CHAPTER 1

INTRODUCTION

1

INTRODUCTION

Name of the Tea Estate : Sholayar Estate

Address : Sholayar Estate , Sholayar Post, Valparai – 642 124

Location : Anamalai Hills, Coimbatore Dist, Tamilnadu, India

Year of Acquisition : 1946

Features : Cultivation of Green Leaf & Tea Manufacturing

Area under cultivation of tea : 395.79

Area under irrigation : Nil

Gross yield : 3570

Awards and Achievements : Award for highest yield in 1971

Certificates Awarded : FIRST ISO 9002 IN PLANTATION & FACTORY

Jay Shree Tea & Industries Ltd. is the third largest tea producer in the world. It has 22

Tea Estates spread throughout India with total area of 9407 hectares under tea plantation. We

have five Gardens in Upper Assam, five in Catcher, four in Dooars & Terai, six garden in

Darjeeling and two in South India. The company also has two tea processing factories which

manufacture tea exclusively from tea leaves procured from other gardens. With the latest

acquisitions in Africa, we now have the best teas the African Continent produces.

The company is one of the largest tea manufacturer-exporter of India having exported

teas of Rs.76.57 corers in FY 2009-10 and already achieved export turnover of Rs.45.40 corers

in the half-year ended Sept 30, 2010 and expected to cross Rs.100 corers in the current financial

year. The company has produced 234 lac kgs last year and have already produced 156.50 lacks

kgs up to 30th September 2010 as compared to 149.47 lac kgs in the same period last year. The

current year-end target is 251 lac kgs of black tea.

THE COMPANY

Incorporated on 27th October 1945, Jay Shree Tea & Industries Ltd. is a part of well

diversified conglomerate of  B.K Birla Group. B. K. Birla Group has been in the forefront of

industrialization in the country since Independence. An inspiration for generations of Indian

2

entrepreneurs, the Birlas are looked upon as the First Family of India Inc., reflecting quality,

reliability and leadership.

Besides tea, Jay Shree Tea & Industries Ltd., is manufacturer of Single Super Phosphate

& Sulphuric Acid. It recently made foray into Sugar Industry by acquiring 100% stake in

M.P.Chini Industries Ltd. It also provides Tea Packaging and Warehousing facilities at Kolkata

and Kochi.

The company is also engaged in real estate business having developed several properties at prime

locations of Kolkata and Bengaluru.

The core business of the company is Tea accounting for 75.56% of the gross turnover

with Chemicals & Fertilizers at 23.52% and others 0.92% during the half-year ended 30th

September 2010.

KEY HIGHLIGHTS

1. It is the only tea company in India having tea estates in all the major tea growing areas of

the country. All the teas of India under one roof!!

2. One of the few Indian tea companies to have tea estates abroad.

3. Contributing around 3% of the national tea output.

4. Contributing around 11% of the total Darjeeling tea, considered Champagne of teas.

FINANCIAL HIGHLIGHTS

1. 91% of the present paid-up Share Capital is represented by Bonus Issues.

2. First Group to return money to shareholders in the years 2001 and 2002 under buyback

scheme of shares.

3. Uninterrupted track record of paying dividend since inception of the company in 1945. 

Last 5 years average payout is 33%.

NEW ACQUISITIONS

As per the strategic tie up with Assam Tea Corporation Ltd. the company is  procuring

green leaf of Longai and Ishabheel  Tea Estates and operating its Longai Tea Factory  to

manufacture 6 lac  kgs of tea per annum from the current season.

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The Parvati Tea Company Pvt. Ltd. acquired by it at Makum (Tinsukia) in the State of

Assam is likely to manufacture 6 lack kgs. of black tea during the current year.

The Company through its investment arm, Birla Holdings Ltd., UAE has acquired 100%

stake in  Kijura  Tea Co. Ltd. and Bondo Tea Co. Ltd., having tea estates, producing around 14

lac kgs of tea per annum in  Uganda (East Africa). Under a joint venture arrangement, it has

acquired 60% stake of Mata Tea Co. Ltd. & Gisakura Tea Co. Ltd., Rwanda. The companies

own tea estates in the best quality tea producing belt of  East Africa producing 42 lack kgs of tea

per  annum.

The cost of producing Tea in East Africa is lower as there is not much need for

application of fertilizers and pesticides in the field because of the better soil condition. Further,

the social cost for the laborers is the responsibility of the local Government.

DIVERSIFICATION IN SUGAR

The company has acquired 100% stake in M.P.Chini Industries Ltd.having a sugar

factory at Majhaulia in Bihar with a capacity of 4600 TCD, which is being enhanced to 5500

TCD. The factory has co-generation facility of 6 MW and its own sugarcane plantation of around

1000 acres. This is one of the best maintained factories in the State of Bihar and will enable the

company to leverage its experience and expertise in managing agro based industries.

WELFARE ACTIVITIES:

Incentive for excellence in work: Apart from their normal incentive, extra incentives are given

to meritorious workers. This encourages other workers also to fall in the line of good performers.

Workers turning up regularly to work (outturn), workers plucking highest green leaf in a year

and those workers plucking more than 100 kg daily are given special prizes.

Best line maintenance: A sort of competition program is organized for improving the sanitation

and maintenance of the labor lines. Best lines are awarded with prizes and above all, Chairman,

Managing Director, President visit and share a cup of tea with the awardees. An unbelievable

and thrilling event for a worker.

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Health awareness program: These are conducted periodically on a continued basis to inculcate

a culture among the workforce for preventive measures against normal ailments.

Present Executives and their contact details.

S.K.Kardile, Group Manager

Phone: 04253-221026, 04253-221030

Awards and Achievements :

1966 -1967, 1978 & 87 Tea Board Trophy for highest yield per hectare in India

1968 Federation of Indian chamber of commerce and Industry Award for outstanding

achievement in the field of agriculture for highest yield of tea in India. The award was

presented by the Hon'ble prime Minister of India, Smt. Indira Gandhi on March 15, 1969

1987 Tea Board Chairman's Challenge Trophy for highest all India average yield

Award for highest price in 1975

Certificates Awarded: FIRST ISO 9002 IN PLANTATION & FACTORY

Welfare Activities:

Incentive for excellence in work: Apart from their normal incentive, extra incentives are given

to meritorious workers. This encourages other workers also to fall in the line of good performers.

Workers turning up regularly to work (outturn), workers plucking highest green leaf in a year

and those workers plucking more than 100 kg daily are given special prizes.

Best line maintenance: A sort of competition programme is organized for improving the

sanitation and maintenance of the labor lines. Best lines are awarded with prizes and above all,

Chairman, Managing Director, President visit and share a cup of tea with the awardees. An

unbelievable and thrilling event for a worker.

Health awareness programme: These are conducted periodically on a continued basis to

inculcate a culture among the workforce for preventive measures against normal ailments.

5

Present Executives and their contact details :

S.K.Kardile, Group Manager

S.N. JAGETIYA, Commercial Manager

ACTIVITIES INVOLVED IN THE MANUFACTURING OF TEA

The main activities carried out here are

Procurement of raw materials

Withering

Cutting

Fermentation / oxidation

Drying(firing)

Sifting

Grading

Quality evaluation

Packing

Distribution

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CHAPTER 2

COMPANY PROFILE

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COMPANY PROFILE

LOCATION : Valparai (Near Pollachi in Anamallai Hills)

YEAR OF ACQUISITION : 1946 

AREA UNDER TEA : 689 hectares

GROSS YIELD : 3405 kg/hectare

What is Tea?

Tea is a product obtained by processing the young tea shoots of tea plant. It is a good

beverage which has a great market demand all over the world, mainly in Russia . Tea contains a

small amount of necessary vitamins and minerals. It is a very good source of antioxidants which

helps in strengthening the immune system of the body

FEATURES:

Sholayar Estate & Kallyar Estate is the earliest purchased property of B.K. Brila Groups.

These two units (Sholayar & Kallyar) were purchased from the Managing Agents M/s Harrisons

& crossfield. The total planted area for both these estates put together is 1730.05 acres, most of it

planted during the First World War time from 1914 to 1918. We are carrying on with the original

planted bushes and only a small area of around 90 acres was newly planted by our company

sometimes in the early 1950s.

Sholayar Group is also the recipient of FICCI Award for excellence in agriculture.

Sholayar group was the first Tea Garden in the Indian Tea Industry to be certified ISO 9002. To

counteract high acidity and low ph due to prevalent fertilizer practices, application of agricultural

lime and dolomite to soils was carried out in these two estates as early as 1963-64. As a leading

player in innovation and development these estates also introduced Split Fertilizer application

and the using of Zinc and a higher dose of potash. The Tea Research Institute, UPASI, later

recommended these.

The group employs 1,501 permanent workers and has been receiving awards

continuously for the highest yield/Hectare in this region. This unit consists of two factories;

Workshop (MV & CTC), Hospital and School. There are 6 units of Estates for Jayshree Tea &

Industries Ltd other than Sholayar & Kallyar

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OVERVIEW OF THE COMPANY

Today with technology changing at a

pace beyond any previous expectations,

and   the world becoming a rapidly

emerging market under global economy,

Jay Shree Tea & Industries Limited - a

B.K Birla Group Company, stands to create the  most  dynamic form of conducting business by

going online. 

As a leading business house - catering for the best possible teas at the most     

competitive prices, it has already created its own niche in the market. Not only in      India but

also in Germany, Japan, U.K, Middle East and the CIS it has a steady      consumer -

oriented presence. Today by effectively harnessing the promising aspects  of the Internet , and

by  addressing every possible tea related market segment with newer value propositions and

transferring its  services across geographical  borders, it aspires to develop further,  creating

brighter  prospects for its customers. 

A new century is at the doorstep. Jay Shree Tea & Industries Limited chooses to  

respond to it thus confirming yet again its penchant for thinking swiftly and innovatively. Indeed,

its functioning mantra has always been balanced on –

Strong Foundation, Sustained Growth, and Proven Leadership.

JAYSHREE TEA & INDUSTRIES LIMITED

LOCATION : Valparai (Near Pollachi in Anamallai Hills)

YEAR OF ACQUISITION : 1946 

AREA UNDER TEA : 689 hectares

GROSS YIELD : 3405 kg/hectare

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FEATURES:

Sholayar Estate & Kallyar Estate is the earliest purchased property of B.K.Brila Groups.

These two units (Sholayar & Kallyar) were purchased from the Managing Agents M/s Harrisons

& Crossfield. The total planted area for both these estates put together is 1730.05 acres, most of

it planted during the First World War time from 1914 to 1918. We are carrying on with the

original planted bushes and only a small area of around 90 acres was newly planted by our

company sometimes in the early 1950s.

Sholayar Group is also the recipient of FICCI Award for excellence in agriculture.

Sholayar group was the first Tea Garden in the Indian Tea Industry to be certified ISO 9002. To

counteract high acidity and low ph due to prevalent fertilizer practices, application of agricultural

lime and dolomite to soils was carried out in these two estates as early as 1963-64. As a leading

player in innovation and development these estates also introduced Split Fertilizer application

and the using of Zinc and a higher dose of potash. The Tea Research Institute, UPASI, later

recommended these.

The group employs 1,501 permanent workers and has been receiving awards

continuously for the highest yield/Hectare in this region. This unit consists of two factories;

Workshop (MV & CTC), Hospital and School. There are 6 units of Estates for Jayshree Tea &

Industries Ltd other than Sholayar & Kallyar.

"Perfection in a tea cup is what we achieved here at Jay Shree Tea"

~ Mr. B.K. Birla ( Chairman )

"Our craving for excellence has been translated into success in terms of higher productivity and

better quality; we have reached out to the world by our commitment and endeavour to bring the

best to our consumers"

~ Mrs. Jayashree Mohta, Director

( Director)

"Technological upgradation and modernization is a continuous process. Factories and packing

units have ISO 9002 and HACCP certification."

~ Mr. D.P. Maheshwari ( Managing

Director)

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PHOTO GALLERY:

SHORT STORY OF THIS GARDEN:

These estates are located in the picturesque Anamallai Hills 110 Km from Coimbatore

and 150 Km from Cochi. The average elevation of these estates is 3500 to 4000 feet above MSL

and the annual rainfall varies between 110 – 150 inches. The minimum temperature falls to 60C

and the maximum temperature goes up to 290c during summer. Anamallai Dist is the highest tea

yielding district in the whole of India and most of the gardens are managed by big corporates.

This district has two growing season, April to June and Oct to Dec.

Sholayar / Kallyar is the earliest purchased properties of our company. These south units

were purchased in the year 1946 from the Managing Agent M/s Harrisons & Cross field. The

total planted area for both these estates put together is 1730.05 acres, most of it planted during

the First World War time from 1914 to 1918. Sholayar / Kallyar estates were the first to

introduce CTC type of manufacturing in South India during 1958.

Sholayar / Kallyar Estates are the first recipients in the world of the coveted ISO 9002

Certificate for a composite unit of plantations and tea factories

TEA ESTATES

Towkok Tea Estate

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Manjushree Tea Estate Sibsagar, Assam

Mangalam Tea Estate

Nahorhabi Tea Estate

Meleing Tea Estate Jorhat, Assam

Dewan Tea Estate

Burtoll Tea Estate

Labac Tea Estate Cachar, Assam

Kalline Tea Estate

Jellalpore Tea Estate

Risheehat Tea Estate Darjeeling, West Bengal

Tukver Tea Estate

Aryaman Tea Estate Jalpaiguri, West Bengal

Ananyashree Tea Estate North Dinajpur, West Bengal

CHEMICALS & FERTILIZERS

Jay Shree Chemicals & Fertilizers has two factories. One factory is located in Khardah,

near Kolkata and another in Pataudi, Haryana. The Kolkata unit manufactures Sulphuric Acid

and Single Superphosphate and the Pataudi unit manufactures Sulphuric Acid. We are marketing

the Single Superphosphate (SSP) under our Brand “Annapurna”. The company has manufactured

76,256 MT of SSP and 39,162 MT of Sulphuric Acid in the FY 2009-10 and in the current year

it targets 90,000 MT of SSP and 82,000 MT of Sulphuric Acid.

The Company has kept pace with development of technology in its field and has

continuously adopted new technologies in its processes by continuous revamping &

modernization of its plants.The process of manufacture of Sulphuric Acid was modified to adopt

latest DCDA – Technology which resulted in lowest emission levels. Similarly, both the SSP

Plants as well as Granulated Fertilizer Plant were revamped and modified with a view to reduce

emission levels and improve productivity. The Company has undertaken effective energy

conservation measures by installing a suitable Turbo-Alternator which utilizes the surplus steam

available from both the Sulphuric Acid Plants.

CHEMICAL & FERTILISERS UNITS

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The Jay Shree Chemical & Fertilisers

Unit I & II @ West Bengal & Unit III @ Haryana

OTHERS

Jay Shree InfoTech Consultants

Kolkata, West Bengal

Warehousing & Tea Export Dept.

Kolkata, West Bengal

Tea Warehouse & Sales Dept

Kochi, Kerala

ALL THE TEAS OF INDIA UNDER ONE ROOF:

Jay Shree Tea & Industries Ltd.  is an outstanding crescendo in the composition that is

the Birla Group. Besides tea, the Company is also actively involved in chemicals &

fertilizers,sugar and education.

Jay Shree Tea has gardens spread all over the tea growing regions of India, some nestled in the

frosty slopes of Darjeeling, a sprinkling of them rolling languidly over the hot and humid valleys

of Assam and Cachar, yet others tucked away in the lower Himalayan reaches of the Dooars and

the Terai and a few dotting the undulating Annamalai hills.

From Darjeeling comes the “Champagne of teas”, teasing the connoisseur with their rich-

yet-subtle essence, with flavors and aromas so rich that one of our Darjeeling gardens fetched a

record price of Rs.10,000 a kg. From Assam comes the hearty, full-bodied teas, invigorating the

sipper with their smooth malt pungency. The Blue Mountains of the Nilgiris down South yield

brisk liquors, with their tantalizing fragrance and fine flavors.

Jay Shree Tea also specializes in packaged tea, sold under the umbrella “ Birla Tea”. It

also offers customized packaging as well as designs to meet the needs of various clients, at home

and abroad. Today, not only is it a leading producer, trader and exporter, but it is also one of the

biggest producer of specialty teas, and a proud member of the Specialty Tea Institute, USA.

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Jay Shree Tea packs its teas right in the gardens to preserve their fresh aromas. Its

gardens have constantly won accolades in terms of price and productivity and several awards

over the years for quality.

Instant acceptance across the globe in countries like Australia, Japan, Pakistan, Russia, Ukraine,

Kazakhistan, Iran, Saudi Arabia, UAE, Egypt, Tunis, Germany, Netherland, Ireland, UK, USA,

Canada and in even tea producing countries like China and Sri Lanka. The well-diversified

company has been enjoying the unwavering trust of a faithful customer base for the last three

decades. At the root of its success lies its commitment to achieve 100 percent customer

satisfaction.

SOCIAL RESPONSIBILITES:

Tea industry is an extremely labor intensive one with plantation workforce hardly having

decent literacy levels. A major part of the work-force live on the estates with their families and

therefore the total population residing and directly dependent on the tea estates is quite large. The

company has to deal with many unions and hence efficient human resource management is the

key to survival and success of the company. We have excellent relations with all the unions and

the labour work-force which is proved by the fact that we have not had any labour unrest in any

of our estates.

The company takes pride in looking after its own people and has set-up facilities to

provide better living conditions for its workforce. We provide them with hygienic living

conditions, subsidized electricity and rations, schools for their children, handicraft centres for

providing vocational training, medical facilities not only to provide basic medical care but also to

take care of emergencies with subsidized medicines. There are community areas for hosting

entertainment programs etc. We also have full-fledged hospitals in a couple of gardens with fully

equipped operation theatres.

In Darjeeling , the best-equipped hospital in the district is in the Puttabong estate, which

has a 52-bed hospital, while the Dewan group of estates in Cachar has a 110-bed hospital with a

fully-equipped operation theatre. Not just this, the Sholayar and Kallyar estates in South India

also have a 50-bed hospital with OT and facilities like ECG, X-Ray, incubator, bedside monitor

and a complete clinical laboratory.

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Jay Shree Tea is concerned with the health of its employees. Medical centres at Jay Shree

Tea's various estates are doing commendable work, holding regular eye check camps, dental care

camps, pulse polio programs, blood donation camps, family planning camps, routine

immunization, snake bite treatments and maternity care.

Nature Conservancy

Jayshree Tea is proud to be eco-friendly. Its inexorable pursuit of technology has not

been at the cost of nature. The management at Jay Shree Tea is equally wedded to the

preservation of environment. Our afforestation programme has met with a  huge success, with

thousands of timber trees being planted along roadsides. We are constantly upgrading our

technical knowhow so as to effectively utilize our natural resources.

With special educational programmes being undertaken on a regular basis for the tea

garden workers and their families, they are constantly being briefed on the importance of

ecology and conservation of natural resources.

Jay Shree Tea is supported by other respectable concerns and organizations. Voluntary

organizations too, together with the management, have taken up various projects to clean village

drains and sewage; a drive for cleaner water has also resulted in fewer ailments among the labour

force.

Our top management is hands-on and is very closely involved in company’s activities

from the grass-root level ensuring the success of every task is undertaken. Our office work-force

is a dedicated lot and the company is not affected by the problem of attrition which is the bane of

all industries across the country.

NEW DEVELOPMENTS:

The company has entered into an agreement with Assam Tea Corporation Limited for

purchase of green leaf of Longai & Ishabheel Tea Estates and to operate its Longai Tea Factory

having a capacity to manufacture around 10 lacs kg of tea per annum w.e.f. the season

commencing March, 2010. The company has also entered into a Memorandum of Understanding

to acquire shares of a company having a tea factory near Makum, Tinsukia, Assam with annual

production capacity of around 11 lacs kg. per annum. This should help the company to increase

its production by around 2 million kgs. from the year 2010 – 11.

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SUGAR

The company has acquired 100% stake in M.P.Chini Industries Ltd. having a sugar

factory at Majhaulia in Bihar with a capacity of 4600 TCD, which is being enhanced to 5500

TCD. The factory has co-generation facility of 6 MW and its own sugarcane plantation of around

1000 acres. This is one of the best maintained factories in the State of Bihar and will enable the

company to leverage its experience and expertise in managing agro based industries and

harnessing the same for growth of all its stakeholders.

OVERSEAS ACQUISITIONS FOR TEA

The company has entered into a joint venture agreement with Rwanda Mountain Tea

SARL,Rwanda in East Africa and has formed "Tea Group Investment company Ltd."(TGIC) at

Dubai through its offshore investment arm "Birla Holdings Ltd." at Dubai to acquire 60% stake

in Mata Tea Co. Ltd., and Gisakura Tea Co. Ltd.,Rwanda, East Africa which was owned by

OCIR-THE, the Government of Rwanda.The said companies owns two tea estates namely

'MAta' and 'Gisakura' in Rwand, the best quality tea producing belt in East Africa producing 4.1

mn. kgs. of tea per annum.The Government of Rwanda has recently issued the notification for

allotment of the said two tea companies to TGIC and the process for acquisition shall be over

within a month's time. The company has also entered into a marketing tie-up with Rwanda

Mountain Tea SARL, Rwanda for the sale and marketing of around 6mn.kgs. of tea from its

existing tea estates whereby it shall utilize its international marketing network to drive better

value for Rwandan teas. Both these acquisition and tie-up shall be in long term interest of the

company. The company through its investment ,Birla Holdings Ltd.,Dubai has entered into a

share purchase agreement with the owners of Kijura Tea Co. Ltd.and Bondo Tea Co. Ltd., to

acquire 100% stake in the said companies having tea estates producing around 1.2 mn.kgs.of tea

per annum ar Uganda in East Africa. The total investment for the aforesaid acquisitions in

Rwanda Nad Uganda is to the tune of US$ 6.5 million (equivalent to Rs.29.25 crore only)for

control of around 11.3mn.kgs.in East Africa.

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CHAPTER 3

ORGANIZATIONAL CHART

17

ORGANIZATIONAL CHART:

GROUP MANAGER

SHOLAYAR KALLAYAR

ASSISTANT MANAGER

OFFICE MANAGER

SALES MANAGER

FIELD OFFICER

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ASSISTANT FIELD OFFICER

SUPERVIOUSOR

LABOUR

SHOLAYAR/KALLYAR COMPARISION:

Sholayar / Kallyar estates are being run with a thin & lean management structure. The

total permanent workers including non-staff is 871, Supervisors-74, Staff-55 and Officers – 9

(including 1 Doctor).

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CHAPTER 4

PRODUCTION DEPARTMENT

20

PRODUCTION PROCESS

PROCESS FLOW CHART:

Obtaining the raw materials directly from the field

Reducing the moisture content(12-18hrs)

Cutting the withered leaves into finer material

Fermentation and oxidation takes place

Dired to remove the moisture and to obtain keeping quality and black Colour

Graded depending on the material size

Quality evaluation

Packing and dispatches

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PLANTING OUT IN FIELDS

Tea plants establish This is a very delicate operation and needs adequate planning and

proper supervision. Correctly planted in the field quickly, grow vigorously and come into full

bearing earlier. On the other hand, a slight error during planting can cause high percentage of

mortality or permanent setback to the plants.

NURSERY:

Polythene sleeves of 150 g may be used in the nursery. It

is recommended to use a 10 cm lay-flat polythene tube of 30 cm

length. The lower three-fourths of the sleeves may be filled with

jungle top soil with appropriate proportions of sand to make it a

sandy loam. The top one-fourth portion of the sleeve should be

filled with the rooting medium. Both the soils should have a pH of 4.5 to 4.8 and EC below 0.05

dsm-1. Single nodal cuttings and the grafted plants are prone to pestalotia attack for the first to six

weeks after planting. Contact fungicides like mancozeb at the rate of 30 g in 10 litres may be

applied for protecting the rooting cuttings from pestalotia attack. Planted cuttings should be

inside the nursery 'Pandal' for six to eight months and then transferred to the open space for

hardening.

TIME OF PLANTING:

June and August are the recommended seasons for planting for the areas receiving south

west and north east monsoon season respectively. Periods of heavy rains should be avoided. One

year old plants are planted in pits with a dimension of 30 X 45 cm. Double hedge system with a

spacing of 135 X 75 X 75 cm ( plant population 13,000 / ha ) is recommended. The selected

plants for planting should have 14 to 16 healthy mature leaves and the root system should have

reached the bottom end of the sleeves at the time of planting. The stem at the collar region

should be about pencil thick and brown.

TYPE OF PLANTS USED FOR PLANTING:

Only healthy plants 40-60 cm high with at least 12 good mature leaves and of pencil (0.5

cm) thickness (at collar) should be taken for planting in field. In general, 9 to 12 month old

22

plants attain this stage. Sub-standard plants should be discarded. Before plants are removed from

nursery, they should be hardened by gradual exposure to full sun. Transportation of the plants to

the planting site in field should be done with utmost care and only after proper labeling.

TYPE OF PLANTING (PROCEDURE FOR GROWING PLANT):

There are two types of planting, i.e., pit planting and trench planting.

PIT PLANTING:

This method is followed when spacing between plants is wide enough to allow digging of

individual pits of proper size and without much difficulty. Pits should be about 45 cm wide and

45 cm deep, circular and straight walled. Smaller pits restrict root growth and retard shoot

growth and development. The excavated soil is conditioned by mixing with 4-5 kg well-

decomposed cattle manure or 150-200g well-decomposed oil cakes and returning the soil into the

pits. No other manure is used except 30 g rock phosphate and 30g SSP at the time of planting.

TRENCH PLANTING:

This method is adopted for closer spacing and in heavy soils. Trenches 30 cm wide and

45 cm deep are dug along the rows. The excavated soil is conditioned and returned back as in

case of pits and tea is planted directly on the trenches.

METHOD OF PLANTING ( PROCEDURE FOR CREATING PLANT ):

There are two methods of planting, for plants raised in nursery beds. They are bheti

planting and stump planting.

BHETI PLANTING:

Here, the plants are lifted along with the bheti and the roots intact from the nursery bed.

This is convenient with plants grown in ploythene sleeves, which reduces difficulty in

transportation, reduce root damage and gives a very high percentage of survival. The polythene

is removed carefully by slitting the tube and the bheti is held in the pit half-filled with the

conditioned soil in such a manner so that the top of the bheti is flushed with the ground surface.

30g rock phosphate is added at the bottom of the bheti and the pit is filled with soil with

23

adequate ramming. At about 5 cm depth 30g SSP is added around the bheti and the pit is filled

up to the collar of the plant with soil. Adequate ramming is necessary to prevent sinking of the

pit level later, which will cause localized water logging. The same method can be used for plants

grown in sleeves.

STUMP PLANTING:

Plants are lifted from the nursery bed without having any soil around the roots. The shoot

portion is cut off 15-20 cm from the collar and the excess roots trimmed off before putting them

into the pits. This method is generally followed with overgrown nursery plants and has the

advantage of easy transport and reduced chances of withering after planting. However, the

percentage of survival is much less than bheti planting.

PLUCKING:

Plucking round describes the time interval in days between consecutive plucking. The plucking

rounds should be maintained at around 10 days during the high cropping months and at about 15 days

interval during the low cropping months

STANDARD OF PLUCKING:

Black plucking removes all above tipping level, except unopened buds.

Standard plucking leaves buds and small one and buds on the bush, remainder plucked to

tipping level.

Coarse plucking leaves buds, one and buds and small two and buds on the bush, remainder plucked

to tipping level.

24

SYSTEM OF PLUKI:

PESTS:

Major Tea Pests

Sucking Pests Chewing Pests

Insect pests Mite pests Caterpillar

a. Looper

Tea Mosquito bug Red Spider Mite b. Bunch

Thrips Scarley Mite c. Red Slug

Jassids Pink Mite d. Red stem borer

Tea seed bug Purple Mite e. Flush worm

Beetles

a. Cockchafer Beetle

b. Metallic Green Beetle

c. Orange Beetle

d. Cerambycid Stem

e. Borer

f. Cerambycid root borer

Termites

a. Live wood eating

b. Scavenging

25

STEPS TO MINIMIZE PESTICIDE RESIDUES IN TEA:

Monitoring and early detection of pests

Integrated pest management

Use of safer pesticides, botanicals and bioagents

Avoid repeated spraying of the same pesticide

Allow sufficient waiting period between spraying of pesticides and plucking

Spot treatment

MANURING:

Fertilizers should be applied only when the tea bushes are ready to utilize them. As a

general rule, the best time for fertilizer application is after the first rain in spring has moistened

the soil to a depth of 45 cm and there is some new growth in case of unpruned tea. In case of

pruned and skiffed teas, the fertilizers should be applied after the bushes have produced two new

leaves. A weed free clean ground is desirable at the time of manuring.

STRIPING:

Before pruning the field taking the full leaf including coarse from the tea bushes called

Stripping

PRUNING:

Pruning is one of the most important operations, next to plucking, which directly

determines the productivity of tea bushes. It is a necessary evil in the sense that it has to be

carried out periodically in spite of huge crop loss it results. If pruning is delayed, in other words

as the age of wood from pruning increases, the size and weight of growing shoots on plucking

surface decreases. To maintain the vegetative growth, pruning is necessary. The objectives are:

To renew the wood.

To provide stimulus for vegetative growth.

To divert stored energy to production of growing shoots.

To correct past defects in bush architecture.

To maintain ideal frame height for economic plucking.

To improve bush hygiene.

To reduce the incidence of pests and diseases.

26

To regulate the crop.

To facilitate consolidation by infilling of vacancies.

SIFTING FLOW CHART:

27

DRIER

Batch Weigher

Fines to 5-T Stalk Extractor

MIDDLET ON

1000 Kgs Vibro with 24 mesh

to separate to BOPF

1000 Kgs of Vibro with 10 mm perforated sheet to

separate the bulk and fines

Bulk to

3-T

Stalk

Fall through to

Middleton passed through

chottamore over 8 FCP through 8

GFOP

Middleton fall thorough to

Chottamore over 8 mesh GFOF Chottamore over 12 mesh – FBOP Chottamore over 18 mesh TGBOB

Spill of Middleton

for OPS

Middleton

Spill of the Middleton

passed through

Hex Googi 10/8 mesh

to The spill of the Googi is

passed through

Middleton with 6 mesh

MECHANIZATION:

Cultural operations such as pitting, pruning and harvesting are now being mechanized. We

recommend the use of machines for increasing the productivity of the workers. The STIHL BT 120 C

earth auger can increase the productivity of the worker nearly three times when compared to manual

method. Pruning machines with spinning discs are nearly four times more efficient than the manual

method.

Types of pruning:

LIGHT PRUNE:

Tea bushes are usually pruned every 3 or 4

years at 4 -5 cm above the last pruning cut. This

type of pruning is called light prune (LP). The

time period from one light prune year to another is

called one pruning cycle and LP is a thus, natural

sequence given at the end of a pruning cycle. It

helps to renew the wood, regulate crop

distribution, reduce pests and diseases and

maintain ideal frame height of the bushes.

HEIGHT REDUCTION PRUNE AND MEDIUM PRUNE:

However, when the tea bushes grow tall and plucking becomes difficult, they are brought

down to an optimum height by height reduction prune (HRP) at 60-70 cm, or medium prune

(MP) at 45-60 cm above ground. Both HRP and MP help in rejuvenating the tea bushes that have

become old and their yields have started declining. MP removes the knots and unproductive

excess woods and facilitate consolidation by infilling of vacancies. Medium pruning thus

provides opportunity for taking many corrective measures for improving the health and

production capacity of old tea sections. Such sections are brought back to the normal 3-4 year

pruning cycles in about 4-5 years.

28

SKIFFING:

DEEP SKIFF:

Deep skiffing (DS) of tea bushes is done normally between 12-15 cm above the last LP

mark. The DS helps to regulate crop distribution and to reduce the ill effects of drought,

excessive creep and the height of plucking table.

MEDIUM SKIFF:

Medium skiff (MS) is normally given at 5 cm over last Deep skiff mark. The objective of

MS is to regulate crop distribution, reduce the ill effects of drought, reduce the incidence of

excessive banji formation and reduce the height of plucking table.

LEVEL OF SKIFF AND LIGHT SKIFF:

Level of Skiff (LOS) is given 4-6 cm above the tipping mark mainly to level the plucking

surface. Light Skiff (LS) is usually given up to 1 cm above the previous tipping height.

TIME OF PRUNING AND SKIFFING:

In general, pruning is carried out when the tea bush is dormant and there is a good reserve

of root starch. Here the pruning is done in the month of July & August. The best time for pruning

may differ with cultivars, which can be ascertained by root starch reserve test.

SOME PRACTICES FOR BUSH DEVELOPMENT:

Some practices stated below can be followed for encouraging the proper formation of the tea

bush: Breaking the stem using thumb and forefinger 25cm above ground in such a way that at least ¼th of

the stem is remained in tact. The dried broken branches can be removed just below the broken portion by

clean pruning using 7.5cm (3") pruning knife. Decentre selectively between 15-20cm.

Debudding by nipping/removing all the growing buds from the main stem/growing shoots above

25cm from the ground. Once the branches below this height are developed, the top debudded portion is

removed by clean pruning using a 7.5cm (3") pruning knife

TIPPING:

The bushes giving leaves after pruning is called as tipping.

29

TEA PRODUCTION PROCEDURE:

Black tea manufacturing technology essentially involves disruption of the cellular

integrity of tea shoots, thereby enabling the mixing up of substrates (polyphenol) and the

enzymes (polyphenol oxidases). This results in the initiation of a series of biochemical and

chemical reactions with the uptake of atmospheric oxygen and formation of oxidized

polyphenolic compounds that are characteristic of tea along with volatile flavor compounds that

impart characteristic aroma to tea. Sholayar/Kallyar estates were the first to introduce CTC type

of manufacturing in South India during 1958, which is now followed profitably by the entire

industry in South, a big breakthrough for tea gardens of South India.

CTC refers to the Crush Tear & Curl process where the withered green leaves are passed

in-between two rollers rotating in opposite directions. There is complete maceration of the leaves

and the resulting powdery material referred to as "cut dhool" or dust. Enzymatic action is

maximum in CTC type of manufacture.

STEPS IN CTC TEA MANUFACTURE:

Withering

Reconditioning

Rolling

Fermentation

Drying

Grading & Sorting

Packing

WITHERING:

Withering is the first processing step in the factory and is a process in which freshly

plucked leaf is conditioned physically, as well as, chemically for subsequent processing stages.

Withering Troughs are generally installed in the first floor of the factory. Green leaf is spread

over a wire mesh (No.4/16 gauge) which is fitted on plenum chamber. The height of the plenum

chamber is 0.6-.76 m (2-2.5 feet) and leaf is loaded over the mesh to.20-.23 m (8-9") height or 8-

9 kg/sq. m. (2.5-3 kg/sq. ft.) of the withering trough.

30

The size of the withering trough is 30.5 m (100') long 1.8 m (6') wider or 22.9 m (75')

long and 1.8 m (6') wide. Better withering can be achieved with smaller trough 22.9 X 1.8 m (75'

X 6'). The trough should be fitted with a suitable fan to deliver the required quantity of air as per

the size of the trough. To achieve proper withering the fan has to deliver 45 CFM air for every

one square foot of trough area. For artificial withering hot air from the drier room is bulked with

outside air and used. Fans are arranged in such a way that they can draw hot air from the drier

and cool air from the atmosphere

GREEN LEAF SIFTER:

It is designed to remove extraneous matter such as stones, metal pieces etc to avoid

damage to CTC rollers. The green leaf sifter consists of a reciprocating tray powered with an

electric motor. The reciprocating tray is fitted with a mesh through which leaves are passed and

unwanted materials removed. Powerful magnets are fitted in the sifter, which removes iron/steel

particles from the green leaf.

GREEN LEAF SHREDDER:

It is a pre-conditioning machine. The machine shreds the leaves into small pieces before

sending it to the rotorvane. Besides, the green leaf shredder helps to increase the rotorvane

capacity and in efficient mixing of RC material to the withered leaf especially in the CTC type of

processing. The machine consists of a cylinder in which the main shaft having knives (blades)

rotate at a speed of 2500 RPM.

RECONDITIONING:

In South India, secondary grades and other

residues, which are obtained while cleaning the primary

grades, are ground and recycled to the withered leaf. It is

known as reconditioning. The primary objective of this

practice is to produce grainy grades as well as tea of high

density. It also helps to minimize or eliminate secondary

grade teas.

The quantity of recycled material, known as recondition dust, varies from factory to

factory; it depends on the quality of green leaf, the moisture content of the withered leaf and

31

standard of machinery available. The percentage of RC is mostly expressed on the weight of

green leaf or made tea basis. However, there is a wide variation in the moisture content of green

leaf and thereby the quantity if made tea produced. So quantifying the amount of RC material for

the made tea to be produced depending upon the green leaf conditions is difficult. The best

practice is that the RC ratio should be calculated on the withered leaf weight basis.

ROTORVANE:

It consists of a cylindrical drum of a diameter of 200 cm (8"), 380 cm (15") or 460 cm

(18"), depending on the capacity. Inside the circumference of the drum, the resistors are fitted at

appropriate distances. The main shaft, which rotates inside the drum, has vanes at equal intervals.

There is a worm arrangement in the main shaft, which facilitates forward motion of the leaves

into the drum. The leaves are crushed in between the vanes

and resistors and discharged through the diaphragm. The

RPM of rotorvane ranges from 30 to 35.

CTC-ROLLERS:

It consists of a main shaft on which the segments are

fixed by heat treatment on a mandrel form. The diameter of

the roller is generally 200 cm (8") and the latest senova

rollers are of 330 cm (13") diameter. Depending on the

capacity of the rollers, their length varies from 600 (24") to

910 cm (36"). Generally two rollers are fixed horizontally and parallel to each other and both

rotate in opposite directions. The ratio of speed between the

low speed and high-speed rollers is 1:10 depending on the

requirement of leaf or dust grade.

Note: Depending upon the market demand they can change

the grade percentage in the factory.

32

FLOOR FERMENTATION :

The rate of fermentation depends on the concentration of substrates in the leaf;

availability of oxygen, activities of the enzymes and temperature Floor fermentation is practiced

by spreading the rolled leaves on the floor to 5 - 8 cm (2-3")

height depending on the weather condition. Floor

fermentation is better than drum fermentation as the former

has better air contact with the leaves. Factories producing tea

aimed at liquor quality can adopt drum fermentation followed

by floor fermentation to achieve good liquor as well as better

appearance and density.

DRUM FERMENTATION :

It is mostly practiced in CTC tea manufacture in south

India. When compared to floor fermentation, drum

fermentation results in more density and better granulation, which give better appearance.

The fermenting drum is a simple cylindrical drum with conical feeding and discharge

ends. The standard drum is 4.8 - 6.1 m (16-20 feet) long and has a diameter of 1.5 m (5 feet) at

the cylindrical portion. The total length of the conical segment is four feet. The capacity of the

drum will be 5.2 kg of rolled dhool for every square meter area of the drum.

DRYING:

The keeping quality of tea mainly depends on the drying technique and the final moisture

content in the made tea. The objectives of drying are to terminate the biochemical changes and to

remove moisture to achieve better keeping quality. During the process of drying, water is

removed from the fermented leaf and its colour turns from coppery red to black and fermentation

is arrested.

FLUID BED DRIER :

It consists of drying chamber, plenum chamber, airflow damper and dust collectors. The

drying chamber is separated by a perforated grid plate through which high pressure hot air from

the plenum chamber gets into the drying chamber for fluidisation. The plenum chamber is

33

divided into four zones that have individual air control valves. These valves control the quantity

of air to the individual zone and the direction of hot air entering the control dampers. At the top

of the drying chamber two centrifugal exhaust fans are fitted with cyclone, one for refiring and

the other for dust extraction. When the fermented dhool is fed into the drying chamber in the first

zone it gets fluidised. With the help of pressurised hot air, water is removed by evaporation. The

inlet and exhaust temperatures for FBD may be maintained at 250°F to 260°F and 150-160°F for

achieving better quality.

VIBRO FLUID BED DRIER:

It works on the principle of 'vibrating fluidized bed'. It works on

pneumatic and mechanical power. The fermented teas are fed

through a feed system into the drying chamber. Hot air from the

heater is passed from underneath to the drying chamber through the

perforated tray carrying wet teas. The tealeaf is effectively fluidised

by a combination of air pressure and mechanical vibration.

FIBRE EXTRACTOR:

This works on the principles of static electricity. There are 4

to 6 PVC rollers arranged in a row. The PVC rollers brushes against

thick pads of felt which imparts a static electricity to develop on the

PVC rollers. When tea is fed in to this machine after firing, frictional force takes place between

fibre and the rollers. As a result static electricity is produced. The PVC rollers act as positive

charge (+) and fibre acts as a negative charge (-), thereby both attract each other and fibre is

collected from the PVC roller

AIR HEATER:

The air heater basically exchanges the heat, released from

the combustion of fuels, indirectly to raise the temperature of

ambient air for drying purposes. Tea drying is a high thermal

energy consuming operation. Hence it is essential to know the

basis of combustion for the efficient operation of heater or stove.

34

Air heaters commonly used in South India are of two types. In the first type, the hot flue gas

from the combustion chamber passes through the tubes of a heat exchanger. In the other type, it

flows outside the multi tubular heat exchanger. The former is most common and suitable for

fluidized bed driers. The selection of the stove should be based on the compatibility with the

drier in regard to heat requirement as decided by the fan characteristics such as air volume and

total pressure. Any under rating of the air heater implies burning more fuel than the stipulated

quantity and results in higher flue temperatures. The efficiency of the heater is mainly

determined by the heat transfer area, insulation, type of fuel used, combustion control and design

of the furnace itself.

VIBRO SCREEN SORTER:-

It is a simple machine that is used to grade the bulk tea from the fibre extractor into

different grades according to their size. Generally the sorter is fitted with meshes of different

size.

GRADES IN CTC TEAS:

BOPL Broken Orange Pekoe Large

BOP Broken Orange Pekoe

BOPSM Broken Orange Pekoe Small

BP Broken Pekoe

BPSM Broken Pekoe Small

PD Pekoe Dust

RD Red Dust

SRD Super Red Dust

SFD Super Fine Dust

WINNOWER:-

After grading the teas in sorter the final teas are again

given one more cleaning in the winnower by this process the

35

teas will be cleaned & stored in different bins. Depending upon the requirement the teas will be

taken for packing from the bin

DXN TEAS:

Three years back they had entered into a MOU with M/s. Daehsan Trading (India) Pvt.

Ltd., Chennai to blend their RG powder (Mushroom powder) in their own tea blend (their Assam

+ South Indian teas blend) and market the same as DXN Teas in jars. They are getting a clear

profit of Rs.35/- per kg on the tea dispatched by them. They have sent so far 28782 kg DXN

Teas in which 11473 Kg sent in this year. If this marketing effort becomes successful then they

might expand their operation by going in for flavored teas making use of the blending machine

supplied free by the Malaysian company.

36

TYPES OF TEA:

All types of tea is produced from the plant Camellia sinensis. However, all the different

varieties of tea grown worldwide, vary merely by the region it was grown in, the time of year the

leaves are plucked, and the method by which they are processed. The process of oxidation is the

primary impact of the way the leaves are processed, and the main indicator of how the tea will be

classified. The chemical process of oxidation is the natural phenomenon, by which, the enzymes

present in the tea leaves are exposed to, and chemically react with, the oxygen in the area, after

the leaves' cellular structures are broken. This process can happen quickly, through rolling,

crushing or cutting, or may be more slowly through the process of natural decomposition of the

leaves. 

WHITE TEA:

White Tea is the least processed of all teas. The tea leaves are withered to remove

moisture and then dried. The name of white tea has been derived from the bleary white 'hairs'

appearing on the unopened or recently opened buds of new growth on the tea plant. The white

tea leaves also tend to have the highest antioxidant content, as they are comprised of the newest

leaves. White tea produces a  pale yellow or green liquor. They are the most delicate in aroma

and flavour. 

GEEEN TEA:

Green Tea is subjected to the process of steaming, pan-firing, and/or rolling before being

dried to freeze the oxidation process. In most green teas very little oxidation occurs. and they are

differentiated from white teas primarily by the extra steps of manipulating or processing the leaf

before drying. Green tea produces a green or yellow colour liquor. It has flavours which range

from sweet to grassy, mixed with mild astringency.Since ancient times Green Tea has been most

enjoyed in China and Japan. In recent years, for its health-giving properties, green tea has also

gained popularity among Europeans and Americans. 

37

OOLONG TEA:

Oolong Tea also undergoes a multi-step process of pan-firing, rolling or steaming.

However, in addition, it is also set out and is allowed to 'wither', thus giving the leaf time to get

oxidized. Typically, Oolongs are bolder in flavour than the varieties of Green or White teas, and

they offer less astringency than either the stronger Black or lighter Green teas. Oolong tea is also

referred to as an aromatic tea, and it features popular flavors rich in aroma.Oolong tea is a form

of Chinese tea, which is positioned between the green and black teas. Oolong's flavour is

sophisticated, and is derived from complex production methods

BLACK TEA:

Black tea is also not an exception in undergoing similar processing to Green tea or

Oolong tea, but the difference is that, it is allowed to oxidize more completely. The liquor

brewed from black tea ranges between dark brown and crimson. The different types of black teas

deliver the strongest flavours. Black tea is the only style of tea regularly drunk with milk and

sugar and is the most popular base for iced-tea, as also used as a delicacy drink mixed with fruits,

herbs, spices.One of the features of black tea is its wide array of production areas and methods of

drinking. Although the flavours vary, the high-quality black teas abound in natural aroma,

flavour and nutrients.

PACKING:

Teas are packed in airtight containers in order to prevent absorption of moisture, which

is one of the main causes for loss of flavour during storage. Now- a - days teas are packed in

laminated jute bags using HMHDPE (High Density Poly Ethylene) liners. Teas are also packed

in Vacuum Packing. Corrugated cardboard boxes lined with aluminum foil and paper sacks

lined with plastic are also employed.

38

BOOKS MAINTAINED IN FACTORY:

Three years back they had entered into a MOU with M/s. Daehsan Trading (India) Pvt.

Ltd., Chennai to blend their RG powder (Mushroom powder) in their own tea blend (their Assam

+ South Indian teas blend) and market the same as DXN Teas in jars. They are getting a clear

profit of Rs.35/- per kg on the tea dispatched by them. They have sent so far 28782 kg DXN

Teas in which 11473 Kg sent in this year. If this marketing effort becomes successful then they

might expand their operation by going in for flavored teas making use of the blending machine

supplied free by the Malaysian company.

RG – I ( Revenue Book I)

Personnal Ledger Account

Tea Book

Green Leaf Payment Book

39

PACKING

CONSIGNMENT / AUCTION

DIRECT SALE / CASH & CARY

DXN

CARTON BOX

LAMINATED PACKS POUCHES PET JAR

Fuel Consumption Book ( Firewood, Agni, Electricity )

Packing Materials Book

Weathering Book

PACKET TEA

We are one of the players of Packet Tea Market in India having small market share in

states like Punjab, Haryana, Rajasthan, Gujarat, Uttar Pradesh, Madhya Pradesh, Orissa and

Himachal Pradesh with brands like Shaandaar, Birla Tea Premium, Birla Gold, Jaandaar, Kalline

Gold etc. We are registered supplier to Defence Forces and Indo-Tibetan Border Force. We

supply and pack teas for reputed brands also.

ORGANIC TEA

Organic teas are nature friendly, naturally grown and naturally made. The organic process

involves planting tea bushes along with leguminous plants, using herbal pesticides and natural

fertlisers. Utmost care is taken to preserve the natural flavour of tea. No chemical pesticides are

used. This is the purest way of enjoying a good cup of tea. Buyers across the world of Darjeeling

teas are now demanding Organic tea and keeping in tune with their demands our company has

converted three of our Darjeeling Estates, Tukvar, Risheehat and Sungma into 100% organic and

another tea estate Singbulli is in the process of conversion and is expected to be converted by

March 2012.

SPECIALITY TEA

We also produce Darjeeling Green Tea, Assam Tippy Orthodox Tea, Oolong Tea, White

Tea,and other speciality Tea which have good demand in global markets.

CERTIFICATIONS

All our Darjeeling Estates have Hazard and Critical Control Point (HACCP) Certification

and we are in the process of getting the certification for our Upper Assam estates. We are also in

the process of obtaining Fair Trade Certification for our Darjeeling Estates. Our warehouse in

Kolkata is ISO 22000 certified with separate storing and blending facilities for Organic and

inorganic teas. We have been recognized as Star Export House by Government of India.

40

BEST QUALITY

Our teas have good demand which is proved by our buyers list which includes the key

packeters of India and abroad. Our teas fetch higher prices than the district averages across all

the key areas like Upper Assam, Darjeeling, Cachar, Dooars/Terai and South India. Our

Darjeeling garden Tukvar (Puttabong) was the first to fetch a record price of Rs.10,000/- per kg

way back in 1992.

ADVANTAGES OF SCALE

After all the acquisitions this year we estimate to produce more than 260 lac kgs tea in

India about 60 lac kgs in Africa and 80 lac kgs sourced from others we estimate to touch 400 lac

kgs this financial itself. With such large quantity we have the flexibility and control to supply

any quality and  quantity of tea from any region to satisfy our buyers i.e. all the teas under one

roof.

DEDICATED TEAM

Employees are our best strength. We have a loyal and dedicated workforce. Our

Managing Director is the present Chairman of Tea Research Association and President of Tea

Association of India, an organization of all the tea companies of India. One of our Vice-

Presidents is the Chairperson of Calcutta Tea Traders Association. This just shows the faith the

tea industry at large has in our company.

LOWER COSTS

We have gardens in each of the key tea producing areas in close proximity and we have

active inter-exchange of resources between these gardens. Further we have invested large sums

of money in last couple of years in our factories and all of them have latest machinery which

ensures high efficiency of production. As a result we achieve high economy of scale and our

costs per kg of tea are lower compared our peers.

41

CHAPTER 5

HUMAN RESOURCE DEPARTMENT

42

EMPLOYEE DETAILS AND TRAINING REQUIREMENTS

1. Prepare a detailed list regarding the qualification, experience and professional training

undergone by individual employees.

2. Based on the above details prepare a plan for training to be given to individual employees.

3. After identification of training needs, communicate the same to respective department

dealing with training and development.

4. In house training shall be organized by the Factory in charge

HEALTH BENEFITS:

Probably, the world's most popular energy drink, tea is not merely rich in taste and

flavour, but it is also a rich source of the health essentials. Tea is a very healthy drink, which

offers a multitude of health benefits from anti-aging benefits to helping prevent several types of

cancers. In general, teas undergoing the least amount of processing like white teas contain more

antioxidants and less caffeine than other teas.

Although, the processing time increases from the making of white to green tea, from green to

oolong tea, and finally from oolong to black teas, nevertheless, all teas maintain a basic and

significant level of health benefits. 

Tea is free of calories, if taken without milk or sugar and can play a major role in

maintaining bodily fluid balance. Tea also has many other health benefits including: 

Tea contains fluoride,  thus strengthening tooth enamel and can help reduce the formation

of plaque.  It promotes the health of your teeth.

Antioxidants in varying degrees are very much present in tea (primarily in white and

green tea, but also black tea in smaller quantities), which may help to reduce the risk of

cancer (specifically, lung, skin and colon cancers).

Polyphenols are also present in tea, the substance which are thought to help inhibit the

absorption of cholesterol into the blood stream and help prevent the formation of blood

clots.

Caffeine, present as a mild stimulant in tea increases the activity of the digestive juices.

Caffeine helps stimulate the heart and circulatory system, which further aids in keeping

43

the walls of blood vessels soft, thus reducing the likelihood of atherosclerosis (hardening

of the arteries).

HEALTH BENEFITS OF WHITE TEA:

Because of the highest level of antioxidants than any other tea, white tea is great for

health.  Antioxidant aids in detoxifying the body. Antioxidants are famous for helping fight

cancer and increasing metabolism. As an added health benefit, white tea is also good for the skin

and helps improve the complexion.

HEALTH BENEFITS OF GREEN TEA:

Green tea has multiple health benefits. Green tea has the most of the EGCG complex,

which is good for metabolism. Polyphenols are also present in green tea, which the body needs

for cancer prevention  and has been known to protect against or decrease the spread of bladder

cancer, breast cancer, ovarian cancer, lung cancer, skin cancer and stomach cancer, among

others. Antioxidant in green tea boosts up the immune system, and helps regulate blood sugar.

HEALTH BENEFITS OF OOLONG TEA:

Oolong Tea is mainly responsible to burn superfluous body fat. Drinking oolong tea

during or after a high-cholesterol meal has been shown to lower the intake of fat content in the

blood. Oolong Tea also contains the most tannic acid, which is good for lowering

cholesterol. This tea is great  for losing weight, since it burns fat built up in the body.

HEALTH BENEFITS OF BLACK TEA:

It has been suggested by medical research that, black tea helps to regulate blood sugar,

lower cholesterol, lower blood pressure, and keep the blood vessels soft because of the caffeine

present in black tea. Other than this, black tea also has other health benefits like promoting

healthy teeth, skin an

44

CHAPTER 6

INFORMATION TECHNOLOGY

DEPARTMENT

45

OFFICE:

Here both the manual & Systems are used for their accounting etc. They are using Visual

Basic as Front End and Ms Access as Back End for their software’s. The Visual Basic software

is used for last 5 Years. Previously they were using FoxPro for their works. Here they are using

FoxPro for Calculating Company TDS and calculation for Deprecation on Fixed Assets.

They are using software for the following Departments.

Payroll Department

Purchase / Inventory Department

Sales / Despatch Department

Accounts Department

PAY ROLL:

Wages & payslip for labours and staffs are prepared in the Group Office and the Salary is

disbursed at the respective division musters. In the case of staff & managements the salary are

deposited directly into the bank account with SBI Valparai. All other payments like SB LWW

MB Gratuity, Bonus, and LTC etc are controlled and maintained in the office only.

Since this is an exempted unit PF contributions are remitted to Birla Industries Provident

Fund at Kolkata. As per the rule the portion of the contribution, say 8.33% is remitted to

Government providement fund towards Family pension Scheme and the balance 3.67 will be

remitted to PF at Kolkata. The Pf settlements are done by the Birla Industries Providement Fund.

46

CHAPTER 7

PURCHASE DEPARTMENT

47

PURCHASE:

Orders for Manure, Chemicals, Pesticides, Machineries & Stationery etc are placed after

obtaining and comparing quotations from various parties. Materials are stored in our stores and

supplied to divisions timely for their application in the fields. They are not encouraging any local

purchase only emergency items are purchased locally. They are maintaining stock register in the

stores. In the stores the details are maintained manually. Unless the Store order slip is issued

from the office the items cannot be move out from the store.

48

CHAPTER 8

MARKETING DEPARTMENT

49

SALES:

They are marketing their teas all over the country except Assam and Orissa. Most of their

teas are selling through consignment only.

As and when we receive orders for tea we are preparing Despatch Instruction and sending

to factories for packing teas. What ever teas are despatched to different destinations, details to

the same i.e. invoice no, grads, brand name, bag serial no qty Despatch , price etc are entered in

the different registers depending on the type of sale, payment & Form F & Form C details are

also mentioned in the respective registers to know the payment position. A separate register is

also maintained for stock of teas lying in the factories.

50

CHAPTER 9

FINANCE DEPARTMENT

51

ACCOUNTS:

Group office maintains the accounts of all divisions. The accounts are maintained in

computers and in the form of books. The account books are maintained perfectly for the purpose

of auditing and taxation. The computerized accounts are sent to Head Office through E-mail.

The group office sends all report and records of account properly to the Head Office at

the end of the every month. Trial Balance, Profit & Loss Account, Balance Sheet, Budget

Preparation are processed in this department. In Accounts department they maintain certain

books like Cash Book, Bank Book, Journal Vouchers, Ledger Book. Etc.

BALANCE SHEET AS ON- 2007 TO 2012 :

Incorporated on 27th October 1945, Jay Shree Tea & Industries Ltd. is a part of well

diversified conglomerate of  B.K Birla Group. B. K. Birla Group has been in the forefront of

industrialization in the country since Independence. An inspiration for generations of Indian

entrepreneurs, the Birlas are looked upon as the First Family of India Inc., reflecting quality,

reliability and leadership.

The core business of the company is Tea accounting for 75.56% of the gross turnover

with Chemicals & Fertilizers at 23.52% and others 0.92% during the half-year ended 30th

September 2012.

Table No : 1 : Income

Years Amount Index

2007 – 2008 191.76 100%

2008 – 2009 269.47 140.52%

2009 – 2010 326.64 170.33%

2010 – 2011 338.37 176.45%

2011– 2012 374.58 195.33%

The above table no : 1 shows the Income position from 2007 -2008 to 2011 – 2012.

From 2007 – 2008 to 2011 - 2012 the Income value shows an increasing trend from 191.76 to

374.58. The Index also increased from 100% to 195.33%.

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191.76

100%

269.47

140.52%

326.64

170.33%

338.37

176.45%

374.58

195.33%0

50

100

150

200

250

300

350

400

2007 – 2008 2008 – 2009 2009 – 2010

2010– 2011

2011 – 2012

Income

Amount

Index

Table No : 2 : Expenditure

Years Amount Index

2007 – 2008 153.49 100%

2008 – 2009 224.43 146.21%

2009 – 2010 266.13 173.38%

2010 – 2011 262.05 170.72%

2011– 2012 284.75 185.51%

The above table no : 2 shows the Expenditure position from 2007 – 2008 to 2011– 2012.

From 2007 – 2008 to 2008 – 2009 the expenditure value shows an increased trend and during

the year 2009 – 2010 the expenditure value is been decreases lightly and again during 2011 –

2012 the expenditure value is been increased the Index value also increased from 100% to

173.38% during 2007 – 2008 to 2009 – 2010 and it decreased from 173.38% to 170.72% during

2010– 2011 and it increased from 170.72% to 185.51% during 2009 – 2010.

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Table : 3 : Pro fit & loss:

Years Amount Index

2007 – 2008 25.30 100%

2008 – 2009 23.07 91.18%

2009 – 2010 36.26 143.32%

2010 – 2011 51.10 201.97%

2011– 2012 67.52 266.87%

The above table No : 3 shows the adjusted profit before Tax position from 2007– 2008 to

2011 – 2012. From 2007 – 2008 to 2008 – 2009 the value has been decreased from 25.30 to

23.07. then from 2009 – 2010 to 2011 – 2012 the value has been in increasing trend from 36.26

to 67.52. The Index value also decreased from 100% to 91.18%. From 2007 – 2008 to 2008 –

2009, then the Index value started to increase from 143.32% to 266.87% from 2009 – 2010 to

2011 to 2012.

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Index

Amount

Expenditure

2011 – 20122010 – 20112009 – 200102008 – 20092007 – 2008

300

250

200

150

100

50

0185.51%

284.75

170.72%

262.05

173.38%

266.13

146.21%

224.43

100%

153.49

25.3

100%

23.07

91.18%

36.26

143.32%

51.1

201.97%

67.52

266.87%

0

10

20

30

40

50

60

70

2007 – 2008

2008 – 2009

2009 – 2010

2010 – 2011

2011 – 2012

Profit & loss

Amount

Index

43.96 46.1142.8

50

Earnings before appropriation

Table No : 4 : Earnings before appropriation

Years Amount Index

2007 – 2008 43.96 100%

2008 – 2009 46.11 104.89%

2009 – 2010 42.80 97.36%

2010 – 2011 31.95 72.67%

2011– 2012 40.41 91.92%

The above table no : 5 shows the earnings before appropriation position from 2007 –

2008 to 2011 – 2012. From 2007 – 2008 to 2011 – 2012. There is a variations like ups and

downs in the value.

The Index value has also variation like ups and downs from 2007 – 2008 to 2010 – 2012.

55

SHOLAYAR& KALLYAR FACTORY 2010:

TEA ESTATES IN INDIA

SL.NO. GARDEN

AREA UNDER

PLANTATION

(Hectares)

PRODUCTION

(FY 2009-10) (lac

kgs)

DARJEELING, WEST BENGAL

01 Risheehat Tea Estate 256 01.81

02 Tukvar Tea Estate 437 02.32

03 North Tukvar Tea Estate 195 00.97

04 Singbulli Tea Estate 303 02.22

05 Balasun Tea Estate 353 00.88

06 Sungma Tea Estate 273 01.36

UPPER ASSAM

07 Towkok Tea Estate 646 18.46

08 Manjushree Tea Estate 616 14.09

09 Mangalam Tea Estate 105 02.26

10 Nahorhabi Tea Estate 695 14.70

11 Meleng Tea Estate 760 16.34

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CACHAR, ASSAM

12 Dewan Tea Estate 726 22.39

13 Burtoll Tea Estate 686 20.50

14 Labac Tea Estate 434 14.51

15 Kalline Tea Estate 463 12.88

16 Jelalpore Tea Estate 367 08.72

DOOARS & TERAI, WEST

BENGAL

17 Aryaman Tea Estate 222 08.96

18 Ananyashree Tea Estate 237 14.11

19 Marionbarie Tea Estate 329 06.71

20 Jayantika Tea Estate 604 13.59

SOUTH INDIA

21 Sholayar Tea Estate 401 14.68

22 Kallyar Tea Estate 299 10.22

Bought Leaves Factories 11.32

GRAND TOTAL 9407 234.00

EDP:

In this department they are generating the reports and send to the management level.

There are various functions done in this department i.e. Yield Statement, Plucking average,

Estimation of green leaf, Distribution of Hands, Manuring Statements, Weeding, DRS (Daily

Report Statement).

Fuel Efficiency Statement, etc all are compared with the corresponding previous year.

Calculation of Company TDS and Salary TDS are prepared. The Income Tax worksheet for the

staffs and managements are prepared.

HOUSE KEEPING:

Hygiene and cleanliness should be given utmost importance in the rolling room to avoid

57

bacterial contamination.

Details regarding factory layout, placement of safety equipment/fire extinguishers and first

aid box shall be made into charts and hung in the factory Office.

Fire exit signs shall be marked in each room.

All Walls inside factory & machinery shall be painted/white washed once a year or earlier

with white polyurethane enamel paint/lime.

In house training shall be provided on safety & house keeping.

Machinery and electrical maintenance shall be done only by qualified persons.

Electrical sub DBs shall carry DANGER sign and follow electrical regulations.

Packing workers/Pulverize workers shall be given dust masks.

Fused tube lights shall be replaced on priority basis. Upper limit of fused tube lights is 10

% in each area.

Brooms are specified in withering rolling, dryer & sorting area, with colored ribbons and

mix up is prevented.

SERVICE RENDED BY MANAGEMENT SOCIAL FORESTRY:

For environmental ecology all fallow areas in the Estates have been brought under the

cultivation of trees such as teak, kadam, shishom

SOCIAL WELFARE ACTIVITIES:

A 50 bed hospital with modern operation theatre and facilities for ECG, X-Ray,

Incubator, Bedside Monitor and a complete Clinical Laboratory is maintained in the Sholayar

Garden.

In Sholayar/Kallyar, there are four primary schools and one middle level school in the

Company’s own buildings, with the student strength of more than 1,100 students. First in the

Anamallai Hills, Sholayar Group has provided education with latest computer equipment to the

workers children.

SPIRITUAL UPLIFTMENT:

The beautiful Siddhi Vinayaka Temple built at Valparai by the Sholayar group in 1971 is

one of the landmarks of this area and a famous tourist attraction.

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Jay Shree Kalyanamandapam was built in Valparai and handed over to the public for

regular use for social, religious and cultural functions.

TRANSPORTING:

Important:

Final inspection should be carried out by the Factory in charge before clearance

Inspection and testing records shall be maintained in the factory for traceability.

Factory In charge should inspect the teas before arranging for transportation.

Prepare proper report/invoice.

Clean the lorry with Broom stick.

Spread tarpaulin sheet at the bottom of the cabin.

Record tare weight of the Lorry.

Load the lorry with tea bags.

While loading do not use hooks.

Cover the cabin with tarpaulin.

Record the gross weight.

Hand over the excise/dispatch documents to the lorry driver before he leaves the Factory.

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CHAPTER 10

FINDINGS AND SUGGESTIONS

60

FINDING AND SUGGESTION:

Link other plantation , jay shree is also facing shortage of labours.

Tea crop is mainly dependent on the climatic and timely execution of cultivation

operation.

Necessary steps could be taken to reduce their overhead charges.

The company has good reputation among the customers for its brand quality so they

should try to maintain the quality.

More care should be taken to improve productivity.

New technology/ mechanization should be adopted to labour force.

Adequate shortage of labour in the industry.

Due to climatic change, yields increased by year by year.

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CHAPTER 11

CONCLUSION

62

CONCLUSION

The employees who work in this organization are all knowlegeble and skillful in their

respective work. The employee of this oraganization treat their work has is workship. It was a

pleasure experience. I was able to gain new insights and comprehensive understanding about the

real industrial working condition and practices. I have more confidence to enter the industrial

world and build my future career.

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