1

SUSTAINABILITY DISCOVERY PROGRAMME

REPORT

Submitted to the

XAVIER UNIVERSITY
For the fulfillment of MBA-SM

By
Soumya Ranjan Nayak
(Roll No.: us15020)

XAVIER SCHOOL OF SUSTAINABILITY (XSoS)

XAVIER UNIVERSITY, BHUBANESWAR
January 2016

ACKNOWLEDGEMENT
I have taken efforts in this project. However, it would not have been possible without the kind of support
and help of many individuals and organizations. I would like to extend my sincere thanks to all of them.
I am highly indebted to Harrison Malayalam Ltd. for their guidance and constant supervision as well as
for providing necessary information regarding the project & also for their support in completing the project.
I would like to express my gratitude towards faculty members of Xavier School of Sustainability, XIMB for
their kind co-operation and encouragement which help me in completion of this project.
I would like to express my special gratitude to Mr. Prashant and Mr. Vinod for facilitating the project and
giving me such attention and time.
My thanks and appreciation also goes to Mr. Romit, Mr. Conrad, Mr. Arun, Mr. Abhishek and Mr.
Chengappa in developing the project and people who have willingly helped me out with their abilities.

TABLE OF CONTENTS

ACKNOWLEDGEMENT ................................................................................................................................................................ 2
TABLE OF CONTENTS ................................................................................................................................................................. 3
SUMMARY ....................................................................................................................................................................................... 4
INTRODUCTION ............................................................................................................................................................................ 5
TEA STATISTICS: GLOBAL SCENARIO .................................................................................................................................. 6
INDIAN TEA MARKET OVERVIEW .......................................................................................................................................... 7
MAJOR PLAYERS IN TEA MANUFACTURING INDUSTRIES ........................................................................................... 11
ABOUT THE ORGANISATION .................................................................................................................................................. 12
HML FACILITIES ......................................................................................................................................................................... 14
FROM FIELD TO TEA ................................................................................................................................................................. 16
IMPORTANT FIELD ACTIVITIES ................................................................................................................................................ 18
WHY SHADE IS REQUIRED? ................................................................................................................................................. 26
PRUNING & SKIFFING ........................................................................................................................................................... 27
HARRISONS INITIATIVE IN SUSTAINABLE AGRICULTURE IN TEA ............................................................................. 28
(HISAT) ............................................................................................................................................................................................ 28
manufacturing process ...................................................................................................................................................................... 31
ORTHODOX MANUFACTURING PROCESS .............................................................................................................................. 32
RAINFOREST ALLIANCE CERTIFICATION ............................................................................................................................................ 38
RA CRITICAL CRITERIAS ....................................................................................................................................................... 40
SUSTAINABILITY AT HML.......................................................................................................................................................... 46
RECOMMENDATION/FEASIBLE INTERVENTION OPTIONS ................................................................................................ 48
REFERENCES ................................................................................................................................................................................. 48

SUMMARY
This report studies various sustainable practises adopted by Harrison Malayalam Limited (HML), an RPG
group company in plantation business and its concurrent direct, indirect, long-term and short-term benefits.
It provides insights about tea manufacturing process i.e. from Tea garden to Cup where it will explain and
differentiate between normal and sustainable practises that is being practised or can be adopted to bring a
considerable change. It also has series of recommendations based on observation.
It highlights the collective effort by businesses, NGOs, labour unions, and governments to restructure the
production and distribution systems of commodities to be more sustainable, while building broad market
demand for sustainable products. If done well, these improved markets will deliver large-scale social and
environmental outcomes that advance the millennium development goals and strengthen the economic
viability of entire commodity sectors and the leading companies involved.
These were developed over a one-month period, involving field visits, desk research and interaction with
field workers, factory workers, managers of various departments.

INTRODUCTION
Commercial production of tea in India began after the conquest of large areas by the British East
India Company, at which point large tracts of land were converted for mass tea production. The widespread
popularity of tea as a recreational drink began in earnest in the 1920s, after a successful advertising
campaign by the Tea Board and several mass promotion drives by the Government, using railway stations as
a base.
Today, India is one of the largest tea producers in the world, although over 70 per cent of its tea is
consumed within India itself. In this, India is also among the top 5 per-capita tea consumers. The Indian tea
industry has grown to own many global tea brands and has evolved into one of the most technologically
equipped tea industries in the world. Tea production, certification, exportation, and all other facets of the tea
trade in India are controlled by the Tea board of India.
Some of the major tea producing states of India with area under production, production season and total
amount of production etc. is shown in the map.

We dont eat it. We certainly dont need it to survive. So, why is tea so important?
Well, its hugely popular with consumers. According to figures from the International Tea Committee, the
global consumption of tea jumped 60% between 1993 and 2010 and significant growth is forecast as more
people become consumers of tea. It also has an ancient heritage, dating back 5,000 years, revealing a rich
cultural history. Today, it is the economic and social importance of tea production that is so significant.
Currently grown in 35 countries, the tea industry provides a vital source of employment and export earnings,
often in some of the worlds poorest countries. And a vast chain or network of people have a relationship
with tea not just consumers, but growers, pickers, suppliers, traders and sellers impacting on the lives
and well-being of millions of people across the world. However, the future of this much-loved beverage is
uncertain. It is grown in some of the country which is most vulnerable to future climate change making it
more susceptible to volatile weather conditions. Producers have already had to turn to irrigation for a
previously rain-fed crop, making them more vulnerable to any water shortages in the future. The land on
which tea is grown is likely to have to compete with other food crops to feed a growing population. The tea

industry faces unprecedented challenges that converge to put pressure on an industry which recognises it
needs to act if it is to create a sustainable future. There are basically ten major challenges that are significant
in terms of their implications for Tea industry which are as follows1. Demographic changes.
2. Resource constraint.
3. Climate change.
4. Competition for land and productivity.
5. Availability of labour and increase in mechanisation.
6. Balance of power across the supply chain.
7. Emergence of new business models.
8. Sustainability leadership in emerging economies.
9. Improvement in wages and labour welfare in the supply chain.
10. Consumer attitudes to food value.
An evaluation of the future of tea indicates that there is a great deal of uncertainty about what the tea sector
could look like by 2030. And this uncertainty is compounded by difficulties in predicting how these
different factors might interact with one another.
TEA STATISTICS: GLOBAL SCENARIO

Tea cultivation is confined only to certain specific regions of the world due to specific requirements of
climate and soil. Majority of the tea producing countries are located in the continent of Asia where China,
India, Sri Lanka are the major producers. African tea growing countries are located mostly around the
tropical regions where Kenya, Malawi, Rwanda, Tanzania, Uganda are major producers. Apart from these
regions, some quantities of tea are also being produced in South America (Argentina, Brazil and others), the
Near East (Iran and Turkey) and the CIS (Russia and Georgia). Globally, tea is cultivated in 36, 91,938 ha
with an annual production of 4066596 thousand Kg (Anonymous, 2010). Over the years, both area and
production has increased substantially with global trade of tea. Being an agricultural commodity whose
production is bound to fluctuate due to vagaries of nature, the prevailing differences between production and
demand is well below any reasonable limits.
Amongst tea producing countries, the principal producers are China, India, Sri Lanka, Kenya and Indonesia.
These five countries account for 77% of world production and 80% global exports.
In terms of area under tea plantation, on an average during the last two decade (1991 2010), China lead
(45%) the world followed by India (21%), Sri Lanka (7%), Kenya (5%), Vietnam (3%).

PRODUCTION AND PRODUCTIVITY

The trend of world tea production was almost the same trend as in case of area. Over the two decades tea
production has shown an increasing trend due to various reasons like increase in area for tea plantation,
improved planting material, advanced technology including integrated package and practices for tea
cultivation etc.
Unlike area and production, tea productivity did not show any significant increase over the two decades. The
global productivity during 1991 was 1026 kg/ha which climbed to mere 1100 kg /ha in 2000. In the first
decade of 21st Century, global tea productivity hovered between 1100-1160 kg/ha. Thus, the growth rate for
the two decades remained the same.

INDIAN TEA MARKET OVERVIEW

The Tea Industry in India derives its importance by being one of the major foreign exchange earners and for
playing a vital role towards employment generation as the industry is highly labour intensive. India is the
second largest producer of tea in the world and contributes to around 30% of the global tea production. The
market size of tea is estimated to be approx. 10,000 Crore with a penetration of more than 90% in the
domestic market. The tea sector in the country is largely organized since 72% of the total area under tea
cultivation and 74% of the total production comes from the organized sector. The Indian tea industry is
having thousands of tea gardens spread across various states. In West Bengal and Assam there are around
8,500 tea estates, while in the southern states of Kerala, Karnataka and Tamil Nadu there are another 5,500
tea estates. Assam produces over half of Indias tea and accounts for over 12% of the annual global tea
yield, according to ASSOCHAM.

Market Segmentation
Indian tea market is huge with large number of local and regional players. With the passage of time and due
to change in the consumption pattern, there has been diversification and value addition in tea production. In
India, tea is consumed in two forms: packaged (branded) or loose. While a major share of the market is of
loose tea suppliers, branded tea manufacturers are also fast increasing their market share. The demand for
packet tea is driven by rising consumer incomes, quality of tea and product diversification with flavoured tea
production. The share of CTC tea constitutes 80% of the tea market followed by Orthodox Tea and
Darjeeling Tea. Apart from them there are also a variety of flavoured teas such as green tea, earl grey tea,
jasmine tea, ginseng oolong, masala chai, green lemon tea, etc.
Trend in the production of Tea in India

Although tea is produced in 14 States in India, five of themAssam and West Bengal in North India, and
Tamil Nadu, Kerala and Karnataka in South India account for over 98% of Indias tea production.
Price Realisation
In India more than 50% sales of tea is routed through auction at various auction centres located in North &
South India. Tea generally moves directly from factory either to auction centre for sale or for direct sale to
national or international buyers. Auction buying is much more fragmented and there exists a sizable gap
between wholesale and retail prices. There is also a clear seasonality in prices of tea within a year. Another
of the variable explaining the variance in auction prices is unit export price. Higher export price raises the
bargaining position of sellers at auctions. Export volume also has an influence on the price formation at
auctions as higher export reduces domestic availability and hikes up domestic price. Further, lots offered and
quantity sold is inversely related with average price realization at auction.

MARKETING CHAIN OF TEA THROUGH AUCTION

Export of tea has remained flat due to increasing competition

India is the fourth largest exporter of tea in the world with major export destinations as Russia, UAE, United
Kingdom and Poland. Though tea production in India has grown over the last 10 years with a CAGR of 3%,
the export has remained more or less static due increase in the domestic consumption as well as increasing
competition from other tea producing countries. Tea export from India during 2012-13 was estimated at
around 216.23 million kgs valued at 4005.93 crore. Over the years tea export has remained flat due to
increasing competition from Kenya and Sri Lanka which are able to sell the tea at cheaper price with the
same quality level. In India orthodox tea, CTC tea are main types in which tea is produced, however, green
tea is also produced to some extent. India exports CTC grade tea mainly to Egypt, Pakistan and the UK, and
the orthodox variety to Iraq, Iran and Russia.
TEA EXPORT QUALITY & VOLUME TRENDS IN INDIA

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On account of rising tea prices and healthy domestic demand, players are expected to focus on the local
market. Moreover, import demand from few countries is anticipated to be subdued. Consequently, Indias
tea exports are estimated to decline by 5% to 195 million kg in 2014 on account of muted global prices and
weak demand from Egypt and Middle Eastern countries due to political uncertainties. On the other hand,
exports of orthodox tea, consumption of which is insignificant in India, are expected to rise by 5% to 95
million kg primarily on the back of healthy demand from countries including CIS and Turkey. In addition,
global orthodox tea prices are estimated to increase by 10% due to flat global production, particularly from
Sri Lanka, the largest exporter of orthodox tea.

CHALLENGES FORESEEN FOR THE TEA INDUSTRY

Fluctuations in the Production due to climatic changes Climate that is conducive to tea growth is one in
which there is sunlight during the day and rain at night on an almost daily basis. Although the quantum of
rain has not changed much, the frequency has reduced and the rise in temperature has adversely affected
photosynthesis in the plants. These climatic changes have resulted in lower crops as well as a higher
incidence of pests and diseases and yields are showing a downward and erratic trend. The production of tea
is not same round the year. There is a wide variation in the monthly production of tea. Although total tea
production in south India is less, but as far as the productivity is concerned they are better than rest of the
country because of the climatic condition of the Southern states. In North India, there is a dormant winter
period, therefore, the growth of tea bushes stopped and hence the productivity goes down considerably.
Climatic conditions not only affect the productivity but also the quality of leaves harvested.
Month wise Tea Production Trend in India

Slower pace of re-plantation Indias productivity has not picked growth due to slower pace of replantation of old bushes. With no substantial increase in tea acreage the increase in productivity can be
achieved through the re-plantation of old bushes. Lack of bush replantation and rejuvenation of bush health
are major deterrents for Indian tea production. Over 1, 48,305 hectare or 37% of entire Indian tea land is
hosting bushes over 50 years of age those which have crossed their optimum producing age. Compared to
that, over 70% tea land in Kenya and 68% in Srilanka are with bushes less than 40 years old. Entire tea
plantation in Vietnam is less than 20 years old and near 35% of Chinese tea plantation is less than 10 years
old.
High cost of production and low productivity The production entails risk on account of weather
conditions and falling prices. Labour cost is quite high since hand picking of tea is labour intensive. To
reduce the cost, some plantations are resorting to longer picking cycles; say 15 to 18 days against the ideal

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10 days. On top of this, they are also harvesting three or even four leave which is resulting in poor quality
and is fetching low prices. The ideal is two leaves and a bud. The high cost of production is affecting the
Assam teas competitiveness in the global market.
Increasing competition in the Global Tea Market India is a major exporter of CTC tea and faces stiff
competition from Kenya. Demand for Kenyan teas is increasing due to relatively younger bushes which are
of higher quality and is better suited for tea bags. Their labour costs are comparatively lower. Therefore, the
tea industry in Kenya is more competitive than the Indian tea industry as is reflected by Indias diminishing
leadership in key markets.
Coffee acting as a strong substitute to tea - Apart from the severe competition that the country is facing
from other tea producing countries, coffee is emerging as near perfect substitute and is posing greater
challenge to the consumption of tea as many coffee outlets have been opened by Barista, Cafe Coffee Day
and others. The branded tea players will have to aggressively take on these challenges and their success will
hinge on the supply of high quality premium tea as well as organic tea.
India needs to draw a number of initiatives in order to strengthen the stand in the global market and tap the
potential market by improving the standards of plucking thereby enhancing the quality of the product sold.
The export growth of the tea has been on a decline and this has resulted in lack of competitiveness in the
global market. New strategies aimed at adding value and reducing production and marketing costs are also
needed. Value addition and diversification for a wide range of tea products need to be developed for
balancing the supply demand scenario.
MAJOR PLAYERS IN TEA MANUFACTURING INDUSTRIES

Asian Tea & Exports Ltd

Assam Co India Ltd

A V Thomas & Co Ltd (AVT)

Bombay Burmah Trading Co

Brooke Bond

Godrej Tea

McLeod Russel India Limited

Sentinel Tea & Exports Ltd

TANTEA (TamilNadu Tea Plantation Corporation)

Tata Global Beverages Ltd

Tata Tea Limited

Unilever brands

United Nilgiri Tea Estates Co Ltd.

Warren Tea Ltd.

Wagh Bakri

Harrisons Malayalam Ltd

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ABOUT THE ORGANISATION

Harrisons Malayalam
With over 100 years of commitment to reliability and sustainability, Harrisons Malayalam has grown from
being the first natural rubber plantation in India to being one of the countrys leading natural rubber and tea
producers. Their operations are conducted through estates and factories based in Kerala and Tamil Nadu.
Committed to the profitable and sustainable growth of the agro industry, the company has implemented
various eco-friendly initiatives such as the Rain Forest Alliance and trustea certifications. It also produces
smaller quantities of a variety of other horticultural crops, such as pineapple, cardamom, pepper, areca nut,
banana, cocoa, coffee, coconut, pepper and vanilla, as well as limited quantities of organic tea and other
spices. The Company produces tea of around 180 mn kilogram per annum The Company also produces a
limited quantity of organic orthodox/ crushes, tear and curl teas. It produces rubber of approximately 10 mn
kilograms annually.
BRIEF HISTORY
HML is one of the oldest agro-based companies in India. The genesis of HML was through Harrisons &
Crossfield Limited and Malayalam Plantations (India) Ltd. Harrisons & Crossfield was established in 1844
in Liverpool, UK. The company started its operations in India in 1907. Some of the salient historical
moment are

In 1984, Malayalam Plantations (India) Ltd and Harrisons & Crossfield (India) Ltd. Merged &
consequently renamed as Harrisons Malayalam Ltd.
In 1989, the company became part of RPG Group.
In 2011, the company started functioning as two separate business units SBU A & B.
SBU-A is the business interest of RPSG, Kolkata.
SBU-B is the business interest of RPG enterprise Mumbai.

SBU-B consists of 6 Rubber Estates with a total planted area of 3716 Ha and 6 Tea estates with a total
planted area of 3250 Ha.
HML as a whole (SBU-A & B) together is the single largest grower of Natural Rubber in the country and
also single largest grower of tea in South India, spread across around 58000 acres in Kerala and Tamilnadu.
HML is based on the Mumbai, Cochin and National Stock Exchanges in India. Currently, the promoters
have a 50.31% share holding in a total equity base of Rs. 18.45 Crores.
It has been mainly a labour intensive plantation company and is the second largest employer in the state of
kerala, after Govt. Of Kerala. An equal opportunity employer, 54% of employee is women in SBU-B. 95%
of the employees are workmen in estate and factories. The other 5% includes executive managers and
supervisory staffs in various functions.
ACHIEVEMENTS & AWARD
1976- First CTC factory opened in Moongalaar Estate.
1990/1997/2001- FICCI Award for labour welfare, for corporate initiatives in family Welfare to improve
the quality of life of the employees and their dependants. Recognition for family welfare programs including
sterilisation operations by Govt. Of Kerala.
1999- Kerala state award for the best ETP plant Rubber.
2005- Golden leaf India Award for best Quality tea.

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2007- Mechanisation in Tea and Golden Leaf Indian Tea Award (TGLIA), organized by the Tea Board of
India in March 2007 at Kochi.
2010- ISO 9001:2008 certification for Head office and Engineering projects.
2010- Tea Board award for producing maximum Orthodox Tea in Southern India.
2011- ISNR 5 grade used by ISRO as a component in the
prestigious chandrayan project.
2013- Introduced TPM in tea factory.
2014- Introduce RA in Tea Estates.

LOCATION

EMPLOYEES

Head Office in Cochin, Kerala.

Estates: 11 Tea & 11 Rubber Estates in Kerala.
2 Tea Estates in Tamil Nadu.

Employee Base of around 10000.

Employing mostly women from rural areas of Kerala
and Tamil Nadu.

Factories in 11 Tea Estates & 6 Rubber Estates.

Tea Blending Unit in Coimbatore, Tamil Nadu.

ICRA LONG TERM RATING BBBICRA SHORT TERM RATING A3

Listed in BSE & NSE

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HML
FACILITIES

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FROM FIELD TO TEA

It starts from preparation of seedbed and goes on to the packing of tea. Seedlings are grown in the nursery
generally for one or two years and are transplanted in the fields. The transplanted young tea plants require
levelling and deep hoeing under shade trees. Proper growth of tea plants demand planting of shade trees,
timely application of manure and fertilizers, maintenance of good drainage, control of pest attacks and plant
diseases. Besides, pruning and plucking are essential operations for inducing vegetative growth and ensuring
continuous supply of green flushes as well as improving quality of manufactured tea.
IMPORTANT TERMINOLOGY
L E T Leaf Expansion Time: Number of days from the time of opening (flagging off) of any mother leaf
from the buds to the time when the leaf has just completed its expansion.
MULTIPLYING FACTOR (MF): Is the factor used to achieve the Target shoot when programming
harvest.
S G T(Shoot generation time) Time taken for a shoot to reach into a harvestable (Target shoot) shoot from
its bud initiation stage.
Shoot Age The SGT of the shoot is known as its Shoot Age.
Generations Shoots developing from the bud initiated on the same day belong to the same generation
irrespective of variations in their physiological stages of growth.

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Physiological stages of growth This refers to different morphologically distinguishable growth phases
during the development of a shoot from an initiated bud. These stages are; bud break, bud elongation,
1L+B, 2L+B, 3L+B etc., in a normal plucking regime.
Bud-break: From bud initiation to the time when bud has broken dormancy and shows signs of active
growth and is boldly visible at the axil.
Bud-elongation: From the time of completion of the bud-break to the time at which the first mother leaf
starts flagging off.
IL+B: From the time when the first mother leaf starts flagging off to the time at which the leaf has just
completed expansion (when the second leaf just starts flagging off) similarly for 2L+B and 3L+B shoots
Target shoot: The shoot stage, which is programmed for as harvestable shoot, considering the quality of the
shoot, weight of the shoot and manufacturing method.
Fields recovering from prune: Those Fields producing shoots after the down time from pruning.
Other Fields: All Fields except fields recovering from prune.
SGH fields: Fields where single generation harvest if practiced.
Non selective level shearing (NSLS) This term indicates the harvesting regime where, using the flat
shear/Machine harvest the Field is harvested to the table level non selectivity. In this regime, it is expected
to harvest every bush completely and thoroughly, leaving no shoot behind (Only 1 L+B of smaller in size
will be left as LOB by default)
HARVEST INTERVAL The time or period between two consecutive harvesting rounds is called as
Harvest Interval. This is to get homogeneity of target shoot growth of the desired quality & quantity at
harvest. The harvest interval is based on (Let *M.factor) and expressed in no of days.
SELECTIVITY: With fully selective plucking /Shearing, only shoots which have reached the target stage
will be harvested. In Non selective harvesting all shoots above the plucking table is harvested.
M L A: Maintenance leaf addition.
LOB :( Left on the Bush-) Shoots left on the bush after harvest.
BANJI: Temporary dormancy of the terminal bud. The terminal bud measures less than half the length of
the first expanded leaf. Increase in the abscisic acid content tilted the promoter: inhibitor ratio towards
inhibitor side which in turn influenced the formation of dormant buds in tea.

FLUSH SHOOT: The terminal bud measures more than half the length of the first expanded leaf

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IMMATURE COUNT: The succulent shoots one leaf & a bud, single leaf small tender banjis & buds are
immature .The count while doing a shoot analysis should not exceed 5 % by weight.
APERIODIC SHOOTS (Primary shoots) the shoots arising from the buds of the pruned frame.
PERIODIC SHOOTS: Flush shoots arising from the axils of leaves.
MAINTENANCE FOLIAGE: The mother leaf /Tipped leaf which provides nutrients to the growing
shoots. (The photosynthetic efficiency of the maintenance leaves starts declining from their age of six
months).Ideal maintenance foliage for tea would be 20 25 cms and the acceptable creep in bush height is
10, 7.5, 7.5,5.0, 5.0 cm in the first, second, third, fourth and fifth year fields .
PHOTOSYNTHESIS -The synthesis of carbohydrate, Uses Carbon dioxide from the atmosphere and water
from the soil in the presence of chlorophyll using sunlight as the source of the energy. (6 CO 2 + 6 H2O ---------- > C6H1206 + 6 O2).Major site of photosynthesis is the maintenance foliage.
YOUNG TEA: The period of tea plants after planting to the first formative pruning.
MATURE TEA: The period of tea which has finished the first formative pruning.
FORMATIVE PRUNING: The first pruning of the young plants
IMPORTANT FIELD ACTIVITIES

1. HARVESTING: Harvesting of tea involves regular removal of young shoots comprising an apical
bud and two or three leaves immediately below it. The shoots arising out of the sticks (frame) of
pruned bushes are called primaries.
OBJECTIVE: To harvest all target or policy shoots.
Materials & Tools: Flat shears, Harvesting Machines, Easy Weigh, Nylon bags.

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HARVESTING POLICY:
TARGET/POLICY SHOOT All 3Leaf +Bud small, 2Leaf +Bud, 1Leaf and 2Leaf Succulent Banjis.
(Target shoot should be at least 80 %).The harvest policy is for achieving maximum yield with the desired
quality of 73 % fine leaf.
TIPPING: The first plucking after the field is recovery from pruning
TIPPING POLICY: To provide adequate maintenance foliage and to induce a quick production of the
secondary branches .The following is the guideline. Tipping is started when 30% of the pruned bushes
recover with a tipping in material 3 leaves and a bud & with the required tiers of leaves above the pruning
cut as above, a fly tipping is done.
FLYTIPPING: A round of tipping is done with a small team of workers using handheld shears , while
targeting a tipping in material of 3 leaf and a bud to be harvested & retaining the Maintenance foliage
required as per the pruning height .The pl/ha used in this operation should be a maximum of 7 to 8 wkr/ha.
Fly tipping is done to induce secondary shoots early and to achieve the quality norm.
DETERMINATION OF H I: The Harvest interval for a particular season depends on the LET of that
period and the oldest generation left on the bush (LOB)
LET The time taken for expansion of one mother leaf, on to an 1 L + B or to a 2 L B, in other words the
time taken for an 1 L+ B small to become 2L + B small or a 2L + B small to become a 3 L + B small.

Target shoot 3 leaf & bud small.

small.

Target shoot 2 leaf & bud

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2. BLISTER BLIGHT CONTROL

OBJECTIVE: To control the fungal pathogens, infecting tea.
BLISTER BLIGHT caused by fungus Exobasidium Vexans
Identification Oily/white bulged lesions seen on the succulent leaves and stem.
Weather parameters favorable for blister blight infection:
Ideal temperature: 17 degree to 22 degree centigrade
Relative humidity: above 60 %
Rainfall
: Mean daily rainfall 20- 100mm.
Leaf wetness
: More than 12 hours favorable
GENERAL UPKEEP:
1. Shade regulation.
2. Weed control (Presence of weed provides a micro climate favorable for the disease).
3. Lane cutting (spraying lane should be cut at every four rows apart for free movement of sprayers at
9 wide for effective spraying).
4. Plucking: Delayed harvest, delayed tipping incomplete harvest will all interfere in the spraying
schedule and effective spraying.
5. Blister count is denoted in % and is calculated as follows:

Blister % =

No. of Shoots infected

100

Total no shoots in the sample

Threshold level 10% of infection is taken as ETL (Economic Threshold level)for the control spray.
(UPASIs 35%)
3. Pest control - Tea is prone to attack by various pests like mites, caterpillars, thrips, etc. Mites are
controlled by spraying Acaricite with water and other pests are controlled by spraying thiodan or
ekalux, etc. Fungal and bacterial diseases are controlled by spraying fungicides.
OBJECTIVE: To avoid the revenue loss due to the pest attack
Pest: Any organism that causes damage to mans health, his crops, animals, or other possessions
CONCEPTS IN PEST MANAGEMENT
Equilibrium Position (EP)

: Average density of the pest population over a long period of time.

Economic Threshold Level (ETL)

: Population level warranting control measures, Cost: Benefit ratio 1:5.

Economic Injury Level (EIL) : Lowest population causing economic damage, Cost: Benefit ratio 1:1.
Cultural control
resistant clones
Mechanical control
Biological control

: Plucking, pruning, shade management, weed control and use of pest

: Manual collection and destruction.
: Use of predators, parasites and pathogens.

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Chemical control

: Insecticides, pheromones, juvenile hormones and chemosterilants

Major Pests in Tea areLEAF: Thrips, Tea Mosquito bug.

STEM: Shot hole borer
ROOT: Nematodes
Major Mites are- Pink Mite, Scarlet Mite, Red spider mite and Yellow Mite etc.
CONTROL FOR MITES
Methodology:
Mite surveillance:

Divide the Field in to two sectors (2Ha) plots.

Collect 100 leaves samples from this plot, at random, in a transparent polythene bag.
Collect leaves from maintenance layer (mature foliage) for all mites except for pink mites.
If pink mite as the major pest is identified, take leaf samples from tender foliage.
Using a mite glass individually count the mites from the 100 leaves.
The total number of mites present/100 leaves is the mite per leaf for the plot or the MITE COUNT.
The Economic threshold level for RSM is 3 and other mites is 5
Based on the ETL plan youre spraying to control the mites.
All Cluster head /Assistant and the worker designated for the pest surveillance should carry a mite
lens (10 X or more).
The records of the mite count should be recorded in the Mite count book.
Cultural:
Shade has a profound influence on the incidence of red spider mites.
The incidence of red spider mite is higher in unshaded or inadequately shaded tea fields.
Steps to be taken to establish the recommended stand of shade.

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Biological: Red spider mites are attacked by several natural enemies, especially by predatory insects and
mites.
Phytoseiid mites, ladybird (Coccinellid) beetles and their larvae and lacewings are the common
predators.
Predatory beetle, Oligota pygmaea (Staphylinidae: Coleoptera) feeding on eggs, nymphs and adults
of red spider mite.
The larvae of the O. Pygmaea preferred the eggs and quiescent stages of red spider mites whereas
adults preferred eggs, nymphs and adults.
Entomopathogen:
Formulation of an entomopathogenic fungus, Paecilomyces fumosoroseus.
Spraying of wettable powder formulation @ 1500 g/has during evening hours, when the relative
humidity is higher, will help in achieving good efficacy of entomopathogen.
Almost similar kind of methodology is adopted to control pest, mites, Mosquito bug & Thrips.
GUIDELINES ON REDUCING PESTICIDE RESIDUES IN TEA
OBJECTIVE: To produce tea which area safe and eco friendly.
Maximum residue limits (MRL) - MRLs are defined as the maximum concentration of pesticide residue
(expressed as milligrams of residue per kilogram of food/animal feeding stuff) likely to occur in or on food
and feeding stuffs after the use of pesticides according to Good Agricultural Practice (GAP), i.e. when the
pesticide has been applied in line with the product label recommendations and in keeping with local
environmental and other conditions). Where there is an approved use of the compound on a particular crop,
or pesticide residues on imported produce ('import tolerances'), the MRL is generally set at a value
determined from field trials (i.e. where the crop has been treated with the pesticide and samples of the crop
have been analyzed to determine residue levels). MRLs can typically be less than a milligram (mg) of
pesticide residue in a kilogram of food (1mg/kg or less than one in a million) up to 5 mg/kg. As an
illustration, 0.01 mg/kg is equivalent to 1 second in 3.2 years.
PURPOSE OF MRLs
MRLs are intended primarily as a check that the pesticide is being used correctly (i.e. that the GAP is being
observed) and to assist international trade in treated produce.
ASSOCIATED HEALTH RISK IF MRL IS GREATER THAN LIMIT
The MRL is not a health-based exposure limit, and exposure to residues in excess of an MRL does not
necessarily imply a risk to health. This is because a use of a pesticide would not be allowed if the proposed
MRL resulted in long-term and short-term exposure of pesticide residues in the human diet above safety
limits (the Acceptable Daily Intake (ADI)) and Acute Reference Dose (ARFD)) which are calculated before
any pesticide approval is given. The MRL is not linked to the ADI or ARFD, and could result in dietary
intakes considerably below these safety levels.
PESTICIDES BANNED BY GOVT. OF INDIA
Dibromochloropropane (DBCP), Endrin, Pentachloronitrobenzene, Pentachlorophenol (PCP), Ethyl
parathion, Toxaphene, Chlordane, Heptachlor, Aldrin, Paraquat-dimelhyl Sulphate, Nitrofen, Tetradifon,
Paraquat and 2,4-D.
Economic Threshold Levels (ETL):

23

Pests/disease

Economic Threshold level

Tea Mosquito Bug

5% infestation

Thrips

Three thrips per shoot

Shot hole borer

15% infestation

Flushworms, Leaf rollers & Tea tortrix

5 infested rolls per bush

Red spider mites

3 mites per leaf

Pink & Purple mites

5 mites per leaf

Blister blight

10% infection

Grey blight

15% infection

Safe harvest interval (SHI): The safe Harvest intervals for the commonly used pesticides are given in the
following table.
Chemical
Propargite 57 EC (Omite or All mite or Simbaa)
Fenpropathrin 30 EC (Meothrin) *
Fenpropathrin 10 EC (Danitol) *
Dicofol 18.5 EC (Kelthane or Colonel-S) *
Wettable sulphur 80% (Thiovit 80% or Ultrasulf 80%)
Lime Sulphur
Deltamethrin *
Endosulfan *

Dosage
(ml/ha)
500
200
500
1000
1 Kg
1:40
200
1000

Safe harvest
interval (Days)
10
10
10
10
10
10
10
10

4. Weed control Weeds are responsible for considerable loss to the crop. It is estimated that dicot
weeds can cause 12% loss in the crop while grasses are responsible for 20% crop loss. Weed control
is achieved by use of paraquat dichloride, 2, 4 - D and glyphosphate. Application of weedicides in
different doses during 3-5 years and hand weeding for 2 years are also made to control weeds.

YELLOW PATCHES ARE WEEDS.

OBJECTIVE: To manage the weed population of the tea Fields and by that achieving better nutrient
efficiency from the soil.

24

WEED: The plant that grows out of place and grows where they are not needed.
CROP LOSS: 12 per cent due to dicots and 21 per cent due to monocots
Harmful effects of weeds
Competes for nutrients and moisture
Grasses are potash robbers
In grass infested areas rat menace will be more
Increases the incidence of blister blight
Alternate host for pests
Thorny weeds are nuisance to workers
Creeper weeds prevent sunlight, suppress crop and make plucking difficult.
CLASSIFICATION OF WEEDS

Based on life span

WEEDS

Biennials

Annual
s

Perennials

METHODS OF CONTROL
Cultural
practices, infilling
Mechanical
Chemical
Biological

:Mulching, raising cover crops, closer planting, higher pruning and tipping
:Weeding with tools( alvangoe ,Mechanized weeder) No slashing
:Use of herbicides
:Controlling weeds using living organisms

Hazards of manual weeding

Accelerates soil erosion

Favors multiplication of grasses
Causes damage to surface roots and collar region
Increases stress on labor availability

25

MANURING
OBJECTIVE: To replenish/improve the nutrient levels of the soil.

PLANT NUTRIENTS
MAJOR NUTRIENTS

Primary Nutrients
Carbon
Hydrogen
Oxygen
Nitrogen
Phosphorus
Potassium

Secondary Nutrients
Magnesium
Calcium
Sulphur

MINOR NUTRIENTS

Micro Nutrients
Zinc
Manganese
Boron
Iron
Copper
Molybdenum
Chlorine

Beneficial Elements
Aluminum
Silicon

MICRO NUTRIENT SPRAYING

Objective: To supply the secondary Micro nutrient viz Zn, B, Mn and Mg requirements of the tea bushes
and for correction of deficiency
Materials and tools: Aspee bolo or High volume sprayers, Zinc sulphate , Manganese sulphate , Boric acid
, Magnesium sulphate , NAA, Measurement packets, measuring jar, Drum 200 ltrs, Carbuoy, Towel,
Markers in red flag, Soap, Petrol, Kerosene, 2toil.
Policy: To supplement the critical Zinc and micro nutrient requirement of the tea bushes/tea plants during
the growing periods.
Foliar application of DAP
Phosphorus is one of vital nutrient elements that could be limiting in tea soils of south India. This element is
required for cell division and essential for growth and plays a role in the formation of new wood and root.
Without adequate P crop cannot reach the economic yield level. Any form of phosphate is water soluble
citrate soluble or acid soluble when applied to acidic soils will be precipitated as insoluble phosphates of
aluminum and iron in varying compositions. Rock phosphate is sparingly soluble in acidic soil and hence the
rate of fixation is slow and gives a continuous supply of soluble phosphorus to soil solution, out of which a
part is taken by the crop and remaining is fixed and subsequently made available in later years. Hence rock
phosphate is the suitable source of phosphorus and recommended on the basis of overall economics for soil
application in tea soils of south India.
Tea responds well to soil as well as foliar application of phosphorus. Phosphorus has been classified
as mobile within the plant and is therefore translocated with ease after absorption. The suitable source of
readily available phosphorus is DAP (diammonium phosphate NP 18:46) and conveniently applied as foliar
spray to meet the P requirement.

26

For sustainable productivity of tea, soil application of phosphorus based on soil test value and yield
level may be supplemented with foliar application of phosphorus annually at the rate of 10 kg P2O5/ha/year
in five splits.
LIME APPLICATION
OBJECTIVE: To amend the soil pH from highly acidic level to the desired level, 4.8 to 5.
(Due to leaching loss, higher inputs of inorganic fertilizer, high rain fall etc, and the pH of the soil turn to
highly acidic range, which has to be corrected to gain the expected results).
MATERIALS/TOOLS:
Agricultural lime, Dolomite, Application bags, Face masks, measuring cups.
SHADE POLICY
WHY SHADE IS REQUIRED?

level.

Regulates Temperature and increases humidity at bush level.

Shade intercepts 40 % of the radiation thereby a favorable microclimate is created at the tea bush
Minimizes loss of water through evaporation and transpiration.
Reduces injury caused by ultra violet radiation
Helps the circulation of nutrients.
Reduces the incidence of sucking pests.
Generate additional income by way of timber and fuel.
Increases soil fertility by addition of 8 10 tones of organic matter/ha/year.
Minimizes soil erosion.
Helps to maintain the ecological equilibrium.
Serves as standard for training pepper.
Helps in getting better distribution of crop.

Shade planting:
Planting can commence in the month of May and should be completed by June.
Grevillea Robusta plants should be a minimum of 18" tall and 6 to 9 months old.
Mature fields Planting should be done in only early pruned fields.
New clearing: To plant grevillea robusta at 20 feet * 20 feet (275 plants per hect)
Low pruned /in filled area To plant Grevillea robusta at 20 feet * 40 feet ( 138 plants per hect)
Other fields : To plant Grevillea robusta at 40 feet * 40 feet ( 69 plants per hect)
Shade Pollarding:
Pollard at 30 feet height. Leaving 3 tiers of branches to all directions when tree reaches 16" girth at
30 feet Ht (Girth at chest level)
Slope the cut and apply tar or waste oil to the stem.
All branches below 22 feet to be cut off and 3 tiers to be established between 22 feet and 30 feet.
In valleys and naturally shaded areas keep one tier of branches.
No handling of trees till the tree attains a height of 30 feet until or unless the branches touch the tea.

27

Shade thinning:
To reduce the shade trees to 40 feet * 20 feet spacing after the young grevillea tree are 8 years and
40 * 40 feet end of 15 years old .
The thinning out should be only done prior to pruning to prevent any damages to Tea
Shade lopping:
To commence the shade lopping by Feb 1st week and completed by April end.
To give priority to early pruned and Blister prone fields.
To remove the erect growing branches on the laterals.
To always maintain three tiers of branches between 22 feet and 30 feet in all the sides.
To maintain only one tier of branches in all the sides in valleys and naturally shaded areas prone to
blister blight.
No amputation of branches, but to allow the branches to spread as far as possible.
To achieve a better penetration of light during monsoon period. And to reduce the incidence of
blister blight.

Shade tree felling:

Felling of grevillea trees only prior to pruning.
Fell as close to the ground as possible not exceeding 6" to 9".
To always do the treatment to extract the starch from the roots to avoid spread of disease.
PRUNING & SKIFFING
Pruning is one of the most important operations, next to plucking, which directly determines the productivity
of tea bushes. It is a necessary evil in the sense that it has to be carried out periodically in spite of huge crop
loss it results. If pruning is delayed, in other words as the age of wood from pruning increases, the size and
weight of growing shoots on plucking surface decreases. There is preponderance of banji shoots on plucking
table as more and more buds fail to grow with loss of vigour of growing apices. Therefore, to maintain the
vegetative growth, pruning is necessary. The objectives are:

To renew the wood.

To provide stimulus for vegetative growth.
To divert stored energy to production of growing shoots.
To correct past defects in bush architecture.
To maintain ideal frame height for economic plucking.
To improve bush hygiene.
To reduce the incidence of pests and diseases.
To regulate the crop.
To facilitate consolidation by infilling of vacancies.
ORGANIC TEA CULTIVATION

Tea produced without the usage of synthetic chemicals, Pesticides or Genetically modified organisms
To create an ecological balanced system and sustainability in Agriculture.

28

Touramla Division of Chundale Estate is certified organic Estate-Tea green leaf,Pepper,Arecanut,And

Vanilla by the certifying agency IMO ,India limited

Selection of site
- Must be sufficiently isolated to avoid contamination
- Necessary to have buffer zone of 100 m width on all sides
Conversion period
- Three years from the last usage of synthetic chemicals
Soil management
- Maintain organic matter status in medium to high category
- Give attention to soil and water conservation
- Maintain optimum soil pH by application of aglime lime once or twice in a pruning cycle
Sources of nutrients
Organic manures, tea pruning, shade tree lopping: NPK
Rock phosphate
Phosphorus
Wood ash
Potassium
Langbeinite (or) patent kali
Potassium
Dolomite
Magnesium
Biofertilisers
Azospirillum sp.

For nitrogen fixation

Pseudomonaus and Bacillus sp.

For phosphate solubilization

Certification agencies
IMO
Institute for Marketecology
IMO control pvt limited ,Bangalore
( Certifing Agency for Touramala Division)

HARR ISONS INITIATIVE IN SUSTAINAB LE AGR ICULTURE IN TEA

(HISAT)
Hisat is a set of guiding principles for our production system based on our knowledge of how to use our
natural resources for production of a safe and healthy end product, achieving economic viability and social
stability, while still balancing our natural resources
NORMS FOR HISAT COMPLIANCE
EDAPHIC FACTORS-SOIL CONSERVATION, SOIL MOISTURE,SOIL FERTILITY
LAND DEVELOPMENT ENERGY AND WASTE MANAGEMENT

29

INTEGRATED CROP MANAGEMENT

PEST AND DISEASE MANAGEMENT
QUALITY MANAGEMENT
HUMAN WELFARE

EDAPHICFACTORS
Healthy soil is the fundamental requirement
SOIL CONSERVATIONIn a sustainable system, soil is looked upon as a living medium. Therefore it must be protected
and nurtured to ensure long-term productivity and stability.
Conserve soil and replenish organic matter content of soil by retaining the pruning / shade lopping in the
field
Leaf fall /pruning from tea bushes add 4-5 tons of organic matter /ha, and 30-50 kgs n/ha
Shade trees and Temporary shade trees like Glyricidia add 8-10 tons of organic matter and 30-50 kgs n to
the soil annually.
leguminous plant and green manure crops like Crotalaria, Mucona, Albizzia etc is planted in vacancies to
add nitrogen content of soil besides preventing soil erosion. To maximize mulching in new plantings and to
reduce soil erosion in freshly planted areas
Vetiver is planted on embankments and tea boundaries at 1ft X I ft spacing to conserve soil.

SOIL FERTILITY
Nutrient replenishment is a major challenge in any agricultural system. Following activities are practiced
Combination of organic manure/ compost and inorganic fertilizer is used.
Timely application of fertilizer at adequate intervals to replace nutrients extracted.
Commence first application of manure on receipt of 5 cms of rainfall.
Follow band width programme based on quantum of crop harvested for manure application.
(Fertilizer policy 2007)
Administer correct dosages with correct methodology.
Maintain records of inputs.
Planting of leguminous varieties of shade trees like Erythrina lithosperma (dadap), Gliricidia
maculata.
Planting crotalaria adds upto 80 tons of green material per ha/annum
SOIL MOISTURE
Maximize water infiltration into the soil.
Reduce the unproductive/destructive efflux of surface water.
Improve water table.
Schedule irrigation accurately.
Harvesting rainwater by making silt pits, farm ponds, will ensure soil moisture for relatively longer period.
Bunding of flowing water with earthen bunds and check dams will further improve the water table
Water shed development and management.

30

Ensure hazardous chemicals do not pollute drinking water.

LAND DEVELOPMENT
Not to leave any land fallow on the estate
Plant cover crops like Mucona, Crotalaria and vetiver in tea areas
Contract farming of ginger/banana etc in swamps/large vacant areas
Preserve jungle areas/sholas on the estate
Plant jungle trees like Neem, Naaval, Kaatuplavu, Kodampuli etc shola areas to conserve fauna
Identify and conserve wild life habitats / nature in and around the estates.
CROP MANAGEMENT
Integrated pest management with eco friendly chemicals like lime sulphur.
Plant pest and disease resistant cultivars
Map areas susceptible to pests and diseases
Record periodic mite/ thrips/ blister blight count to ensure need based spraying.
Commence spraying only at specified economic threshold levels-ETL.
Proper training of spraying teams and supervisors
Adequate protective gear for spraying teams
Adhere to proper dosages and maintain accurate records
Use chemicals cleared for tea
Use pesticides on rotational basis
Adhere to manufacturers instructions
Ensure that equipment used for application complies with safety and maintenance standards
Record kill percentages after 2/3 days of spraying to ensure spraying efficiency
Maintain safety harvest intervals of 10-12 days to ensure specified maximum residue levels.
MAINTAIN QUALITY OF PRE-HARVEST, HARVEST AND POST-HARVEST OPERATIONS
Plan harvesting interval(HI) in accordance with the leaf expansion time (let) based computerized
harvesting plan to ensure quality raw material
Maintain L.E.T.blocks in 2nd year field, and tag 5 shoots daily.
Record let on a daily basis.
Generate and modify the harvesting plan weekly on the basis of let and multiplication factor(MF).
Harvest only the target shoot(TS) applying non selective level shearing.(NSLS),leaving desired L.O.B.(Left
On Bush) generation
Target Shoot = L.O.B.+ H.I.
Harvesting Interval= L.E.T.+ M.F.
Proper leaf handling post harvesting to ensure leaf damage is minimal
Early transportation of leaf from field to the factory
Maintain hygiene during leaf transportation
Maintain 27% coarse leaf with black leaf not exceeding 3% at all times.
0% leaf rejection at the factory
No extraneous matter in the leaf
Record coarse count and black leaf percentage in the field and factory.
Assess leaf for coarse%, black leaf, bruise count, blister damage on arrival into the factory
ENERGY AND WASTE MANAGEMENT
Recycle organic waste

31

Introduce community-based composting

Adopt energy saving methods in design, maintenance and use of machinery
Use alternate sources of energy e.g.. Biofuels
Renewable sources programmed felling of fuel areas planted with Eucalyptus Grandis, and ensuring
regeneration through selective copusing
Dispose inorganic waste safely
HUMAN WELFARE
Health, hygiene and safety of employees is of utmost priority
Hospitals and dispensaries provide free round the clock medical attention to employees, and their
dependants
Round the clock medical attention for local community
Medical camps for employees and local community conducted by medical officers to improve community
health awareness
Specific attention to pre and postnatal child care to ensure child health.
Ensure childcare and education through crche and balawadies.
Rakshita-centre for special children and young adults
who are differentially abled is our commitment to
uplift the local community.

MA NU FA C TU R IN G P R O C ES S

From withering to drying, the same Camellia sinensis

tea leaf is treated differently during the process to produce the very different aroma and flavour effects of
white, green and black teas.
White: Green Bud Withering (72 hrs) Drying(110C/65C)
White tea is neither rolled nor fired, so it is essentially non-oxidized and it is the least processed. Instead of
being exposed to an artificial heat, the leaves are simply allowed to wither and dry in a carefully controlled
environment, which results in the most delicate, fresh-from-the-garden tasting tea.
Green: Steaming/Roasting Cooling 1st Rolling 1st Drying (110C/70C) Final
Rolling Final Drying (120C/80C)
Green tea is passed through a steaming treatment before rolling. Steaming applies light heat to the leaves to
help halt the oxidation process before the leaves are rolled into shape. Steaming also helps expose the fresh,
grassy flavour of the leaf. Green tea leaves are not allowed to oxidize after rolling, which is why they remain
light colour and flavour.

32

Black: Withering 1st Rolling Oxidizing/Fermenting Drying (110C/65C)

Our black tea is rolled immediately after withering to help get the oxidation processes started quickly. The
leaves are then fully oxidized before they are dried, which is how they get their dark colour and rich flavour.
Aside from water, black tea is the worlds most popular beverage, being grown and manufactured in many
parts of the world. Even though many types of teas are available, the most popular one is black tea, and is
extensively used for blending and drinking. According to the Black Tea Vocabulary (International
Organization for Standards - ISO 607: 1992, black tea is defined as a product manufactured solely and
exclusively from the shoots (leaves, buds and tender stems) of varieties of species Camellia sinensis
(Linneaus) O.Kuntze after various processes like withering and rolling with a special type of rollers or
crushing, tearing, curling (CTC) followed by fermentation and drying (moisture removal up to 3 %) prior to
sorting. The tea produced by the above process shall be blackish / brown in appearance.
To satisfy the above requirements, undamaged plucked shoot free from insect infestation and plant disease /
damage shall be used for manufacture. Plucking of tea shoot shall be done after minimum recommended
period of application of specified chemicals / nutrients to leave its residue in plucked material. No further
treatment with any chemical agent, edible or no edible material has been rendered on the plucked shoots
before receipt at the factory. The shoots shall also be free from any visible extraneous matter Quality of tea
is usually assessed by experienced tea tasters through organoleptic evaluation. The characters accounted for
evaluation includes, appearance of dried and infused leaf, character of liquor and flavour. The tea shall have
no taints and be reasonably free from extraneous matter. The liquoring character depends on many factors
including the type of water used for brewing.
There are basically two types of manufacturing process i.e.
1. ORTHODOX PROCESS- Orthodox black teas are loose leaf artisan made teas in a variety of
different
styles and types available from various countries around the world.
2. CTC (Cut, Tear & Curl) - Manufacturing method was developed in the 1950's in response to
the ever growing popularity of the tea bag. With this process the leaf is withered the
same as for orthodox tea, but rather than being rolled, a CTC machine is used to chop the
tea into tiny pieces, with blades that rotate inside at various speeds.
In India, till the 1960s, orthodox tea dominated India's tea production. Till the 1980s, the share of orthodox
tea was significant (32 per cent) as given in the table 1.3. However, since the 1990s, constitutes of CTC tea
has recorded a sharp rise and now shares 90.8 per cent of tea production in India. Black Tea includes two
types of process as mentioned above Orthodox tea and CTC (Crushing, Tearing and Curling) tea. Both of
these teas vary due to their manufacturing differences. Orthodox teas are manufactured with the help of
orthodox roller in the process of rolling while CTC machine/Rotervan is used in rolling process in
manufacturing CTC teas. India and Kenya produces more CTC whereas Sri Lanka produces more orthodox
tea. The tea processing in any Factory in the traditional way includes 5 phases, such as Withering, Rolling,
Fermentation, Drying, Sorting and Grading.
ORTHODOX MANUFACTURING PROCESS
WITHERING- The production method of orthodox tea consists of five stages: withering, rolling,
fermentation, Drying and sorting. The freshly-picked green leaves are spread out to dry on ventilated trays.

33

During this process, approximately 30 per cent moisture is extracted from the leaves, making them soft and

pliable for further processing.

Quality surveillance steps during withering process:
a. Use ambient air when hygrometric difference is above 3C.
b. If the hygrometric difference is below 3C, use hot air with suitable proportion of ambient air.
c. The temperature of hot air should be below 35C.
d. To get even wither, the trough should be loaded with 2-3 kg/sq. ft. of green leaf.
e. Well ventilated lofts and access for drawing large volume of air is essential.
f. The ideal qualities of air for withering are low dry bulb temperature with high hygrometric difference.
g. Use reversible air flow system to get better withering and to avoid more handling of leaves manually.
h. Tapering cross section in the plenum chamber helps to maintain uniform pressure throughout the length of
the trough.
ROLLING- The leaves are then rolled by applying mechanical pressure to break up the cells and extract the
cell sap. After 30 minutes, the leaves still damp from the sap are sieved to separate the finer leaves. These
are spread out immediately for fermentation, while the remaining coarse leaves are rolled for a further 30
minutes under higher pressure. If necessary, this process is repeated several times. A short rolling time
produces larger leaf grades, while longer rolling breaks the leaves up more resulting in smaller grades.
During the rolling process, the cell sap runs out and reacts with oxygen, thus triggering the fermentation
process. At the same time, the essential oils responsible for the aroma are released.

Quality assurance in the rolling process:

1. Use green leaf sifter to avoid jamming of machine.
2. Use leaf shredder to avoid over heating of dhool in the rotorvane.
3. A ball breaker is essential after the rotorvane, which will cool the tea before feeding into the CTC.
Temperature of the rotorvane tea should not reach above 35C which reduces the enzyme activity.
CTC MACHINE
To maintain zero-defect in quality, the following should be checked regularly:
a. The temperature after each cut-every two hours.
b. The size and style of the leaf from all the machines-every two hours.

34

c. The moisture content after shredding (70-72%) and after fifth cut (60%).
d. Magnet may be fixed on all the conveyers.
e. Ensure daily cleaning of CTC machine.
FERMENTATION- During this process, the substances contained in the cell sap oxidise. In this production
phase, the green leaf gradually turns a copper colour. The colour and typical odour tell the person
supervising the process how far the fermentation has progressed. Various chemical reactions cause the leaf
to heat up during fermentation. It is critical for the quality of the tea that the fermentation process be
interrupted at its peak, when the temperature is at its highest.
Error prevention process during fermentation
a. Co-current air flow arrangement is essential to supply more oxygen during the initial stage of
fermentation.
b. The air should be fresh, cool and saturated with moisture.
c. The optimum temperature of dry bulb should range between 25C and 27C and the relative humidity of
the air should be around 95%.
d. A post fermentation ball breaker is essential.
e. Fermenting drum must be cleaned with hot water or steam to avoid bacterial contamination.
DRYING- Next, the tea is dried with hot air at a temperature of approximately 85-88C in order to
Interrupt the oxidation process. The residual moisture is thereby extracted from the leaves, the extracted sap
dries on the leaf and the copper-colour leaf turns dark brown to black. Finally, the dried tea is sieved to
separate the different leaf grades. The orthodox production method provides teas of all leaf grades: leaf,
broken, Fanning and Dust. Leaf grades only refer to the leaf size, however: they are not necessarily an
indication of the quality of the tea.
Key points for value-adding to quality, during drying:
a. Maintaining exact inlet and exhaust temperature is important to get uniform firing.
b. Proper loading of drier is also essential to get uniform firing:
Over loading causes back pressure and results in uneven drying.
c. Maintaining drying time and temperature is very important.
Longer the drying time detrimental to quality & flavour.
Shorter the time results in thin liquor.
Higher the temperature results in bitter tea.
d. In the ECP drier, the optimum inlet temperature for CTC process is 1005C, while exhaust temperature
is maintained at 55C.
e. In the FBD drier, the desirable inlet temperature ranges from 120-125C, while the exhaust temperature is
maintained at 60-65C.
f. Magnet can be fixed in the drier mouth, which will help in removing iron particles from made tea
SORTING & GRADING- Sorting is to remove fibre from the bulk tea and separate the tea particles into
various shapes and sizes relevant to trade requirements.
a. Sorting enhances the appearances and quality of liquor.
b. Flakes of coarse leaf in the primary grade can be separated to avoid harshness.
d. Light bulbs used for ionising fibres should be replaced with some other mechanism.
e. Use of stainless steel meshes is desirable for good sorting.
f. Meshes should always be tight; loose meshes cause loss of bloom and uneven grading.

35

STORAGE & PACKAGING- Black tea, being a highly hygroscopic material picks up moisture from the
atmosphere, if packing is not proper.
a. Three per cent (3%) moisture level is advisable when packed if the moisture content of tea reaches 6%
the keeping quality is impaired.
b. Tea should not be stored in open condition.
c. Use of bins for storage of the finished product is very essential.
d. Tea should be cooled to ambient condition, before it is taken to bins.
e. Tea can be passed under powerful magnet grills to ensure iron free tea while packing.
CTC MANUFACTURING PROCESS

The only difference between the Orthodox & CTC is that CTC machine is used instead of rollers in orthodox
method The term CTC is short for cut-tear-curl which describes the production process of these teas. The
cut-tear-curl machine was invented in 1931 to complete the production process in three easy steps,
revolutionizing the manufacture of tea.
The CTC machine essentially crushes and tears the fresh leaves, rolls them into tiny green pellets, which are
then sent along on a conveyor belt beneath large blowers that quickly dry the tea.
Orthodox teas are generally high-quality whole leaf teas. They go through the same production process as
CTC teas...to a point, but much more attention and time is given to making traditional orthodox tea. With
CTC teas the flavour is forced from the leaf, but with orthodox teas, it is slowly coaxed out by the tea maker,
much like a fine wine is by the vintner.
There is no strict restriction in grading for raw material for CTC fragment black tea. However, there must be
no of wood nature for tea, fresh tea leaves should be withered and dehydrated by means of spreading them
out for cooling on a withering bed, with ventilation below the withering troughs to avoid the tea heated and
deteriorated. The moisture content of the processed tea should be below 85%.

36

The fresh tea leaves after withering cannot directly enter into the rubbing and crushing machine for
processing. It should be cleaned through a vibrating and cleaning machine to remove small stones, tea tree
stalks and metal articles mixed with the tea leaves when picked up, and with some small non-uniform leaves
with poor nutrient being picked out. The fresh tea leaves after cleaned will enter into the cylinder of the
rubbing and cleaning machine and will be crushed into broken pieces by means of rubbing and crushing
actions of both moving and static cutters to make preparation for next processes. Then, the tea will enter into
the triplex rolling and crushing machine to form granular tea, all performed respectively by means of three
groups of toothed rolls in succession. This is the most critical step influencing the quality of tea and its
granular formation. Each group of toothed rolls consists of fast and slow rolls. While rolling and crushing,
the tea leaves are rubbed and curled into granular.

ROTOR VANE- A size reduction process

Horizontal shaft with blades (vanes) enclosed by a cylinder having resistors

Size of cut can be fixed
Fermentation commences
Reduces load on CTC machine
Leaf turns dark after passing through the rotorvane

37

CTC MACHINE
It is also a continuous processing machine
5 pairs of horizontal toothed stainless steel contra rotating rollers with adjustable clearance
24-36 inches long and 8-8.25 inches diameter
1:10 to 1:12 speed ratio between the rollers
Leaves are Crushed, Teared and Curled
Juices are brought out to the surface and mixed for fermentation

CTC MACHINE

FERMENTING DRUM
Time 75-90 minutes
Length 20 ft and diameter 6 ft
Length 16 ft and diameter 5 ft
Capacity 600 and 400 kg dhool
Dhool temperature 25-270C
Relative Humidity 90-95%
Speed 1-2 RPM

Fresh air duct

Flights

Temp 25-270C
RH 90%

EFFECTS OF FERMENTING
1-2 RPM

Increase air contact between tea

particles
Better fermentation
Improved granulation
Reduction of ball formation in the drum
Produce blacker and brisker teas

Co-current air-Air and dhool should travel in the same direction

38

RAINFOREST ALLIANCE CERTIFICATION

Presently beside RA certification, HML also got certified by Trustea and UTZ in all the HML SBU-B tea estates subsequent to
the audit held between 14th to 18th December 2015.

39

The Rainforest Alliance works to conserve biodiversity and ensure sustainable livelihoods by transforming
land-use practices, business practices and consumer behavior.
Rainforest Alliances approach is the understanding that the health of the land is inextricably connected to
the wellbeing of those who depend on it for their livelihoods. Its
approach includes training and certification to promote healthy
Quick facts about the Rainforest
Alliance
ecosystems and communities in some of the worlds most
vulnerable ecosystems.
Established: 1987
Members: 35,000
It works with forward-thinking farmers, foresters and tourism
FY15 Operating Budget:
entrepreneurs to conserve natural resources and ensure the long$52.9m
term economic health of forest communities. In order for a farm
Employees: 300+
or forestry enterprise to achieve Rainforest Alliance certification,
Global Offices: 9 countries
or for a tourism business to be verified, it must meet rigorous
Charity Navigator Rating:
standards designed to protect ecosystems, safeguard the well4 Stars
being of local communities and improve productivity. The
Rainforest Alliance then links these farmers, foresters and tourism
businesses to the growing global community of conscientious consumers through the green frog seal.

The Rainforest Alliance Certified seal is an internationally recognized symbol of environmental, social and
economic sustainability that helps both businesses and consumers do their part to ensure a brighter future for
us all.
Sustainable Agriculture Standard

Rainforest Alliance Certified farms have met these rigorous social and environmental standards set by
the Sustainable Agriculture Network (SAN).
The SAN is the oldest and largest coalition of non-profit conservation and rural development organizations
in the Americas, Africa, Europe and Asia, promoting the environmental and social sustainability of
agricultural activities through the development of good practice standards, certification and the training of
rural producers throughout the world.
The SAN/RA certification system is jointly owned by the Sustainable Agriculture Network and Rainforest
Alliance. Farms that meet the SANs requirements and binding rules are recognized with the Rainforest

40

Alliance Certified seal. Since 1992, more than one million small farms, medium, large and cooperatives in
more than 40 countries around the world have met the SAN standards that ensure protection of workers and
wildlife, conservation of natural resources and support the financial viability of farms.
The standards developed by the SAN comply with the Code of Good Practice for Setting Social and
Environmental Standards of the International Social and Environmental Accreditation and Labelling
(ISEAL) Alliance.
The ISEAL Alliance is an association of leading voluntary international standard-setting and conformity
assessment organizations that focus on social and environmental issues. ISEAL Alliance members
collaborate to build international recognition and legitimacy for their programs. This collaboration
represents a significant global movement to promote the interests of workers, communities and the
environment in world trade.
Through the collaboration of ISEAL members, certification processes are continually improved. For
Rainforest Alliance Certified farms, the accredited certification bodies verify that farms comply with SAN
standards. Other inspection bodies, typically local NGOs, are authorized by these certification bodies to
provide audit services for farmers and agricultural companies in their respective countries. Inspection bodies
also offer their knowledge and experience to help continually refine and develop Sustainable Agriculture
standards.
RA CRITICAL CRITERIAS
Principle 1: SOCIAL AND ENVIRONMENTAL MANAGEMENT SYSTEM
1.3 Critical Criterion. The farms upper management must demonstrate a commitment to certification and
to complying with the requirements stipulated in the standard and by law. The management must also be
familiar with and endorse the system and its programs and support its execution by providing the necessary
resources.
1.10 Critical Criterion. The farm must have a system for avoiding the mixing of certified products with
non-certified products in its facilities, including harvesting, handling, processing and packaging of products,
as well as transportation. All transactions involving certified products must be recorded. Products leaving
the farm must be duly identified and accompanied with the relevant documentation indicating a certified
farm as origin.
Principle 2: ECOSYSTEM CONSERVATION
2.1 Critical Criterion. All existing natural ecosystems, both aquatic and terrestrial, must be identified,
protected and restored through a conservation program. The program must include the restoration of
natural ecosystems or the reforestation of areas within the farm that are unsuitable for agriculture.
2.2 Critical Criterion. From the date of application for certification onwards, the farm must not destroy
any natural ecosystem. Additionally, from November 1, 2005 onwards no high value ecosystems must have
been destroyed by or due to purposeful farm management activities. If any natural ecosystems have been
destroyed by or due to purposeful farm management activities between November 1, 1999 and November 1,
2005, the farm must implement the following analysis and mitigations:
a. Conduct an analysis of the ecosystem destruction to document the scope and ecological impact of the
destruction.

41

b. Develop a mitigation plan with advice from a competent professional that is consistent with applicable
legislation and that compensates for the negative impact.
c. Implement the activities of this mitigation plan, including for example the set aside of a significant
percentage of the farm area for conservation purposes
Principle 3: WILDLIFE PROTECTION
3.3 Critical Criterion. Hunting, capturing, extracting and trafficking wild animals must be prohibited on
the farm. Cultural or ethnic groups are allowed to hunt or collect fauna in a controlled manner and in areas
designated for those purposes under the following conditions:
a. The activities do not involve species in danger of or threatened with extinction.
b. There are established laws that recognize the rights of these groups to hunt or collect wildlife.
c. Hunting and collection activities do not have negative impacts on the ecological processes or functions
important for agricultural and local ecosystem sustainability.
d. The long-term viability of the species populations is not affected.
e. These activities are not for commercial purposes.
Principle 4: WATER CONSERVATION
4.5 Critical Criterion. The farm must not discharge or deposit industrial or domestic wastewater into
natural water bodies without demonstrating that the discharged water complies with the respective legal
requirements, and that the wastewaters physical and biochemical characteristics do not degrade the
receiving water body. If legal requirements do not exist, the discharged wastewater must comply with the
following minimum parameters:
Water Quality
Parameter

Value

Biochemical
Oxygen Demand
(DBO5, 20)

suspended solids Less

than 50 mg/L

pH

Between 6.0 9.0

Grease and oils

Less than 30 mg/L

Fecal coliforms

Absent

The mixing of wastewater with uncontaminated water for discharge into the environment is Prohibited
4.7 Critical Criterion. The farm must not deposit into natural water bodies any organic or inorganic solids,
such as domestic or industrial waste, rejected products, construction debris or rubble, soil and stones from
excavations, rubbish from cleaning land, or other materials
Principle 5: FAIR TREATMENT AND GOOD WORKING CONDITIONS FOR WORKERS
5.1 Critical Criterion. Complaints or grievance mechanisms to protect workers rights are implemented
5.3 Critical Criterion. The farm must not discriminate in its labour and hiring policies and procedures
along the lines of race, colour, gender, age, religion, social class, political tendencies, nationality, union

42

membership, sexual orientation, civil status or any other motive as indicated by applicable laws, ILO
Conventions 100 and 111, and this standard. The farm must offer equal pay, training and promotion
opportunities and benefits to all workers for the same type of work. The farm must not influence the
political, religious, social or cultural convictions of workers.
5.6 Critical Criterion. Workers must receive pay in legal remuneration greater than or equal to theregional
average or the legally established minimum wage, whichever is greater, according to their specific job. In
cases where the salary is negotiated through collective bargaining or other pact, the worker must have access
to a copy of this document during the hiring process. For production, the established pay rate must allow
workers to earn a minimum wage based on an eight-hour workday under average working conditions, or in
cases where these conditions cannot be met.
5.9 Critical Criterion. It is prohibited to directly or indirectly employ full- or part-time workers under the
age of 15. In countries where the ILO Conventions have been ratified, the farm must adhere to Convention
138, Recommendation 146 (minimum age). Farms contracting minors between the ages of 15 and 17 must
keep a record of the following information for each minor:
a. First and last name.
b. Date of birth (day, month and year).
c. First and last name of parents or legal guardian.
d. Place of origin and permanent residence.
e. Type of work carried out on the farm.
f. Number of hours assigned and worked.
g. Salary received.
h. Written authorization for employment signed by parents or legal guardian.
Workers between 15 and 17 years old must not work more than eight hours per day or more than 42hours
per week. Their work schedule must not interfere with educational opportunities. These workers must not be
assigned activities that could put their health at risk, such as the handling and application of agrochemicals
or activities that require strong physical exertion.
5.10 Critical Criterion. The worst forms of child labour are prohibited:
a. Work that harms the health, safety or morals of children, including handling of pesticides,
hazardous substances or residues; operating or assisting to operate power machinery or tools; activities
requiring strong physical exertion, such as heavy lifting; work on steep slopes, near steep cliffs or drop-offs,
on any high surface or in high places; work in storage areas, silos and construction sites; and night work.
b. Any type of paid or unpaid work by a child under the age of 12 years old, except tasks that are traditional
to children in the location and which are undertaken for the purpose of transmission of the familys or local
culture;
c. Young workers do not work more than eight hours per day. Young workers may work only if registered, if
permitted by compulsory school and other applicable laws;

43

d. All forms of slavery or practices similar to slavery, including the sale and trafficking of children; debt
bondage and serfdom; forced or compulsory labour, including forced or compulsory recruitment of children
for use in armed conflict;
e. Use, procuring or offering of a child for prostitution, for the production of pornography or for
pornographic performances;
f. Use, procuring or offering of a child for other illicit activities, including the production and
Trafficking of drugs as defined in the relevant international treaties.
5.11 Critical Criterion. Any type of forced labour is prohibited, including working under the regimen of
imprisonment, in agreement with International Labour Organization (ILO) Conventions 29 and 105and
national labour laws. The farm does not withhold any part or all of workers salaries, benefits or any rights
acquired or stipulated by law, or any of the workers documents, in order to force them to work or stay on
the farm, or as a disciplinary action. The farm does not use extortion, debt, threats or sexual abuse or
harassment, or any other physical or psychological measure to force workers towork or stay on the farm, or
as a disciplinary measure.
5.13 Critical Criterion. Workers must have the right to freely organize and voluntarily negotiate their
working conditions in a collective manner as established in ILO Conventions 87 and 98. The farm must have
and divulge a policy guaranteeing this right and must not impede workers from forming or joining unions,
collective bargaining or organizing for ideological, religious, political, economical, social, cultural or any
other reasons. The farm must periodically provide opportunities for workers to make decisions regarding
their rights and alternatives to form any type of organization for negotiating their working conditions.
5.15 Critical Criterion. When housing is provided by farm management to workers and their families, its
disease-free, hygienic and safe. Rooms are not overcrowded. Housing has windows for natural lighting and
ventilation, and non-leaking roofs.
5.16 Critical Criterion. Farmers, workers, and their families have access to safe drinking water. Safe
drinking water is provided through access to a public drinking water system or by the farm management or
group administrator. In the absence of either of these, group administrators train smallholders in applying
drinking water treatments.
Principle 6: OCCUPATIONAL HEALTH AND SAFETY
6.3 Critical Criterion. All workers that apply, handle, transport or come into contact with agrochemicals
or other chemical substances must be trained in at least the following subjects:
a. General occupational health.
b. Formulations, names, and the biocide action or toxicity in the case of pesticides, of the
Substances used.
c. Interpretation of the pesticide labels and of the Material Safety Data Sheet (MSDS) for the substances
used.
d. Correct use of personal protective clothing and equipment.
e. Preventative measures and measures for reducing damage to health and the environment caused by
chemical substances: equipment, techniques, signage, medical examinations, etc.

44

f. Emergency procedures, first aid and medical attention for cases involving poisoning or undue contact with
chemical substances.
g. Techniques for handling chemical substances and for the correct application of agrochemicals.
h. Secure handling and transportation of agrochemicals for drivers.
Only persons with proven knowledge and experience in the subject must carry out the training.
Farms with ten or more permanent workers in production or processing must document for each training
event the objectives, topics, the workers or positions that must attend training, the training materials used,
the frequency and duration, and the list of participants.

6.13 Critical Criterion. All workers that come into contact with agrochemicals, including those who
cleaner wash clothes or equipment that has been exposed to agrochemicals, must use personal protection
equipment. The farm must provide this equipment in good condition, and must provide incentives to workers
to use the equipment. The equipment must reduce contact with the agrochemicals and the possibility of
acute or chronic poisoning, and must comply with the strictest of the following requirements: a) the
requirements indicated on the products Material Safety Datasheet, b) any applicable laws; or c) the
equipment indicated in Annex 2 of this standard
6.16 Critical Criterion. The farm must have showers and changing rooms for all persons that apply or
come in contact with agrochemicals. There must be policies and procedures that require that all workers that
apply agrochemicals shower and change their clothes immediately after finishing the application and before
leaving the farm at the end of the workday. There must be exclusive and separate areas for washing personal
protection equipment and for washing application equipment.
Principle 7: COMMUNITY RELATIONS
7.2 Critical Criterion. The farm management must implement policies and procedures for
Identifying and considering the interests of local populations and community interest groups Regarding farm
activities or changes that could have an impact on their health, employment or local natural resources. The
farm must document and make available for public view all complaints and comments it receives related to
its activities and its replies to them.
Principle 8: INTEGRATED CROP MANAGEMENT
8.4 Critical Criterion. The following chemical or biological substances cannot be used on certified farms :(
Banned)
a. Biological or organic substances that are not legally registered in the country for commercialise.
b. Agrochemicals that are not registered officially in the country.
c. Agrochemicals that are mentioned in the List of Banned and Severely Restricted Pesticides in
The U.S. by its Environmental Protection Agency (EPA) or pesticides banned or severely restricted in the
European Union.
d. Substances that have been banned globally under the Stockholm Convention on Persistent Organic
Pollutants (POPs).

45

e. Substances listed in Annex III of the Rotterdam Convention on Prior Informed Consent (PIC), in relation
to national bans or severe restrictions for documented health or environmental reasons in at least two regions
of the World.
f. All Pesticide Action Network Dirty Dozen substances.
List of Prohibited Pesticides Sustainable Agriculture Network is binding for the inserts 8.4.c, 8.4.d,8.4.e
and 8.4.f of this criterion.

8.6 Critical Criterion. The farm must take steps to avoid introducing, cultivating or processing transgenic
crops. When nearby transgenic materials are accidentally introduced into a certified farms crop, the farm
must develop and execute a plan to isolate the crops and provide follow-up in order to comply with the
requirements of this criterion
Principle 9: SOIL MANAGEMENT AND CONSERVATION
9.5 Critical Criterion. New production areas must only be located on land with the climatic, soil and
topographic conditions suitable for intensity level of the agricultural production planned. The establishment
of new production areas must be based on land use capacity studies that demonstrate long-term production
capacity. The cutting of natural forest cover or burning to prepare new production areas is not permitted.
Principle 10: INTEGRATED WASTE MANAGEMENT: Nill

Ethical Tea Partnership (ETP)

ETP is a nonprofit organization that unites tea companies from Europe, North America and Oceania. ETP
evaluates producing conditions of tea companies across the world and provides support to tea manufacturers
to build their capacity to help them improving living and working conditions for workers and environmental
management. Its longterm goal is to have all its members produce tea in a socially responsible way. It
focuses on aspects such as health, safety, field management, environmental protection and energy
conservation of tea manufacturing companies.
Solidaridad
Solidaridad is a pioneer, developer and innovator from Netherland in the field of fair trade. Presently Trustea
certification is promoted by Solidaridad. Its current effort is to promote sustainable development of supply
chain to create a peoplefriendly and environmentfriendly chain by joining hands with companies,
consumers as well as producers and farmers from developing countries to alleviate poverty and improve
producers. Solidaridad has developed a big programme for producer support, and stimulates improvements
in product quality, certification, processing, trade, traceability, financing, purchasing, communication and
the marketing of the end product.
Trustea
Trustea code is designed to evaluate social, economic, agronomic & environmental performance of Indian
tea estates, small holders & BLFs. The certificate holder will be tea Plantation Company, the bought leaf
factory, or the independent producer groups together with the factory. The code covers all aspects of
production and manufacturing. The entry-point of the code for compliance will be the factories in estates,
BLFs or grower group representative having an arrangement for processing, who will then work with the
production sites and the smallholders respectively.

46

SUSTAINAB ILITY AT HML

1. HML is the single largest holder of land and largest employer in Wayanad District of Kerala
with more than 2 lakh people living within and around our Estates. It has been her endeavor
to protect all our resources right from Employees, Community, Soil, Water, Plants and
Animals. It was done by sensitizing all stakeholders from Employees, Community and
School Children. Training by experts from the field was done at various levels. It broke down
the entire process into Activities which were then Implemented reviewed and refined

2. For making Estates Plastic free, Community participation was ensured by making School
children our Ambassadors. Awareness programs were organized at various levels involving
Employees, Panchayats, Self help groups and Health Dept. Segregation, Collection and
Disposal of Plastics to authorized Recyclers were put in place. Its Waste Management
initiatives were recognized and awards given by 3 GramaPanchayats

3. Major threat areas identified for the future were Soil health and Water Shortage. In order to
contain Soil Erosion, 14 kms of Vetiver planting and 162 ha of Silt Pits were taken and in
order to raise the water table they have built a number of small and medium sized Check
Dams and Weir Dams. All Waste water is treated through soak pits before being released
into the environment.

47

4. Usage of Personal Protective Equipment and Safe Use of Agrochemicals were our focus
areas. A huge change in Workers mindset need to be brought from resistance to using PPEs
to a demand for providing PPEs. It is being done through sensitizing workers by External
and Internal Training programmes.
BEFORE

AFTER

5. Estate hospitals have been opened to public at nominal fees, Number of Medical Camps were
conducted for public, Under 5 clinics, Plastic free Initiative extended to 7 schools,
RAKSHITHA- Centre for Children and Young Adults with Special needs open to public,
Annual Summer Camps and Quiz competitions with Sustainability themes were organized.

48

RECOMMENDATION/FEASIB LE INTERVENTION OPTIONS

Initiate an institutional mechanism with representation of multi-stakeholders from the tea industry,
Government bodies and nodal agencies to provide better social infrastructure for workers in all tea
gardens.
Institutional support for governing promotional schemes for workers is required and workers should
be adequately represented in such schemes.
Initiate programmes to create awareness among workers regarding personal and domestic hygiene,
occupation hazards and various water/seasonal related diseases and its preventive measures.
Initiate participation from workers to the major decision-making process and programme for sharing
the short-term benefits of their productivity.
Monitoring and creating new development schemes for small and marginal tea cultivators can also
sustain all regions if there is high participation from cultivators.
In all factories of HML fire wood is the major source of energy requirement, which may seems to be
feasible currently but will surely be unsustainable in near future. So certain incremental changes
should be bought out by bringing a gradual shift from fire wood to renewable energy source like
solar.
Presently bureaucratic organisational design is being followed in every tea estate which has its own
pros & cons. Organistic design at tea estate can be implemented which may increase employee
productivity & can enhance HML business or can give new dimension to tea business. At least in
pilot basis trial can be taken to initiate such change.
CTC was invented by William McKercher during 1930-1931, and the process spread in the 1950s
through the 1970s, most rapidly in India. Today, most black teas produced use the CTC method or
the closely related rotorvane orthodox manufacture. Every tea firms are depended on UPASI for
R&D & It has bought considerable changes in tea manufacturing processes but not in machineries. It
is evident from this that still firms are using CTC methods which were invented during 1930. So
HML should look into it & try to fill in this gap by bringing out new innovative methods of
production.
Due to climate change issues, it was found that rainfall was very erratic in waynad district as a result
of which there were also instances of draughts in tea estates. So HML should initiate water
conservation methods & also should invest more in rain water harvesting.
REFERENCES

1. Ushadevi T V, 2004. Impact of decline in tea industry on socio-economic conditions of workers:

A study at peermade taluk of Idukki district, Unpublished Reports, The Kerala Research
Programme on Local Level Development (KRPLLD), http://krpcds.org/reportleft.htm
2. Sivaram B, 2000. Productivity Improvement and Labour Relations in the Tea Industry in South
Asia, Working Paper No. SAP 2.54/WP.101, ILO.
http://www.ilo.org/public/english/dialogue/sector/papers/proschem/index.htm
3. http://www.indiatea.org/
4. http://www.swannteas.com/abouttea2.html5. http://www.teaportal.org

49

6.

http://www.indiateaportal.com

7.

http://www.indiancommodity.com/Gen/tea.html

8. http://www.upasi.org/aboutus.html