TEA MANUFACTURING PROCESS OF NEW FERNLAND FACTORY ULAPAne

Since our factory is depending on 100% bought leaf our process of manufacture can be categorized as
below

1. Leaf Collection

2. Processing

3. Grading

4. Packing

5. Marketing

Leaf Collection

The factory has selected number of green leaf suppliers registered with us who supply leaf to the
factory. They go to the growers who pluck their tea leaves, weigh and bag them. The lorry goes to the
small holder estates weigh the leaf and bring them to the factory.

The factory again, weigh the leaf and take over.

We maintain records of each supplier and they are paid accordingly at the end of the month. Some
suppliers take advances also and we do keep records of them and pay the balance at the payment date.

We have set standards for the leaf that we accept from the collectors as the standards of leaf directly
has a impact on the end product.

Processing

The leaf supplied by the collectors, are undergoing three staged manufacturing process as follows.

a. Withering

b. Rolling

c. Firing

In withering the leaf is put in to troughs, and make them to wither by artificial wind flow by fans then
once the leaf is withered they are put in to a machine called as roller and make them to roll and get
twisted. Then it is passed through machine called as roll breaker and the parts coming through the mesh
is taken as dhools and they are spread in the fermenting table for fermentation. This is the time that the
rolled leaf is getting oxidized and the color gets changed. The rolling and roll breaking process is
repeated for three to four times to harvest the maximum quantity of dhools and what is coming above
the mesh at last is called bigbulk.
The dhools are regularly checked in close intervals to see whether the fermentation is reached to the
required level and then it is sent through a Machine called as the drier. Once it is passed through the
drier the extra moisture is evaporated and the black tea is made.

Once the tea comes out the drier the processing part is over.

Grading

The manufactured tea is then sent to the area called as sifting room where the grading of teas take place
according to the size and appearance. Then they are cleaned by sending through a machine called as
color separator which can sort the tea according to the blackness of tea particles. There are lot of
accepted names for various sized teas.

Packing

When grading is completed the graded teas are sent to the packing room and they are packed into
special made bags. There is accepted quantity for each grade for packing and they will be numbered and
selling mark is printed on the bag.

Marketing

Once the tea is packed and bags stenciled with details the bags will be sent to the brokers warehouse
with the invoices. once they reach the brokers they value them and catalogue them to sell at the
auction.

*The factory has a way of recording every moment of the process starting from leaf weighing to filing of
sales report.

*close supervision is given to every item of the process with trained staff who are well aware of the
required standerds.

Company Introduction

Our company ESR HOLDINGS PVT LTD is a limited liability company, registered under the company
registration act of Sri Lanka and the board comprises with three directors, which deals with tea
manufacturing and plantation management at the moment. The factory is named as NEW FERNLAND
TEA FACTORY and situated in ULAPANE.