tea manufacturing process part 1
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Tea ManufacturingProcess of
Rathnayaka Tea (Pvt) Ltd
Presented by : Group A & C
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Content
• Introduction• Rathnayaka Tea (Pvt) Ltd• Tea Plucking• Withering• Rolling• Fermentation
• Drying• Sorting & Grading• Storage & Packaging• Limitation• Recommendation• Conclusion
I Part II Part
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Introduction
• History of Tea• Growing Conditions• Types of Tea• Tea Growing Regions• Benefits of Tea
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History of Tea
• The second emperor of China, Shen Nung, discovers tea when tea leaves blow into his cup of hot water .
• In 1824 the first tea plant was brought to Ceylon & planted in the Royal Botanical Gardens, Peradeniya.
• The pioneer of Ceylon Tea industry James Taylor planted the first 19 acres of tea in “Loolecondra” Estate near to the Kandy.
• Tea Sector plays most vital role in Sri Lankan economy.
“ Camellia Sinensis”
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Growing Conditions
• A hot, moist Climate• Temperature ranging from 10 – 30 degrees centigrade• Average yearly rain fall, around 200mm• Ground level of between 600 – 200m above sea level
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Types of Tea
• Black Tea• Green Tea• White Tea• Oolong Tea
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Tea Growing Regions
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Health & Benefits of Tea
• Higher antioxidant capacity than fruits & vegetables.• Help to relax on human• Assist in natural immune• Response to infection• Reduce risk of heart diseases, cancers, cholesterol
level, higher blood pressure.• Reduce eye fatigue.
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Rathnayaka Tea (Pvt) Ltd
• Location
Deniyaya
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• In 1919
• 1942
• 1974
• 1979
• 1993
• 2008
• Mr. A.A.W Muhamdiram started the Rathnayaka Tea Factory.
• Properly organized the company management .
• The Rathnayaka Tea Factory was over taken by the Government.
• Rathnayaka family was able to get their company again.
• John Keells Group of Company joined with management of Rathnayaka Tea factory.
• John Keells Group of Company secession from the management of Rathnayaka Tea Factory.
History
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Current Situation
• In Present Rathnayaka Tea Factory is handling by the third generation of Rathnayaka family.
• New management had changed the factory name as
“Rathnayaka Tea Factory (Pvt) Ltd.
• They mainly produce Black Tea & export their total
production to foreign countries. Their main customer is Russia.
• They had awarded as one of “One Star Rating Tea Factory” due to the proper following of 5S’ concept within the factory.
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Product Life Cycle of Rathnayaka Tea Factory
• Now they are in Maturity Stage in their product life Cycle.
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Employees.
• Rathnayaka tea factory provide employment opportunity to more than 250 workers.
• Within the company they provide good working environment for their workers.
• The workers do their jobs every week days 7.30am to 4.30pm and also Saturday 7.30am to 12am.
• The company pay salaries & bonuses for the workers based on their work.
• They have insurance their employees.
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Tea Processing Cycle
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Plucking
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It is a process of harvesting and collecting tea leaves.
Before the tea plucking we have to maintain foliage & tipping.
There are mainly 3 types of Plucking Systems,
– Scale leaf plucking– Fish leaf plucking– Mother leaf plucking
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Mechanical Plucking
Reasons Shortage of manual labors . Low efficiency in manual plucking.
High labor wages.
Additional man power equipments.
During peak flush period necessitate mechanical .
Limitation Decline in leaves Quality.
Difficulty in using high sloppy land.
Difficulty to repair .
•Mechanical Plucking System can use when there is a scarcity of pluckers during July to September.
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Withering
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• The primary aims of withering are, to reduce the moisture content of the leaf and to soften it.
• the tea leaves are spread out on a large tray of wire mesh, and hot air blowers are used to heat the leaf and drive the moisture out.
• Withering duration is dependent on temperature and humidity and could range from 18 to 24 hours.
• At this point, the leaf has become limp and turned into a darker shade of green.
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Rolling
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• It is a process where rollers are used to rupture the cell walls of the withered leaves for oxidation of the polyphenols in the presence of oxygen from air.
• There are two methods used by manufacturers,– Orthodox– CTC
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Fermentation
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• It is the process of oxidation of leaves.• The mechanical aspect involves spreading out of the
leaves macerated by rolling a layer 5-8 cm thick, for 45 minutes to 3 hours, depending on the quality of the leaves.
• In here pay more attention to humidity & Temperature.