Manufacturing Process of Tea In Kolukkumalai Estate

The Tea is being manufactured by using the following process in Kolukkumali Tea Estate.

Process 1: Withering

Withering is the first process in orthodox tea manufacture. Freshly plucked tender green tea leaves are spread on the huge trough tables with large mesh bottoms. Below the mesh was a fan system, which blew hot and cold air alternatively into these leaves causing to lose 50% of their moisture. Once the leaves turned brown, an innovative duct system helped the workers to directly transfer the leaves to the rolling machine on the ground floor for the next Process.

Process 2: Rolling

Rolling the second process was itself divided into 3 stages, which aimed at removing the juices from the leaves. Three complicated Roller machines were using pressure through a lever system of chains, the leaves were kept in the first machine for 40 minutes. After that, leaves were transferred to the roll breaking machine which separated big leaves from Small ones. Then they were transferred to the second roller machine and then again to the roll breaker. The process was then repeated with the third roller machine. Finally the small leaves were then moved on to the fermentation room.

Process 3: Fermentation

In Fermentation Room, the tea leaves brought from process second are being spread on the floor for 2 to 3 hours to make the leaves into coppery red colour. For which the minimum temperature is being maintained by using the water fan. This process is called as Fermentation.

Process 4: Drying

In this process, the fermented leaves are placed in the Drier Machine. Two wood furnaces are used to generate heat for the machine. The drier consists of different trays on which the fermented leaves pass on. The dried leaves from this process then shifted to next process.

Process 5: Fibre Extraction

The dried leaves from the above process transferred to Fibre Extractor machine using state electricity. Fibre s on the tea leaves were removed. And then good quality fresh tea is finally received here.

Process 6: Grading

The Separator Machine is assorting the tea particles into various grades according to their size. The tea, according to its sizes is being stored in big wooden cabins for more than one week to improve its flavor.