Tea Production in Sri Lanka - Cultivation and Processing

Cultivation and Processing

Over 188,175 hectares (727 sq mi) or approximately 4% of the country’s land area is covered in tea plantations. The crop is best grown at high altitudes of over 2,100 m (6,890 ft), and the plants require an annual rainfall of more than 100–125 cm (39–49 in).

Tea is cultivated in Sri Lanka using the ‘contour planting’ method, where tea bushes are planted in lines in coordination with the contours of the land, usually on slopes. For commercial manufacture the ‘flush’ or leaf growth on the side branches and stems of the bush are used. Generally two leaves and a bud, which have the flavour and aroma, are skilfully plucked, usually by women. Sri Lanka is one of the few countries where each tea leaf is picked by hand rather than by mechanization; if machinery were used, often a considerable number of coarse leaves and twigs could be mixed in, adding bulk but not flavor to the tea. With experience the women acquire the ability to pluck rapidly and set a daily target of around 15 to 20 kg (33 to 44 lb) of tea leaves to be weighed and then transported to the nearby tea factory. Tea plants in Sri Lanka require constant nurturing and attention. An important part of the process is taking care of the soils with the regular application of fertilizer. Younger plants are regularly cut back 10–15 cm (4–6 in) from the ground to encourage lateral growth and are pruned very frequently with a special knife.

The tea factories found on most tea estates in Sri Lanka are crucial to the final quality and value of manufactured tea. After plucking, the tea is very quickly taken to the muster sheds to be weighed and monitored under close supervision, and then the teas are brought to the factory. A tea factory in Sri Lanka is typically a multi-storied building and located on tea estates to minimize the costs and time between plucking and tea processing. The tea leaves are taken to the upper floors of the factories where they are spread in troughs, a process known as withering, which removes excess moisture in the leaf. Once withered, the tea leaves are rolled, twisted and parted, which serves as a catalyst for the enzymes in the leaves to react with the oxygen in the air, especially with the production of black tea.

The leaves are rolled on circular brass or wooden battened tables and are placed in a rotating open cylinder from above. After rolling is finished, the leaf particles are spread out on a table where they begin to ferment upon being exposed to heat. However, the preliminary heat is from the natural air temperature, so fermentation times fluctuate according to the temperature and humidity. Regulating the temperature, humidity and the duration of fermentation times requires a great deal of attention, and failure to follow the exact guidelines will make the flavor of the tea disappear. As oxidization occurs the colour of the leaf changes from a green to a bright coppery color. It is now that artificial heat comes into play as the fermented leaf is inserted into a firing chamber to prevent further chemical reactions from taking place. The tea leaves are fired to retain the flavour after the fermentation process is complete. Again the regulation of the temperature plays an important role in the final quality of the tea, and on completion the tea will become black and harder.

Grading (ordered by size in Sri Lanka) then takes place as the tea particles are sorted into different shapes and sizes by sifting them through meshes. No artificial preservatives are added at any stage of the manufacturing process and sub-standard tea which fails to initially comply with standards is rejected regardless of the quantity and value. Finally, the teas are weighed and packed into tea chests or paper sacks and then given a close inspection. The tea is then sent to the local auction and transported to the tea brokering companies. At the stage of exporting the Sri Lanka Tea Board will check and sample each shipment after the completion of packing to ensure that the finest quality tea is exported and then it is finally shipped in various forms of packing to many parts of the world.