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World Bank Document THE WORLD BANK FA U-15 Public Disclosure Authorized Public Disclosure Authorized 11 - Public Disclosure Authorized Agro -Industry Profiles TEA Public Disclosure Authorized . ... - .I PROFILES IN THIS SERIES: OILCROPS - OVERVIEW........... FAU-01 OIL SEEDS. .. .FAU-02 OIL PALM.....e . o.. ee* n *@FAU-03 COCONUT. e.e.... e o e.. ... FAU-04 SUGAR.e .e * .e ,e ee .* D. e e. e e o *e FAU-05 ETHANOLn . e . e . e e . .e e ..FAU-06 WHEAT. e o. * oe oe o o e. .e .eeFAU-07 RICE.. o oe de . * * * **o. * o.e .9 .eFAU-08 CORN . oe . s e .e . s. e o. e . FAU-09 CASSAVA . .e *.. ... e o . eFAU-10 ANIMAL FEEDS ................. eFAU-11 FRUITS AND VEGETABLES. .......e FAU-12 RUBBER. e . e. .e . .e * . .o e. eFAU-13 COFFEE. e e e e . e s .e .. s e. e o oe o e e **FAU-14 TEA. @*e¢e ¢ X e X @eeo.oo oes v@ @ee oee eFAU-15 COCOA. e .e e * . e. e . e . e . e e . .*e. .FAU-16 COTTON. * *Q * * e . eo . o . * . o e * e 6 .FAU-17 MEATe e ANDeo ESETAeeeo* e oL eFAU-18 SPICES AND ESSENTIAL OILS .. e...eFAU-19 ABSTRACT The objective of this Profile is to provide a review of the tea processing industry. It examines all aspects of the tea industry, from the production and processing of the raw material to the marketing of the finished product. It contains yield specifications and conversion rates, a glossary of key words, and a bibliography of useful references. The Profile discusses various processing procedures, including withering and fermentation, and distinguishes the different processes used in black, oolong, green, and instant tea production. Marketing aspects such as quality control, storage, market barriers, and prices are addressed, as are the criteria for factory location. An Annex containing examples of operating and investment costs is included at the end of the Profile, along with Metric/US convers ion tables. FOREWORD The nature of project and sector work in the World Bank is such that staff are often called upon to work outside their major fields of specialization, if only to make an initial judgement on the utility of further, often costly, investigation. Under these circumstances, up-to-date and authoritative reference material is essential. The profiles in this series are designed for use by operational staff with experience in the agricultural sector but who do not have a technical knowledge of the particular commodity under discussion. Their purpose is not to substitute for technical expertise but to provide a reliable inhouse reference which will help Bank staff to determine when and what expertise is needed in the detailee evaluation of investment proposals in agro- processing. The conditions for any particu.lar proposal are bound to be unique in a number of respects, and the use of norms and general data in project analyses could give rise to significant errors. On the other hand, by providing responsible staff with a guide to the issues on which appropriate expertise should be sought, these profiles can contribute to the overall quality of agro processing investment. Used with care, they should also.facilitate broad pre-screening such as may occur during sector work and reconnaissance. Questions, comments and further inquiries should be addressed to: Agro-Industries Adviser Finance and Agro Industry Unit Agriculture and Rural Development Department The contribution of Harrisons Fleming Advisory Services, Ltd. in the review of this profile is gratefully acknowledged. September 1985 Tea CONTENTS DATA SHEET................................................... INTRODUCTION ...............................................1 GLOSSARY ................................................... 1 RAW MATERIALS................................................3 PROCESSING ................................................. 5 MARKETING ASPECTS............................................14 OTHER FACTORS................................................16 BIBLIOGRAPHY................................................18 ANNEX I EXAMPLES OF INVESTMENT AND OPERATING COSTS ANNEX II CONVERSION TABLES (METRIC/US) Tea DATA SHEET The average yield of made black tea from principal sources is about 1,000 kg/ha/yr, a1thour..-. yields of up to 3,000 kg can be achieved on well-managed estates. Yields are influenced primarily by climate, altitude, cultivation &.nd harvest practices and growing conditionis, including latitude and the number of daylight hours. 100 kg fresh green leaf produces approximately 45 to 70 kg withered tea, depending on conditions and requirements. 100 kg fresh green leaf produces approximately 18 to 27 kg made black tea, depending on the process and other factors. 100 kg withered leaf produces approximately 32 kg to 45 kgs made black tea. i INTRODUCTION Tea is classified as: fermented; partially fermented; or unfermented. The teas produced in these classifications are: black tea, oolong tea, and green tea respectively. Black tea is the most important of the three and accounts for about 75% of world tea production and over 90% of international tea trade. This Profile can be supplemented with more detailed information in Tea Processing by J. Werkhoven, FAQ (1974). GLOS SARY Black Tea Fermented tea; leaves are withered, distorted, fermented and dried. Blending Mixing of teas to satisfy market demands. CTC Crushing, Tearing, Curling; machine used for leaf distortion. Fermentation Development of flavor, aroma and color in black or oolong tea by permitting enzymatic oxidation under controlled conditions. Firing Drying to check fermentation. Flush Seasonal growth periods in the tea plant. Green Tea Unfermented tea; leaves are steamed, rolled and dried. Instant Tea Liquor from either black made tea or green leaf is dried to produce water-soluble particles. Leaf Distortion Rolling, crushing, tearing or otherwise breaking the leaves; fluids are released which begin fermentation. Liquor Brewed tea. Made Tea Black tea after the firing process has been completed. 1. Oolong Tea Partially fermented tea; leaves are withered, fermented and steamed. Packet Tea Loose tea in small retail-sized packages. Plucking Harvesting of the leaf. Rolling Traditional technique for leaf distortion. Soluble Tea Instant tea. Tea Bags Individual sachets of tea for retailing. Withering Preliminary drying of fresh leaf; first stage. of black and oolong tea manufacture. RAW MATERIALS Tea (Camelia assamica or Camelia sinensis) is grown in tropical and subtropical regions. Although usually grown on large estates, it is also cultivated on small farms. The tea plant starts to yield usable leaf two to three years after planting, reaching full producticn after seven to ten years. Yields of made tea vary depending on climate, variety and cultivation practices. The average is just over 1000 kg/ha, but some yields reach as high as 3000 kg/ha. The quality of tea produced is closely linked to growing conditions and cultivation practices. Quality of tea depends on the nature and chemical composition of the plucked leaf. The characteristics of the leaf vary according to the plant's growth patterns and growing conditions as well as cultivation and harvesting practices. Although tea is harvested or 'plucked' year-round, its growth pattern is characterized by distinct seasons when shoots develop at higher latitudes. These seasonal changes in the plant affect the internal composition, size and fineness of the leaf, and subsequently the quality of the end product. From a processing viewpoint this pattern determines the harvesting frequency. These patterns are affected by temperature, humidity, and rainfall. 2 The most important cultivation practices affecting tea growth and yield are pruning, plucking, and use of fertilizers. Different pruning cycles are practiced and are largely dependent on tradition and local situations. Plucking itself is a form of pruning and great skill and care is required to ensure that the plant remains productive. Other significant factors are shade and pest/disease control. Plucking As noted above, plucking is one of the most critical operations in tea production. It helps to determine the quality of the final product and has a significant effect on the growth of the plant. Plucking is usually by hand, although various mechanical devices are used in some areas. Traditionally, higher quality tea is produced from 'fine' plucking of 'two leaves and a bud'. To obtain higher yields (more leaves processed)-, 'coarse' plucking of up to five or six leaves and a bud is employed. Although production will increase, quality will decrease and, if practiced continuously the plant's growth will slow down. Mechanical harvesting also results in 'coarse' plucking. The fineness of the plucking system should be linked to processing requirements. In some high altitude areas where leaves are produced with inherently high quality, fine plucking is essential, in other areas where the quality is lower anyway, a coarser pluck may be employed. In general, fine plucking will produce 'blacker' tea, good liquoring characteristics. and a higher percentage of better grades in the finished product. Tea bushes are usually plucked once every one to two weeks depending on the season. Plucking in the morning often produces better quality leaf than evening plucking. Once the leaf is plucked it should be taken to the factory for further processing as quickly as possible so that bacterial attack and leaf deterioration can be reduced. Uncontrolled fermentation due to bruising, and overheating result from poor handling. Clean leaves waiting for processing should be kept in the shade and away from heat. 3 PROCESSING Introduction The main purpose of tea processing is to allow chemical changes to take place within the tea leaf. Because of this, the processing itself does not involve complicated machinery or sophisticated technology. It is, however, time-,space-, and usually labor-intensive. Developments in mechanization are mainly concerned with limiting the amount of space, and in some cases labor, needed. Because of the long-standing traditions of tea consumption, the major aim of processors is to achieve consistent levels of quality and appearance. Recent changes in consumer habits have led, however, to the elimination of some processing steps in the production of some tea products, e.g.
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