Ep 1. Tea Bags

Inside the Factory is a British televison programme that takes viewers on a tour of various factories around the country, showcasing the manufacturing processes of some of our favourite products. In the Season 3 premiere episode, titled Tea Bags, we get a behind-the-scenes look at the making of the iconic English cuppa.

The episode begins at the tea fields in Kenya, where the majority of the tea used in UK tea bags is grown. To guarantee a perfect cup of tea, it all starts with the harvesting process. We learn that the age of the leaves on the tea plant is critical to the flavour of the tea. Younger leaves are picked for high-end tea while more mature leaves are used for standard teabags. The harvested leaves are then quickly transported to the processing factories in Kenya and Malawi.

At the factory, we get to witness a fascinating process of sorting and blending the leaves to get the perfect taste. We see how the teas are initially sorted by machines and then by experienced tea tasters. Over 300,000 cups of tea are tasted in a year, and the process involves a careful analysis of factors such as taste, aroma and colour. The tea tasters have highly developed senses and are able to identify and describe subtle differences in the teas, like the difference between black tea and green tea. They are even able to detect when tea has been over-processed or is of lower quality.

After sorting and blending, the tea is put through a rolling process. The leaves are spread out on rollers and rolled to extract the juices, which gives the tea its distinctive colour and flavour. The rolling process is followed by a drying process that involves baking the tea leaves, which makes them brittle and easier to handle. At this point, the leaves are ready to be shipped to the UK to be put into tea bags.

Now comes the main part of the episode: the making of the tea bags. We see how the tea is packaged into the paper pouches and sealed using a heat-sealing machine. The tea bag machines are some of the fastest in the world, producing over 2000 bags a minute. Tea bags are typically made of filters made from wood pulp, and these are folded into the familiar rectangular shape and filled with tea.

One of the most fascinating aspects of tea bag production is the shape of the tea bag. We see how designers create intricate patterns and shapes in the tea bags which add not only to the visual appeal but also to the taste. The shape of the bag affects how the tea diffuses in the water and therefore how the tea tastes. The designers use different folds and cuts to create the perfect shape for each type of tea.

Finally, we learn about the packaging process. The tea bags are packed into boxes and then shipped to stores around the UK and the world. Drying is an essential part of the packing process to ensure the tea does not become mouldy or spoil. We are also informed that the quality of the tea bags is continually tested throughout the chain to the consumer, from the tea field to the tea cup.

The episode ends with a fascinating insight into the world of tea tasting. We see how trained professionals taste tea and assess its quality in controlled environments. We also learn about the different types of tea - such as green tea and white tea - their health benefits and how they are processed. The final word is on the importance of tea as part of British culture and how tea production remains an industry of immense importance to the UK economy.

In summary, this episode of Inside the Factory takes viewers on a journey through the fascinating world of tea production, from the fields of Kenya to the tea cups of the United Kingdom. The programme provides an illuminating insight into the process of tea bag production, and showcases the technology and skills that go into creating the perfect cup of tea. Balancing informative content and stunning visuals, this episode is a must-watch for anyone who enjoys a good brew!