Rooibos-Processing: From Field to Cup
4. From the Rooibos Branch to the Silage Cut
At the cutting site, the Rooibos harvested the previous day is processed. Due to the dry air and cool nights, almost no histamines form in the cut Rooibos.
The bundled branches are untied and gradually fed onto a conveyor belt. This conveyor belt leads the branches into a rotary cutting machine. The cutting blades, resembling a propeller with four staggered knives, chop the branches at high speed into lengths of 1.5 to 5 millimeters. To maintain consistent quality, the blades must be sharpened with a grinder every hour.
The branches are not only cut but also slightly crushed. This step releases plant compounds that oxidize during fermentation. This process develops the characteristic amber hue and the unmistakable aromas of Rooibos. These attributes give Rooibos its distinctive flavor and its name, which translates to “Red Bush” in English.
The chopped Rooibos is collected in a silo and then spread in a heaped row on the Tea Court.
5. Fermentation of Rooibos
In the afternoon, around 3:00 PM, the fermentation process begins. The Rooibos, which has been heaped in rows on the drying yard since early morning, is evenly irrigated. This step triggers the "sweating" or fermentation process, during which Rooibos develops its characteristic color and unique aroma.
During the approximately 15-hour fermentation process, the tea is aerated multiple times: three to four times until 6:00 PM, then again at 10:00 PM, 2:00 AM, and 5:00 AM the next morning. This regular aeration keeps the temperature of the Rooibos stable. Ideally, it should remain at 38°C, within a range of 34°C to 42°C. A drop below 34°C can result in a bitter taste, while temperatures above 42°C may lead to a bland flavor.
Fermentation is essentially an oxidation process. Naturally occurring enzymes in the plant trigger chemical reactions that change the color from green to deep amber. At the same time, aromatic compounds are formed, making Rooibos truly unique.
6. The Drying Process of Rooibos
In the morning, around 6:00 AM, the drying process begins. The fermented Rooibos, which now feels creamy to the touch, is first aerated several times and then pressed. A tractor drives over the rows of Rooibos, pressing out the red liquid formed during fermentation from the needles into the woody pieces (stokkies). This ensures that even the stokkies retain their red color.
Care is essential: pressing too hard could impair the quality of the Rooibos. After pressing, the Rooibos is pushed to the center of the drying yard and spread across the area using a machine. Brooms and scrapers are then used to smooth smaller piles, creating a thin, even layer across the drying yard.
During the drying period, the Rooibos is arranged in stripes. Between these stripes, rooibos-free concrete areas quickly heat up under the sun. Several times a day, the Rooibos is shifted onto these sun-warmed areas to ensure an even drying process.
After approximately nine hours, the Rooibos is sufficiently dried. This is checked using a moisture meter: if the residual moisture content is below 8.5%, the tea is ready for further processing. The Rooibos is then collected from the drying yard using a machine, filled into large sacks, and prepared for transport.