March 24, 2025

How to design best humidification system for tea factory

Maintaining the right humidity in a tea factory isn’t just a technical detail — it’s essential for preserving flavor, color, texture, and yield. A well-designed humidification system helps retain leaf moisture, supports fermentation, minimizes static, and ultimately delivers a higher-quality tea product.

In this guide, we’ll walk through why humidity matters in tea production, which systems to consider, and how to design the right solution for your facility — plus some real-world tips to avoid common mistakes.

Why Humidification is Critical in Tea Factories

Humidity plays a direct role in nearly every stage of tea production — from withering to packing. Here’s what the right moisture levels help you achieve:

Benefit	Impact on Tea Quality
Preserves leaf moisture	Prevents breakage and drying during withering and rolling
Supports fermentation	Promotes optimal oxidation, flavor, and aroma development
Reduces dust and static	Improves working conditions and cleanliness
Enhances weight retention	Helps retain leaf mass for better yield
Controls drying consistency	Ensures uniform taste, texture, and appearance

Critical Zones & Ideal Humidity Ranges

Each processing zone requires its own humidity and temperature settings to ensure consistent tea quality:

Processing Zone	Ideal RH (%)	Temperature (°C)
Withering Room	75–85%	25–30°C
Fermentation Area	90–95%	28–30°C
Drying Section	50–60%	35–45°C
Packing & Storage Rooms	60–70%	25–30°C

A common pitfall: using a one-size-fits-all humidifier across all zones. Each stage needs a tailored solution for best results.

Recommended Humidification Systems for Tea Factories

System Type	Best for	Features
High-Pressure Fogging System	Withering, fermentation rooms	Fine mist (5–15 microns), fast RH rise, no wetting, energy efficient
Ultrasonic Humidifiers	Small fermentation chambers or QC labs	Ultra-fine fog, very precise RH control
Centrifugal Humidifiers	General production areas	Good balance of coverage and cost
Steam Humidifiers	Cleanroom-like environments	Accurate but power-heavy and costly

High-pressure fogging systems are most suitable for most tea processing areas due to energy efficiency, fast humidity control, and no wetting risk.

Design Considerations for a Tea Factory Humidification System

a. Gather Requirements:

Area dimensions of each zone (L x W x H in meters)
Existing ambient RH and temp
Target RH for each zone
Power supply (single/three phase)
Water quality (RO/soft/hard water)
Automation requirement (Yes/No)

b. Estimate Humidity Load

Water required per hour (liters) = Volume (m³) × RH increase (%) × 0.3

Example:
Fermentation room = 300 m³
RH increase = 30%
300 × 30 × 0.3 = 2700 liters/hour

c. System Layout Recommendations

Withering & Fermentation Rooms:

High-pressure pump (700–1000 psi)
Fine mist nozzles (brass or SS, anti-drip)
Nozzle spacing: 2–3 meters
Automation with humidistat

Packing Room:

Centrifugal or ultrasonic humidifiers
Lower droplet output, quiet operation

Water Supply:

Use RO or soft water to prevent nozzle clogging
Install 5–10 micron filtration

Control System:

Humidity sensors with digital control
Zone-wise valves for different processing stages
Optional remote monitoring system

Maintenance Plan for Long-Term Reliability

Component	Task	Frequency
Filters	Clean or replace	Monthly
Nozzles	Descale, clean	Monthly
Pumps	Oil & routine service	Quarterly
Sensors	Recalibrate	Bi-annually