Tea ManufacturingProcess of

Rathnayaka Tea (Pvt) Ltd

Presented by : Group A & C

Content

• Introduction• Rathnayaka Tea (Pvt) Ltd• Tea Plucking• Withering• Rolling• Fermentation

• Drying• Sorting & Grading• Storage & Packaging• Limitation• Recommendation• Conclusion

I Part II Part

Introduction

• History of Tea• Growing Conditions• Types of Tea• Tea Growing Regions• Benefits of Tea

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”

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

Types of Tea

• Black Tea• Green Tea• White Tea• Oolong Tea

Tea Growing Regions

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.

Rathnayaka Tea (Pvt) Ltd

• Location

Deniyaya

• 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

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.

Product Life Cycle of Rathnayaka Tea Factory

• Now they are in Maturity Stage in their product life Cycle.

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.

Tea Processing Cycle

Plucking

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

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.

Withering

• 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.

Rolling

• 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

Fermentation

• 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.