcha in the world
In 2018, tea exports from Tokyo, Japan, reached a record high, driven primarily by the rising popularity of matcha-based drinks and desserts in the US and Asian markets During the first five months of the year, Japan exported 1,978 tons of green tea, marking a 4% increase from the same period in 2017 and the highest export volume since 1988 The Japan Tea Producers Association highlights that matcha leaves are a significant contributor to this growth, with an average selling price of 3,100 yen ($30) per kilogram, compared to 1,400 yen for sencha.
In 1998, Suzuki's Marushichi Seicha, a renowned Japanese tea producer, began producing green tea powder, commonly known as matcha To date, the company has successfully exported over 30 tons of matcha to key international markets.
The global demand for green tea powder, particularly matcha, is on the rise, with significant usage in ice creams and desserts In 2019, Japan exported over 5,000 tonnes of matcha, primarily to the United States, highlighting its growing popularity across regions including the US, Europe, Africa, and the Middle East.
According to government data, matcha imports from Japan have surged to ten times their volume from two decades ago, with China, Sri Lanka, India, and the United States being the primary importers This growing popularity has led many major café chains in the United States to incorporate matcha into their menus.
In recent years, green tea lattes have gained immense popularity, with matcha becoming a favored ingredient in desserts Over the past 25 years, matcha sales in the United States have surged fivefold, exceeding $10 billion.
Figure 2 Matcha Market: Market Size by Region, Global 2018
The biggest matcha demand is North American and European countries In
In 2016, the Asia-Pacific region dominated the global matcha market, driven by traditional tea consumption in Japan and China The market was valued at $2.62 billion and experienced a compound annual growth rate (CAGR) of 9.3% from 2018 to 2022, with a projected steady growth rate of 4.60% expected through 2027.
Figure 3 Global Matcha Market by Region 2020 – 2027
(Source Internet: Maximizemarketresearch.com 2020) Use in foods and supplements:
Market segmentation for matcha reveals two main types: direct beverages and additives used for flavoring or coloring in various foods Additionally, matcha can be categorized by application into three primary forms: drinks, cakes, and ice cream While traditional green tea consumption in Japan is declining, matcha's popularity is on the rise, driven by changing lifestyles and the need for innovation within the tea industry Today, matcha is predominantly enjoyed as a beverage, with various by-products such as smoothies, lattes, and juices also gaining traction Furthermore, matcha is incorporated into products like mochi rice cakes, soba noodles, and green tea ice cream, highlighting its versatility in modern cuisine.
Matcha, a finely ground green tea powder, is recognized for its extensive pharmacological benefits and is increasingly used in the pharmaceutical industry as a functional food Notable products include Matcha Japanese Catechin Functional Food and Kirkland's Green Tea, which combines Sencha and Matcha, highlighting the versatility and health advantages of this superfood.
Functional foods, such as those offered by Vhealth in Vietnam, provide numerous health benefits including anti-aging properties, cancer prevention, detoxification, and fat loss These Matcha-containing supplements also support bodybuilding, prevent and treat gingivitis and gastritis, reduce the risk of diabetes, strengthen bones, alleviate arthritis, lower high blood pressure, and enhance memory while combating Alzheimer's disease Additionally, they may help prevent HIV infection, protect against radioactive contamination, lower blood sugar and cholesterol levels, and fight bacteria and flu viruses.
Matcha powder is rich in antioxidants, including EGCG and polyphenols, providing 20 times more antioxidant power than vitamin E, 16 times more than blueberries, and 80 times more than broccoli This superfood effectively addresses various skin issues, offering antibacterial and anti-inflammatory benefits, treating acne, absorbing excess sebum, deeply cleansing and tightening pores, and preventing signs of aging such as wrinkles and crow's feet.
Matcha green tea cosmetic products have gained significant popularity in the market, offering a variety of options including matcha green tea cleansers, masks, lip balms, makeup removers, and acne creams These products harness the natural benefits of matcha to enhance skincare routines and promote healthy skin.
Production, consumption and exporting of green tea powder matcha in Vietnam
Since 2016, the popularity of Japanese matcha has surged in Vietnam, recognized for its numerous benefits in beauty, weight loss, anti-aging, and culinary applications Despite this growing trend, Vietnam continues to rely on importing matcha each year.
The matcha manufacturing industry is thriving in response to the growing domestic demand for organic products Popular matcha-infused items in the local market include Cozy green tea biscuits, AFC's Kinh Do brand green tea-filled biscuits, Richy's green tea butter cake, Tibo's Tipo Huu Nghi brand green tea biscuits, and Vinasoy's Soymen soy milk, which is marketed as the first soy milk specifically for men.
In 2013, the price of green tea powder in Vietnam varied between 700,000 and 1 million VND, while matcha green tea powder in Japan was priced 2-3 times higher In Vietnam, the matcha market primarily caters to two key segments: food and beverage additives.
Matcha Ntea adheres to rigorous procedures and standards to produce high-quality organic green tea powder, with prices averaging around 70,000 VND for a 50-gram pack In 2019, the company successfully exported 1,005 products to the domestic market Currently, Ntea Thai Nguyen's matcha and other tea products are popular in Vietnam and are also exported to international markets, including Japan, Korea, the US, and Germany The company offers a variety of product lines to cater to diverse consumer preferences.
Ntea has garnered significant recognition and support from leaders at both the central and local levels, receiving a merit certificate from the Thai Nguyen Provincial People's Committee for its contributions to provincial activities The company has also become an official member of the Vietnam Tea Association, the Vietnam Association of Small and Medium Enterprises, and the International Federation of Organic Agriculture Movements (IFOAM) Additionally, Ntea was honored in the "TOP 100 ASEAN Famous Brands - Products/Services" program in Bangkok, Thailand, and achieved accolades in the TEA Masters Cup 2016 competition held in Vietnam and Korea, as well as the 2017 ASEAN Outstanding Product and Service Brand Award in Myanmar.
CHAPTER III STATUS OF THE CONSIDERED ISSUE AT THE
Object and scope of the study
Survey of Matcha green tea powder process at Ntea Viet Nam J.S.c in Dong Hy- Thai Nguyen
Size of Ntea Viet Nam JSc in Dong Hy- Thai Nguyen
Location and Time
Ntea Thai Nguyen Joint Stock Company at Van Huu Village - Hoa Thuong Commune - Dong Hy District - Thai Nguyen Province
Research contents
Surveyed matcha green tea powder production process at Ntea J.S.c in Dong Hy- Thai Nguyen
Surveyed the standards applied for products system at Ntea Company: 5S process, ISO certification in manufacturing and product quality control, and Biocert-IFOAM certification.
Research methodology
- Directly involved in the production
- Refer to Company Documents and related documents from various sources.
Green tea powder manufacturing process at Ntea Vietnam J.S.c in Dong Hy-
3.5.1.1 Management processes: a.Automatic watering system:
The tea hill utilizes factory-installed water jets linked to a sensor system that monitors environmental indices, enabling the development of a cloud computing environment for data storage This integration allows for active control through connected devices like phones and computers, significantly reducing labor costs and enhancing tea tree productivity Additionally, the use of enzyme USA Biofertilizer, organic microbiological preparations, nano silver, and organic fertilizers made from chili, lemongrass, and garlic further contributes to the overall efficiency and sustainability of tea cultivation.
Since it is an organic product, the cultivation always uses organic substances From 10 months to 1 year, cutting tea will be done once, in order to rest tea trees
Ntea Thai Nguyen mainly uses existing tea hills The land reclamation process at the company is as follows:
Silver nanoparticles are microscopic particles, averaging only about 6-12 nanometers Silver nanoparticles are often used to kill bacteria because they have
21 a large surface area, increase the ability to contact bacteria, thereby supporting better sterilization
Nano-silver is currently produced directly from pure silver, resulting in exceptionally pure nanoparticles Utilizing electrolysis with pure silver electrodes for sterilization on tea plants achieves nearly complete bactericidal effectiveness, eliminating up to 99.99% of bacteria.
Mix 50ml of nano-silver with 20 liters of water, spray evenly on the surface of leaves, spray down the wind, according to each bed
Silver nanoparticles exhibit exceptional fungicidal properties, surpassing traditional plant protection agents Their small size leads to a higher concentration of atomic particles on the surface, resulting in increased flexibility as surface energy decreases This allows atoms to detach more readily, enabling silver nanoparticles to release positively charged ions (Ag+) These ions effectively target and eliminate fungi and pathogenic bacteria through a specific mechanism.
Nano-silver exhibits a potent bactericidal mechanism through its absorption properties When Ag+ ions are released, they rapidly bind to the negatively charged cells of microorganisms via electrostatic attraction, leading to their penetration and subsequent destruction This process occurs swiftly, enhancing the resistance of tea plants against harmful pathogens Additionally, nano-silver interacts with peptidoglycan, the polymer that constitutes the cell walls of these microorganisms, further contributing to its antimicrobial efficacy.
Silver ions (Ag+) disrupt the cell wall function of most bacteria, hindering their ability to transport oxygen and affecting their metabolism When Ag+ interacts with the membrane of pathogenic bacteria, it reacts with the thiol (-SH) groups of oxygen-carrying enzymes, inactivating them and inhibiting bacterial respiration Additionally, nanosilver binds to microbial DNA, preventing replication and inhibiting bacterial growth.
Nano-silver effectively eliminates viruses, fungi, and bacteria that threaten tea plants and agricultural land It is safe for human health, even at high doses, and contains no chemical additives or harmful residues This makes nano-silver a sustainable option for long-term use without the need to switch to other biocides.
Enhance the ability to absorb light for the leaves thereby enhancing the plant's photosynthetic efficiency
Enzyme USA Biofertilizer organic microbiological preparation:
Dosage of 1-3 liters of EMZ-USA per hectare depends on the ecosystem Activate the enzyme before spraying The activation procedure is as follows:
Step 1: Dilute 1 liter of Enzyme with 100 liters of clean water (ratio 1/100) and 3 liters of molasses or 3 kg of brown sugar, mix well
Step 2: Incubate the mixture for 48-72 hours until the surface appears thick film and the mixture is dark brown During the incubation process, it must be
23 kept in a dry place, avoiding insects flying in
Step 3: After incubation is complete, spray the mixture on tea hills The mixture can be used for 14 days from the date of activation Spraying Enzymes after fertilizing and after rain will help the enzyme penetrate faster and work better Normally, Enzyme is sprayed every 2 months
Making soil porous, promote nitrogen fixation for the soil by microbiological pathways for the soil
Composted for 3-5 months from agricultural products, green manure crops, animal manure
Note: when using supplies such as agricultural residues and farm animal manure, it must be certified organic
Applying organic fertilizer twice a year, in the rainy season
To create a flavorful fermented mixture, combine equal parts chili, lemongrass, and garlic, then puree the ingredients and add water Allow the mixture to ferment for 15 days in a sealed container stored in a cool location This preparation can be used for up to 4-5 months.
When spraying, spray evenly on the surfaces of leaves, spray down the wind direction to limit flying into the eyes of workers causing burning
This herb has a spicy odor and is effective in repelling and destroying the pests of plants In addition, it also works against fungi and bacteria
Figure 5: Simulate the organic green tea powder manufacturing process a Plucking (Harvesting):
Figure 6: Simulate tea collection process
Before harvesting tea, workers are equipped with clean gloves, protective clothing, hats and masks, and boots
Tea is picked when it is old enough and picked on non-rainy days
Harvest cycle from 1-2 months/time
Tea should be hand-picked, avoiding metal effects on the tea plant
Cleaning tea and transfer to a dry place so that the temperature in tea leaves is stable before being processed
To collect tea to be raw materials for Matcha, tea is classified in category 2 (type B) with >10-20% old leaves according to Vietnamese standards TCVN 1053-86 [7] and TCVN 1054-86 [4]
- High-quality tea, tea buds are picked according to the standard of 1 apical bud 1 leaf (a new bud sprouted and a young leaf just below it)
- Production materials require high quality, tea is usually collected at the beginning of the crop
- The tea buds harvested for organic green tea production are fresh tea buds with 1 apical bud, 1 young leaf, not crushed, rancid, and having a strange smell
When harvesting tea, it is essential to avoid crushing the leaves and to prevent the presence of pests and diseases If the infestation of pests and diseases exceeds 70%, the quality of the tea must be downgraded, and affected leaves should be discarded to maintain overall quality standards.
- Picking tea at the right age and right time
- Limiting the collection of tea on heavy rainy days (except for long rains) causes difficulties for the processing process and low-quality tea
- During the harvesting process, do not compress too much or let it sit for long on the hill, causing steam absorption, affecting the quality of the finished Matcha
- Tea after being harvested must be transported immediately to the place of processing and preservation, to minimize possible defects such as rancid, sour,
Figure 7: Tea farm at Ntea, Dong Hy, Thai Nguyen b Withering process:
After harvesting, the tea is brought to the wilt
Freshly picked tea leaves are spread evenly on a well-ventilated net that measures approximately 20cm in length To ensure optimal drying conditions, the net is positioned 30cm above the ground and exposed to 40% light, preventing contamination from dirt and impurities.
Withering time for tea typically spans 4 to 5 hours, during which the leaves are shaken every 1.5 to 2 hours In adverse weather conditions, the shaking duration is reduced to 1 hour per session to facilitate proper air circulation and heat dissipation Additionally, the company employs a fan to enhance the withering process.
In rainy and windy conditions, it is essential to continue tea picking to ensure the leaves wilt quickly and prevent rancidity This process helps to facilitate faster drainage of water from the surface of the tea leaves During withering, it is important to minimize mechanical disturbances to the tea mass to maintain quality.
At the conclusion of the wilting phase, temperature and humidity influence the physicochemical and biological processes in tea buds, leading to flexible tea leaves with a water content of approximately 60-62% Excess moisture can prolong enzyme deactivation, causing matcha powder to appear yellow rather than green, ultimately diminishing product quality.
The purpose of this stage is to reduce a certain amount of moisture, facilitate biochemical reactions, through that, the tea will retain its natural aroma Request:
The wilting process significantly reduces the water content in tea leaves, resulting in a profound alteration of their cell structure This leads to a decrease in both the mass and surface area of the leaves, making them softer and more pliable Consequently, this transformation enhances the efficiency and speed of the subsequent tea-drying process.
- The total amount of tannin (a bitter-tasting polyphenol compound) will be decreased by 2-3%
- The chlorophyll in the wilting process is also reduced by 30-40% compared to the original, so tea after wilting will have an olive green color and reduce the pungent odor
- Protein is converted into soluble amino acids, increased caffeine, vitamins, chlorophyll, starch, especially vitamin C are reduced
Factors affecting tea wilting process:
To maintain the quality of tea, especially Matcha, it is crucial to avoid exposing it to direct sunlight, as this can accelerate the wilting process and diminish its natural green color Proper storage in a shaded location is essential for preserving the tea's integrity.
Tea should be placed in a dry, airy place, high ground to avoid dirt, impurities affecting tea quality c Enzyme- Deactivation Process:
The factors influence the accumulation of some chemical compounds in tea
Light plays a crucial role in regulating plant growth and development Research indicates that there are significant differences in amino acid concentrations when comparing plants exposed to natural sunlight versus those grown in shaded conditions This variation in total amino acids highlights the impact of light on plant physiology.
Research indicates that tea leaves grown in natural sunlight have a 44.3% lower concentration of beneficial compounds compared to those shielded from direct light Covered tea plants yield higher quality tea, as their aroma is softer compared to naturally grown varieties Light intensity significantly influences the synthesis of beneficial compounds in tea, particularly L-theanine, an amino acid unique to tea leaves and abundant in Matcha, which contributes to the sweet umami flavor of green tea L-theanine is synthesized from the roots and is converted to polyphenols in the leaves through sunlight exposure To enhance quality, tea plants are typically covered with a black net for 20-30 days to reduce direct sunlight However, excessive shading can lead to a decrease in L-theanine levels, highlighting the need for balanced light exposure.
Harvesting time in Vietnam's Thai Nguyen province is significantly influenced by the region's climate and natural conditions, which are characterized by three distinct seasons: early, mid, and late.
The early season, or spring tea season, spans from late February to mid-April, marking the period when tea plants begin to bud and the first phase of tea harvesting occurs During this time, the sunlight is weak, and the new tea buds are still fragile, resulting in a lower concentration of beneficial chemical compounds Consequently, the quality of tea harvested at the beginning of the season tends to be less than perfect.
Mid-season (also known as summer tea season, the main season): counted
From May to September, the optimal conditions of ambient temperature, humidity, and sunlight significantly enhance the growth of tea trees, leading to high-quality tea buds This period not only boosts tea productivity but also promotes the formation of beneficial chemical compounds in the buds.
The last season, or autumn tea season, spans from October to December In this period, lower ambient temperatures and reduced humidity compared to summer contribute to the hardening of tea buds, resulting in a decrease in beneficial compounds due to the impact of weak sunlight.
To achieve the highest quality matcha, tea leaves are harvested between April and September Early-season harvests yield tea rich in amino acids, resulting in a fresh flavor, while late-season leaves contain higher tannin levels, imparting a slightly acrid taste to the matcha.
The chemical composition of tea is influenced by various factors, including the tea variety, season, leaf age, climate, and growing conditions Selecting high-quality tea varieties is crucial for achieving optimal crop yields and product quality, ultimately enhancing the economic viability for tea growers.
Tea is primarily categorized into two types: Chinese and Indian Chinese tea features small leaves that thrive in cold climates, boasting a high amino acid content ideal for green tea, which is characterized by a green-yellow hue and a rose-like aroma with a sweet flavor In contrast, Indian tea, known for its larger leaves, has lower cold tolerance and a high polyphenol content, making it perfect for black tea production, which is distinguished by its bright red color and bold, clear taste.
Japan cultivates over 80 tea varieties, but only five—Yutakamidori, Sayamakaori, Yabukita, Kanayamidori, and Okumidori—are primarily used for matcha production These specific varieties are favored due to their low tannin content, rich natural aroma, and superior flavor and taste quality during green tea processing.
Vietnam is renowned for its diverse tea varieties, including Trung Du tea, Shan tea (Tuyet), PH1 tea, A1 tea, and TRI777 tea In the tropical monsoon climate of Thai Nguyen, the region predominantly cultivates Trung Du tea, characterized by its small wooden stems and medium-sized leaves measuring 12-14 cm in length and 5-7 cm in width The buds weigh between 0.70-0.78g, and tea plants aged 10-25 years can yield 8-10 tons of buds per hectare, while those in poorer soil and under vegetarian cultivation produce only 2.5-3 tons per hectare This variety is primarily processed into black tea, green tea, and matcha powder, meeting export standards with tannin levels exceeding 26.3% and solubility at 51.4%.
Surveyed the standards applied for organic tea products at Ntea Company
The 5S process, developed in Japan, serves as a fundamental framework for establishing product quality assurance systems It emphasizes the importance of maintaining a clean, organized, and efficient work environment, which not only enhances employee morale but also boosts labor productivity By fostering such conditions, organizations can effectively implement a robust quality management system.
S1- Sort: Remove unnecessary items from each area
Sorting means classifying and organizing items in an order This is the first
45 step that businesses need to take in 5S process The main content of S1 is to classify, remove unnecessary things, and sell or reuse [15]
S2- Set in Order: Organize and identify storage for efficient use:
Once you've eliminated unnecessary items, the next step is to organize the remaining items efficiently, ensuring they are easy to find, visible, accessible, and simple to return.
S3- Shine: Clean and inspect each area regularly:
Maintaining a clean workplace is essential for enhancing the working environment and minimizing risks and accidents Regular general cleaning and daily maintenance of equipment and work areas help improve the accuracy of machinery by reducing the impact of dust.
S4- Standardize: Incorporate 5S into standard operating procedures:
The initial routine maintenance and standardization of the 3S system is crucial for its effective implementation To ensure the 3S principles are consistently upheld, it is essential to create standard procedures that clearly define each person's responsibilities regarding 3S, as well as the methods and frequency of its application at the site.
S4 is also a process in which the compliance awareness of employees in an organization is forged and developed
S5 - Sustain emphasizes the importance of assigning responsibility, tracking progress, and maintaining the 5S cycle in the workplace By fostering a culture of self-discipline and compliance with regulations, employees become more self-aware of the significance of 5S practices This heightened awareness encourages each team member to proactively integrate 5S standards into their daily tasks, ultimately enhancing both individual productivity and overall corporate efficiency.
The main goals of the 5S process:
- Building a sense of innovation for everyone in the workplace
- Develop leadership roles of leading officers and managers through practical activities
- Building foundations for inclusion in improved techniques
- Building team spirit among everyone
The meaning of the 5S process:
- Building an organization/business image, bring opportunities in business management
- The workplace is convenient and safe
- Raise a sense of discipline in the agency
- Officers and employees are proud of their workplace
3.7.2 ISO certication in manufacturing and product quality control:
On September 1, 2005, the International Organization for Standardization (ISO) released the ISO 22000:2005 standard, developed by ISO/TC34 This international standard focuses on food safety management systems, addressing the needs of consumers and stakeholders globally ISO 22000:2005 effectively integrates Hazard Analysis and Critical Control Points (HACCP) and Good Manufacturing Practices (GMP) in food production, streamlining the implementation of management systems within organizations By adopting ISO 22000:2005, organizations can significantly reduce effort and costs, particularly when simultaneously complying with ISO 9001.
Achieving ISO 22000:2005 certification signifies that a food supply chain enterprise has implemented effective management systems, ensuring food safety and quality This recognition assures consumers of the safe and reliable food products provided by the certified organization.
ISO 22000:2005 is a comprehensive food safety management system designed to enhance the food supply chain Developed by international experts in the food sector, it integrates key principles from the Hazard Analysis and Critical Control Point (HACCP) system to ensure food hygiene This standard is aligned with the guidelines set forth by the CODEX Alimentarius, a joint agency of the Food and Agriculture Organization (FAO) and the World Health Organization (WHO), aimed at establishing robust food safety standards globally.
Steps to implement a food safety management system according to ISO 22000:2005:
Step 1: Find out the standard and determine the scope of application:
Company leaders need to understand the meaning of ISO 22000: 2005 for organizational development, direction of operation, identification of objectives and specific conditions of application
Step 2: Creating a food safety management team: Applying ISO 22000:
In 2005, the establishment of a food safety management team became essential, comprising a Team Leader and representatives from departments implementing ISO 22000:2005 The food safety team leader acts on behalf of the company’s leadership to oversee the application of the ISO 22000:2005 system and holds responsibility for ensuring compliance in this area.
Step 3: Assessing the current status of food manufacturers against the requirements of standards: It is important to consider the activities, consider the requirements and extent of the food manufacturer’s response This assessment is the basis for planning human resources that need to be changed or supplemented Thereby, the company builds detailed programs and projects to ensure control of food safety hazards at all times when consumption
- Achieved ISO 22000: 2005 certification, allowing companies and businesses to compete in international markets In the domestic market, this can help the company stay one step ahead of its competitors
- Thanks to a systematic approach, risks are controlled more efficiently, quickly, and flexibly
- Since the risk points are pre-defined, production defects should be avoided, thereby reducing production costs
- Food poisoning is completely prevented
- All consumer food safety needs are fully met
- Everyone working in the organization is aware of food safety and hygiene issues
- Delivery time is done exactly
- Guaranteed consumer satisfaction from which to get their trust
Every product produced must adhere to strict quality and quantity standards Any errors encountered during production must be thoroughly documented and investigated to determine their causes and appropriate solutions Once the quality inspection confirms that the product meets the updated standards, it will be released to consumers.
Every factory has a Quality Control (QC) department that ensures quality throughout the production process This department meticulously inspects samples, evaluates raw materials, examines packaging, and oversees all stages of production to maintain high standards.
Figure 15: Certification of food hygiene and safety
IFOAM, the International Federation of Organic Agriculture Movements, was established in 1972 during a conference in France organized by a French farmer organization With 870 members across 120 countries, IFOAM plays a crucial role in promoting organic agriculture globally.
The organic industry has undergone extraordinary changes in phases: Organic 1.0, Organic 2.0, and Organic 3.0
Organic 1.0: Pioneers from around the world Organic 1.0 was started by numerous pioneers, who observed the problems with the direction agriculture was taking at the end of the 19 th century and beginning of the 20 th century They saw the need for a radical change[17][9]
Organic 2.0: Norming and Performing: There is more and more evidence highlighting the positive impacts of organic on a range of important issues including consumer health, biodiversity, animal welfare and the improved livelihoods of producers[17][9]
DISCUSSION AND LESSON LEARNED
DISCUSSION
Research on matcha and its applications in food and functional products is extensive; however, counterfeit products that fail to meet international quality standards are increasingly prevalent This thesis investigates the production process of organic green tea powder at Ntea Thai Nguyen Joint Stock Company, where strict adherence to manufacturing protocols is essential for maintaining the quality of this organic product Key processes such as steaming and crushing significantly influence the matcha's quality, taste, and color Ntea's matcha organic green tea powder not only complies with all quality standards but is also competitively priced, offering a quality comparable to Japanese matcha It is versatile, used in beverages and beauty products, with popular beverage forms including hot drinks, cold drinks, and ice cream Additionally, Ntea Thai Nguyen produces 4-in-1 milk tea products featuring matcha, which have garnered positive consumer feedback, positioning the company for growth and stability in both domestic and international tea markets.
Ntea Thai Nguyen is committed to delivering 100% organic products of the highest quality The company continually enhances its infrastructure and upgrades its equipment, fostering an environment that supports product development and aligns with its visionary goals.
LESSON LEARNED
After 4 months of my internship at Ntea Thai Nguyen company I have given myself lessons, experiences, responsibilities at work, have been exposed to a real and serious working environment; be engaged to work as an official employee It is necessary for me as well as other students can be ready to work after graduation
However, due to the limited internship time and the influence of the Covid-
The COVID-19 pandemic briefly disrupted my internship, but this experience ultimately enhanced my skills and adaptability I gained valuable insights into completing tasks effectively and preparing for potential challenges in a professional work environment.
CONCLUSION
Following my internship at Ntea Thai Nguyen, where I transitioned from theory to practice through data collection via interviews, observations, and hands-on involvement in production, I completed my thesis titled "Survey of Matcha Green Tea Powder Process at Ntea Vietnam J.S.C in Dong Hy, Thai Nguyen." This research addresses several key issues related to the matcha green tea powder production process.
I thoroughly investigated the production process of Matcha green tea powder at Ntea Thai Nguyen, focusing on every stage from cultivation to the final product My hands-on experience in production revealed that creating a high-quality organic green tea powder requires adherence to stringent steps and regulations.
To enhance the quality of tea products, it is essential to evaluate the factors influencing the accumulation of specific chemical compounds in tea, as well as the changes these compounds undergo during processing By understanding these elements, we can develop targeted solutions to improve tea quality in the future.
Ntea Thai Nguyen Joint Stock Company adheres to stringent quality standards, ensuring food hygiene and safety through its ISO 22000:2005 certified processing stages Recognized by the Vietnam Tea Association and awarded by Biocert International for its commitment to delivering safe, high-quality products, the company emphasizes quality as a competitive advantage, with customer satisfaction as a key measure of success.
59 policy of a closed production process that meets organic standards, confidently brings consumers high-quality organic products
The company has yet to reach full operational capacity and relies on a significant workforce due to incomplete automation To enhance production efficiency and machinery quality, it is essential to address issues with production equipment Implementing advanced solutions can effectively tackle external challenges, ultimately boosting product productivity and achieving optimal results.
1 Documents circulated internally by Ntea Vietnam company
2 Dang Thi Thanh Quyen (2007) Research on green tea powder matcha production technology and application in some foods, Doctoral thesis
3 State Science and Technology Committee (No 265-QĐ – 1986), Fresh bud tea- Method of determining the content of old leaves - TCVN 1053-86, Ha Noi
4 State Science and Technology Committee (No 265-QĐ – 1986), Fresh bud tea- Method of determining the water content of outside the buds- TCVN 1054 – 86, Ha Noi
5 Associate Professor Do Ngoc Quy, Nguyen Kim Phong (1997), Vietnamese
6 Associate Professor Do Ngoc Quy (2003), Vietnamese Tea: production, processing, and consumption, Nghe An Publisher
7 D Le Tat Khuong, M Hoang Van Chung, M Do Ngoc Oanh (1999), Tea Curriculum, Agricultural publisher
8 Pham Thi Hong Dieu (2010) Effecting of tea variety and material quality on resistance to Bacillus Subtilis, Bacillus Cereus and Proteus Sp, Graduation thesis, Ha Noi Agricultural University
9 The IFOAM NORMS for Organic Production and Processing version July 2014
10 ORGANIC 3.0 for truly sustainable farming and consumption version 2016(pp.5-7)
11 Espen Fikseaunet (2016) Land of the Rising Tea - An Introduction to Global and Japanese Tea History
12 Yukihiko Hara (2001) Green tea: Health benefits and applications
According to T.H from Reuters (2012), Vietnam's tea production and export statistics have shown significant trends over the years The comprehensive data and forecasts highlight the country's evolving role in the global tea market For detailed insights, visit the source at VinaNet, accessed on April 3, 2020.
14 Thuy Chung (Source: VITIC) (2020) - Tea export markets in 2019 (accessed on 11/06/2020): http://vinanet.vn/thuong-mai-cha/thi-truong-xuat-khau-che-nam-2019-
Organic fertilizer EMZ-USA enhances plant and soil vitality, promoting healthier growth and improved soil quality For more information, visit the US Fertilizer EMZ-USA Blog.
16 Adam Henshall (2019)- Improve Organization with 5S: The Theory Behind Marie Kondo (accessed on 11/06/2020): https://www.process.st/5s/
17 VietNam Standards and Quality Instimute (VSQI) (2016) - ISO 22000
(accessed on 15/06/2020): http://www.vsqi.gov.vn/iso-22000-a43
18 IFOAM ORGANICS International - About IFOAM- Organics International (accessed on 19/06/2020):