The document summarizes the field training program completed by the author at Balangoda Plantations PLC, which includes 4 estates - Wewesse, Glen Alpin, Ury, and Telbedde. The training covered various activities related to tea cultivation and manufacturing over a period of 1 month. Key activities included replanting, pruning, shade management, labor management, Orthodox tea manufacturing, plucking, weeding, pest and disease control, nursery practices, and fertilizer application. The objective was to understand practical aspects of tea production and management to improve productivity and sustainability in the tea industry.

1. Field Training program on Tea Production
At
Balangoda Plantations PLC
By
O.C. DE SILVA
The Report Submitted in Partial Fulfillment of the Requirements of the
Degree of
BACHELOR OF SCIENCE IN TEA TECHNOLOGY AND VALUE ADDITION
Uva Wellassa University, Sri Lanka
Certified by
……………………......................... ……………………………….
Mr. N. P. Liyanage Mr. J. U. Hulangamuwa
Superintendent – Telbedde Estate Superintendent – Ury Estate
……………………………………. ……………………………….
Mr. P. K. Senanayake Mr. H. S. C. Nanayakkara
Superintendent – Wewesse Estate Superintendent – Glen Alpin Estate
………………………………….
Mr. T. A. G. De Mel
General Manager
Balangoda Plantattion PLC
Date: ………………………….
……………………………………
Dr. K. G. Premathilake
Internal Senior Lecturer
Coordinator (Field Training Programme)
Department of Export Agriculture
Uva Wellassa University
Date: ………………………….
……………………………..
Dr. L. M. H. R. Alwis
Head
Department of Export Agriculture
Uva Wellassa University
Date: …………………..

2. ACKNOWLEDGEMENT
I would like to indebted to Dr.G.Chandrasena, Vice chancellor, Uva Wellassa University of
Sri Lanka, Dr.S.C.Jayamanne, Dean, Faculty of Animal Science and Export Agriculture, Uva
Wellassa University, Dr.L.M.H.R.Alwis, Faculty of Animal Science & Export Agriculture,
Uva Wellassa University and Dr.K.G.Premathilake, Coordinator, Field Training Programme,
Uva Wellassa University for Facilitating the field training programme on tea production and
providing me an opportunity to follow it.
I would like to express my deepest sincere gratitude to Mr.T.A.G.De Mel, General Manager,
Balangoda Plantations PLC, for facilitating an one month field training programme for
undergraduates of Tea Technology & Value Addition Degree programme.
I would like to express my heartful gratitude to the superintendents of all four estates for
providing kind patronage, comments, encouragement, valuable advices and inspiring co-
operation during this month.
I offer my obeisance to Miss.R.M.S.D.Rathnayake, Lecturer, Faculty of Animal Science &
Export Agriculture, Uva Wellassa University and my internal supervisor Miss.G.M.P.Kanthi,
Temporary Demonstrator, Department of Export Agriculture, for their inspiration and
intellectual contribution for my studies and my work.
I express my sincere gratitude and thankfulness towards all members of staff in Balangoda
Plantations PLC, assistant superintendents, other officers, estate workers and those who have
contributed significantly during the field training to make it worthwhile and informative.

3. 1. ACKNOWLEDGEMENT
2. TABLE OF CONTENT
3. LIST OF TABLES
4. LIST OF PLATES
5. LIST OF FIGURES
6. CHAPTER 01
6.1. INTRODUCTION
6.1.1. General Objective of Field Training ……………………………………. 1
6.1.2. Background of the Balangoda Plantation PLC ………………… ............ 2
6.1.3. Overview of Estates and activities Completed during Training Progr …. 2
6.1.4. Organizational Chart ……………………………………………………. 4
7. CHAPTER 02
7.1. ACTIVITIES UNDERTAKEN
7.1.1. Nursery ………………………………………………………………….. 5
7.1.1.1. Site Selection for Nursery ………………………………….…… 5
7.1.1.2. Site Selection for Soil …………………………………………… 5
7.1.1.3. Identification of Mother Bush Cultivars ………………………… 5
7.1.1.4. Preparation of Nursery Soil ……………………………………… 6
7.1.1.5. Fumigation ………………………………………………………. 6
7.1.1.6. Bagging of soil …………………………………………………... 7
7.1.1.7. Planting Materials ……………………………………………...... 8,9
7.1.1.8. Planting the Cuttings …………………………………………….. 9
7.1.1.9. Shade Management …………………………………………….... 10
7.1.1.10. Watering …………………………………………………………. 10
7.1.1.11. Fertilizing ………………………………………………………... 10

4. 7.1.1.12. Pest and Disease Control ………………………………………… 11
7.1.1.13. Traini9ng Nursery Plant ………………………………………… 11
7.1.1.13.1. Disbudding …………………………………………........ 11
7.1.1.13.2. Thumb Nailing ………………………………………….. 12
7.1.1.14. Restacking ……………………………………………………..... 12
7.1.1.15. Cleft Grafting in Nursery ……………………………………….. 12
7.1.2. Replanting Works ………………………………………………………. 13
7.1.2.1. Land Selection ………………………………………………….. 13
7.1.2.2. Profile Pit ……………………………………………………….. 14
7.1.2.3. Uprooting ……………………………………………………….. 15
7.1.2.4. Forking and lateral Drains …………………………………….... 15
7.1.2.5. Leader and lateral Drains ……………………………………….. 16
7.1.2.6. Dolomite Application …………………………………………… 16
7.1.2.7. Soil Rehabilitation ……………………………………………..... 16
7.1.2.8. Establishment and Management of Shade Trees ……………....... 17
7.1.2.9. Lining, Pegging, Holding and Planting of Tea …………………. 17
7.1.3. Plucking …………………………………………………………………. 18
7.1.3.1. Manual Plucking ……………………………………………....... 19
7.1.3.2. Mechanical Plucking ……………………………………………. 20
7.1.3.2.1. Shear Plucking …………………………………….......... 20
7.1.3.2.2. Machine Plucking ……………………………………….. 20
7.1.3.3. Transport of Green Leaves …………………………………....... 20
7.1.3.4. Weighting of Green Leaves …………………………………….. 20
7.1.3.5. Plucking Norm ………………………………………………….. 21
7.1.3.6. Leaf Counting Process ………………………………………….. 21

5. 7.1.4. Pruning ………………………………………………………………….. 21
7.1.4.1. Clean Pruning …………………………………………………… 22
7.1.4.2. Rim-lung Pruning ……………………………………………….. 23
7.1.4.3. Starch Test ………………………………………………………. 23
7.1.4.4. Frame Sanitation ………………………………………………… 24
7.1.4.5. Burying of Pruning ……………………………………………… 24
7.1.4.6. Tipping and Plucking in ………………………………………… 24
7.1.5. Fertilizing of Tea ……………………………………………………….. 25
7.1.5.1. N-Fertilizer Requirement ………………………………………. 25
7.1.6. Draining ………………………………………………………………… 26
7.1.6.1. Construction of Leader and Lateral Drains …………………...... 26
7.1.6.1.1. Cutting of Leader Drains ……………………………….. 27
7.1.7. Forking …………………………………………………………………. 27
7.1.7.1. Deep Forking …………………………………………………… 27
7.1.7.2. Envelop of Forking …………………………………………….. 27
7.1.7.3. Time of Forking ……………………………………………….... 27
7.1.7.4. Frequency of Forking …………………………………………... 28
7.1.7.5. Forking in Related to Weather ………………………………..... 28
7.1.8. Weeding ……………………………………………………………….... 28
7.1.8.1. Importance of Weeding ………………………………………… 28
7.1.8.2. Weed Control Method, Manual/Chemical ……………………… 28
7.1.8.3. Time of Applications of Chemicals …………………………….. 29
7.1.9. Tea Manufacture ………………………………………………………… 29
7.1.9.1. Tea Manufacture – Orthodox …………………………………… 29
7.1.9.1.1. Withering ………………………………………….......... 29

6. 7.1.9.1.2. Rolling …………………………………………………... 30
7.1.9.1.3. Role Breaking …………………………………………... 30
7.1.9.1.4. Fermentation ……………………………………………. 30
7.1.9.1.5. Drying/ Firing …………………………………………… 30
7.1.9.1.6. Sifting and Grading ……………………………………... 30
7.1.9.1.7. Packing …………………………………………….......... 31
7.1.9.1.8. Dispatching ……………………………………………… 31
7.1.9.1.9. Tea Testing and Moisture Testing ………………………. 31
7.1.9.2. Tea Manufacture – Rotorvane …………………………………... 32
7.1.9.3. Familiarizing with Raising of Samples, Cataloguing and Marketing 32
Process
7.1.9.3.1. Raising of Samples ……………………………………… 32
7.1.9.3.2. Cataloguing and Marketing Process ……………….......... 32
7.1.9.4. Objectives of ISO 22000:2005 Food Safety Management Policy 33
7.1.10. Maintenance of Estate Records …………………………………………. 33
7.1.10.1. Estate Record Books ………………………………………......... 33
7.1.10.1.1. Name of Books in Estate Head Office ………………….. 33
7.1.10.1.2. Name of Books in Factory ………………………............ 34
7.1.10.1.3. Name of Books in Estate Division ……………………… 35
7.1.11. Welfare Activities ……………………………………………………… 35
7.1.11.1. Welfare Staff and Responsibility ……………………………….. 36
8. CHAPTER 03 …………………………………………………………………….... 37
8.1. PROBLEMS IDENFIED AND SUGGESTIONS ………........................ 37,38,39
9. CHAPTER 04 ………………………………………………………........................ 40
9.1. CONCLUSIONS AND RECOMMENDATIONS ……………...................... 40

7. 10. REFERENCES …………………………………………………………………….. 4

8. LIST OF TABLES
1.1 Work Schedule and Capacities of Each Estate ………………………………….... 3
1.2 Chemicals Use in Tea Nurseries for Control Pest and Disease …………………... 11
1.3 Types of Pruning ………………………………………………………………….. 22
1.4 Recommended Basal Mixtures for Seedling Tea ………………………………… 26
1.5 Recommended Basal Mixtures for Seedling Tea …………………………………. 26

9. LIST OF PLATES
Plate 2.1 Collecting Soil for Nursery ………………………………………………….. 7
Plate 2.2 Nursery Bag Filling ………………………………………………………….. 8
Plate 2.3 Suitable Cutting ……………………………………………………………… 9
Plate 2.4 Unsuitable Cutting ………………………………………………………….... 9
Plate 2.5 Planting the Cuttings ………………………………………………………... 9
Plate 2.6 Providing Low Shade Using Bracken fern ………………………………….. 10
Plate 2.7 Restacking …………………………………………………………………… 12
Plate 2.8 Steps of Cleft Grafting ……………………………………………………….. 13
Plate 2.9 Replanting ……………………………………………………………………. 13
Plate 2.10 A Profile Pit ……………………………………………………………….... 14
Plate 2.11 Uprooting ………………………………………………………………….... 15
Plate 2.12 Forking ……………………………………………………………………... 16
Plate 2.13 Leveling ……………………………………………………………………... 16
Plate 2.14 Establishment of Shade Trees ………………………………………………. 18
Plate 2.15 Tea Shoot ……………………………………………………………………. 19
Plate 2.16 Manual Plucking …………………………………………………………….. 19
Plate 2.17 Pruning …………………………………………………………………….. 22
Plate 2.18 Starch Test ………………………………………………………………….. 24
Plate 2.19 Burring of pruning ………………………………………………………..… 24

10. LIST OF FIGURES
2.1 Lateral Drain ……………………………………………………………………… 27
2.2 Leader Drain ………………………………………………………………………. 2

11. CHAPTER 1
INTRODUCTION
Tea is a leading export crop in Sri Lanka and it plays a significant role in Sri Lankan
economy with high GDP contribution which illustrates its economic viability. To ensure the
long term sustainability of tea industry, it is important to have the practical knowledge and
skills belongs to their precise working environment.
Therefore, as undergraduates of Tea Technology and Value Addition degree program of Uva
Wellassa University, we had a valuable opportunity to conduct the field training programme
at Balangoda Plantation PLC under Glen Alpin, Telbedde, Wewesse and Ury Estates to
obtain hand experience and a practical knowledge regarding the tea plantations, tea
manufacturing and other cultural aspects of the tea estates. All four Estates are situated near
to Badulla with a varying elevation between 3000 to 6000 feet under Uva medium category.
The duration of the creeper training was 1 month from 22nd
of September 2014 to 17th
of
October 2014 and it was conducted under the supervision of the external and internal
supervisors.
The field training report is designed based on the skills, experiences, activities, information,
practical procedures and other field and factory related functions gained from the field
training program. Within this one month of training period we,
 Applied theoretical knowledge on tea cultivation and processing chain in the real
working environment.

12.  Enhanced knowledge and developed skills on identification and evaluation of tea
production system.
 Identified pests and diseases of tea with their symptoms.
 Learned about appropriate control measures Integrated Pest Management etc.
 Enhanced knowledge and skills on fertilizer programs, tea nursery management and
rotorvane manufacturing of tea.
1.1 General Objectives of Field Training
 To understand theoretical and practical aspects of tea cultivation and management for
higher productivity and sustainability of tea cultivation
 To acquire the competencies in technical, operational and managerial practices in tea
industry while identifying and assessing the development needs.
 Determine the problems in the tea industry and suggest feasible solutions for them.
 To understand about key functions of labor management and welfare.
 Identified pests and diseases of tea and their symptoms and learn appropriate control
measures.
1.2 Company Profile of the Balangoda Plantation PLC
Balangoda Plantations PLC is a company which managed by the Stassen group. It is
engaged in the cultivation, processing and selling activities under tea and rubber. The
company has 16 tea estates, one rubber estate and 7 tea and rubber mixed cropping
estates.
Balangoda plantation PLC was incorporated in 1992 to take over the assets and liabilities
of various estates owned and managed by the Janatha Estate Development Board (JDB)
and the Sri Lanka State Plantation Corporation (SLSPC) as a public limited company.

13. Their vision is to achieve excellence in the production and marketing of tea and rubber both
locally and internationally. Their mission is to increase productivity as well as to encourage
team work and motivate amongst employees and provide for carrier development.
1.3 Overview of Estates and Activities Completed during Training Program
Table 1.1 : Work schedule and capacities of each estate
Estate
name
Extent(Tea)
hectare
Labor
force
Training period Activities Completed
Wewesse 285 432
22th
September to
27th
September 2014
 Uprooting
 Soil rehabilitation
 Soil conservation
 Replanting
 Pruning
 Shade management
Glen Alpin 352.73 566
29th
September to
04th
October 2014
 Labor management and
welfare
 Muster
 Orthodox manufacturing
Ury 356 548
06th
October to 11th
October 2014
 Plucking
 Chemical weeding
 Pest and disease management
 Records keeping
Telbedde 697.97 1300
13th
October to17th
November 2014
 Fertilizer application
 Nursery management
practices
 Rot vane manufacture

14. 1.4 Organizational Structure
Field Staff
Welfare officer
Chief clerk
General Manager
Mid wife
Senior factory
officer
Superintendents
Assistant Superintendents Office Staff
Field officer
Factory Staff Welfare Staff
Managing Director
Chief Executive Officer
Estate doctor
Assistant field
officer
Field workers Child
Development
Officer
Divisional clerk
Factory officer
Kangani Factory workers

15. CHAPTER 2
ACTIVITIES UNDERTAKEN
The training activities and other related functions which were carried out during the training
period and theoretical background of each activity can be obtained as below.
2.1 Nursery
Nursery is the place where, plants keep with special attention until they obtain the optimum
desirable qualities for field planting. The main objective of nursery management is to raise
healthy, vigorous and uniform plants with minimum casualties at a minimum cost.
2.1.1 Site Selection for nursery
A nursery site must be centrally located to facilitate easy and constant supervision. The size
of the site depends on the annual requirements of the plants and the slope of the land. The
following factors are considered when selecting a site for nursery.
 Good drainage.
 Proximity to water source.
 Proximity to soil source.
 Protection from wind.
 Place without overhanging branches of trees

16. 2.1.2 Site Selection for Soil
Growth of the nursery plants largely depends on the ratio of sand, silt and clay composites in
the nursery soil and pH of soil should maintain within the range of 4.5-5.5 to accomplish the
successful rooting. The soil chosen for bagging should be free from stones, pebbles and large
root particles.
The sites of soil suitable for nurseries are as follows.
 Grass soil- A soil where grass (mana) has been grown for over period with
appropriate rooting ability
 Patana soil- A soil from patana lands where grasses, ferns and shrubs have grown
naturally
 Jungle soil- A soil from Eucalyptus and Pines blocks/plantations can be used.
2.1.3 Identification of Mother Bush Cultivars
Mother bush cultivated plots should be establish near to the nursery which has the land with
gently slope. Selected mother bush cultivars should have the high yielding, pest and disease
resistance, drought tolerance like qualities. Bushes were pruned 4-5 months prior to obtain
cuttings. Well adopted mother bush cultivars for Uva region are as follow, TRI 4006, TRI
4042, TRI 4046 and D.N cultivars.
2.1.4 Preparation of Nursery Soil
Soil was transported from the site to nursery and sieved by using number 4 mesh to remove
the stones, grasses and large roots. The soil heap arrangement is done in 10' x 10' x 1' area
which close to the nursery. Here also, labour has given a norm for loading, unloading and

17. sieving as one cube of soil/one labour for loading and unloading where 1 ½ cube sieved
soil/one labour for sieving.
Plate 2.1 : Collecting soil for Nursery
2.1.5 Fumigation
All tea nurseries should certainly fumigate their soil with recommended fumigate to control
the nematode infection. Recommended fumigates are the ;
 Metham Sodium (liquid) 600ml and 32 liter pure water were used for 1 cube soil
 Basamid 500g for 1 cube soil.
Then, after fumigation turning of soil has to be done 9th
, 12th
, 15th
days after treatment and to
check the severity of Metham Sodium, cowpea is planted in the fumigated soil after 21 days.
If there is any growth after 3 days, the soil will take for bagging.
2.1.6 Bagging of Soil
Normally polythene are used for bagging process. The nursery bag should have 150 gauge
thickness and standard size of the bag refers 5” width and 9” length. The bottom end left

18. opened and few holes were punched in order to facilitate drainage. About one cube of soil is
required to fill 1000 sleeves.
When filling the sleeves, a small layer of lightly wet soil is gently rammed at the bottom to
make it hold on to the sleeve. Then filling by gently pressing the soil inside, but not ramming
it hard. No air pockets should not be left in the soil while filling as it could result in sagging
of the bag.
Plate 2.2 : Nursery bag filling
2.1.7 Planting Material
Tea plants are raised from planting of inter nodal cutting obtaining Single node cutting. Erect
shoots with vigorous growth were chosen from mother bushes. Normally 3-5 cuttings per
shoot and approximately 60-70 shoot cuttings per bush could be obtained. One worker can
harvest 500 shoots and take about 3000 cuttings.

19. Cuttings were taken from the tender, middle portion of shoot by shooting a sharp knife and
kept them in a water basin to prevent the dry off. Cut surface should be smoothed and angled.
Overgrown shoots, flowery buds and damaged mother leaf should be avoided the cuttings
were obtained in order to the recommended procedure and gently pressed them in to the
nursery bag with angled direction, without disturbing other laid cuttings.
Plate 2.3 : Suitable cutting Plate 2.4 : Unsuita blecuttings
2.1.8 Planting of Cuttings
Only one cutting was planted per bag by inserting vertically down in to the soil. The cutting
were obtained in order to the recommended procedure and gently pressed them in to the
nursery bag with angled direction, without disturbing other laid cuttings. Planting of cutting
should be done in the manner the leaves are oriented in one direction at an angle to the row.
Two single node cuttings were planted in the bags which were placed in the margin to
recover the die back. One worker should plant 1000 cuttings per day.

20. Plate 2.5 : Planting the cuttings
2.1.9 Shade Management
Cuttings should not be exposed to the direct sunlight. So in order to provide the medium
shade bracken ferns were used as clusters and placed them in the nursery bags to provide the
about 2- 3 shoots between polythene bags as low (Plate 2.3) 80% of shade within first 3
months, commence from the planting of cuttings. One worker should cover the 300 plants per
day.
Plate 2.6 Providing low shade using bracken fern

21. 2.1.10 Watering
In early stages, regular watering with two three times per day is necessary and it depends on
the weather condition. In dry season, watering frequency should increase to uphold the plant
condition. Watering helps to maintain the proper soil moisture level at the nursery site. Per
day, one worker should watering the 25000 plants.
2.1.11 Fertilizing
Fertilizers should be used only after the cuttings have been rooted. One or two plans can be
uprooted to check whether plants are rooted or not. After the application of fertilizer watering
was done to prevent the chemical scorch.
The recommended fertilizer mixture is T 65 with the rate of 35g per 120 plants per
application. It was given at 14 days interval in the first 5 months. Thereafter the rate could be
increased up to 70g per 120 plants per application, at 14 days interval.
To enhance the early bud break and for active growth of plants, ZnSo4 can be applied as
foliar application about a week after the first application of T 65. One labor should spray
ZnSo4 for 100,000 plants per round by using knapsack sprayer.
2.1.12 Pest and Disease Control
Common pests found in tea nurseries are tea tortrix (Homona cofferia), yellow mite
(Hemitarsonemus latus) and shot hole borer (Xyleborus fornicates). Common diseases found

22. in tea nurseries are the blister blight (Exobasidium vexans) and black blight (Rizoctonia
solani).
Pest / Disease Pesticide
Tea tortrix Mimic / Atabrone
Shot hole borer Lebasid
Blister blight, Yellow mite Copper sulphate
Table 2.2 : Chemicals use in tea nurseries for control pest and disease
2.1.13 Preparation of Nursery Plants for Field Planting
2.1.13.1 Disbudding
Disbudding was practiced to encourage the formation of lateral branches from the former
level of the stem.
This refers the removal of terminal bud of the growing plant at the 4-5 leaves stage and it was
repeated again for the axillary buds when they have grown out. One worker can attend to
5000 plants per day.
2.1.13.2 Thumb nailing
This involves the removal of bud and the first two leaves and it is recommended to undertake
at the 7-8 leaves stage. One worker should attend to 2500 plants per day.
2.1.14 Restacking

23. Restacking was done based on their growth rate. The objective of restacking is to give
uniform growth conditions such as water, sunlight, soil and fertilizer for similar size plants.
First restacking was done at 4-5 months after planting the cutting and second restacking was
done at 6-7 month stage. It is better to give more attention to low grown plants.
Plate 2.7 : Restacking
2.1.15 Cleft Grafting in Nursery
Cleft grafting is grafting techniques which obtain desirable characteristics of two cultivars
into one plant. This technique was practiced to obtain high yielding, pest and disease
resistance, drought tolerance and productive tea plant.
This practice is done under sealed polythene tent in the nursery bed. D.N variety and TRI
4006 varieties were respectively taken as stock and scion were taken for cleft grafting. A
skilled worker can produce 30 grafts for an hour.

24. Plate 2.8 : Steps of cleft grafting
2.2 Replanting Works
Major objective of replanting operation is to obtain high productive plants by removing old
and poor yielding bushes at the field. However it should decide by the estate management,
depending on the availability of estate labors, economic status and Marketing potential of the
estate.
Even though the replanting is one of the most important field practice, mostly it is prolonged
since it requires high investment. This program is planned for 2- 2 ½ years before planting, to
remove old shade tree plants from the entire tea field. It is taken more than 18 months
including ring barking activity.
Plate 2.9 Replanting

25. 2.2.1 Land Selection
Field categorization should be done, according to the TRI guidelines (LU1, serial No.16/03).
Replanting areas could be selected from the lower „B‟ category and upper end of „C‟
category fields.
Following factors have to be considered for replanting
 Slope less than 70%
 Well-drained soil
 Soil depth greater than 50 cm
 Rockiness less than 20% Gravel content less than 50%
Climatic factors such as rainfall and wind should also be considered when selecting lands for
planting tea. Then, twelve profile pits per hectare were cut to identify the suitability of land
for tea planting. The width, length and depth of the profile pit are 90 cm (3 feet). Thereafter,
these profile pits are inspected by inspectors of TRI. The suitability of the land is decided by
them.
2.2.2 Profile pit
Then 12 profile pits per hectare should be cut with 90 cm length, width and depth. TRI
inspectors are observed the profile pits and decide the land which is suitable for replanting.
90cm
90cm

26. 90cm
Plate 2.10 : A profile pit
2.2.3 Uprooting
All the roots of tea bushes and shade trees which were more than pencil thickness were
removed manually by using Mamoty and “Alavangu” or mechanically by Backhoes.
According to TRI guidelines uprooting should commence from the uppermost section of a
slope. But, when it is used Backhoes to this operation it is not practicable with some field
restrictions.
Plate2.11 Uprooting
90cm

27. 2.2.4 Forking and Leveling
The objective of forking is to ensure deep cultivation of soil in the mild degree. Usually
mechanical deep forking activity was practiced during the uprooting of tea bushes by using
Backhoes in large extends of tea land. But, for small extend normally used fork, alawangu
and mamoty. About 1 ½ ' width of soil have to be removed in forking phase to remove all
stones and roots of vegetation in the land. While forking, the soil is opened up at the center of
the inter row space without turning over the clod and with minimum disturbance to the feeder
roots. With the prolonged dry weather, forking should be avoided.
At the leveling phase, removal of stones and other root particles which are up to pencil
thickness of both tea bushes and shade trees was required.
2.2.5 Leader and Lateral Drains
Construction of leader and lateral drains at the field is important in replanting process to
manage the water flow running through the field with the purpose of preventing the soil
Plate 2.12 : Forking Plate 2.13 : Leveling

28. erosion. Leader drains are the main drains which were constructed on natural drainage lines.
All the lateral drains are gently sloped towards the leader drains.
Leveled land was pegged by using along with wooden sticks the contour at a gradient of
1:120, towards the leader drain by using “A-Frame” or “Road tracer” to construct the lateral
drain.
The space between lateral drains is depend on the slope of the land and amount of rain fall
(usually it is taken 6-12 m).
2.2.6 Dolomite Application
4000 kg of dolomite was evenly applied per 1 ha to increase the soil pH up to desirable level
(4.5-5.5). But this amount is depending on the pH level of particular soil.
2.2.7 Soil Rehabilitation
Mana grasses were planted on contour rows with the space of 6-9'' within the raw and 2'
between rows to rehabilitate the soil. Mana, which planted at the upper end was commenced
with the gap of 1.5' and lower end was commenced with the 1' gap to prevent the collapse of
lateral drains.
Mana plants were well driven in to the soil and compacted with soil without leaving any air
pocket. It was checked by using randomly selected mana plants.Lopping of mana grass was
commenced with the height of 1.5' and 2nd
lopping was done at the height of 2‟ lopping of
mana grass was practiced 3-4 times per year before they came in to flowering stage.However,
with the labor shortage and high cost involved this conditions are not practicable at the field.
Fences were prepared to protect the mana grass from stray cattle.

29. The minimum time required to be kept under rehabilitation is 18 months.
2.2.8 Establishment and Management of Shade Trees
Two types of shade trees are established at the same time with the mana planting. Dadap
(Erithrina lithosperma)sticks with 6' of height were taken and established as low shade at
10'× 10' spacing as initial shade (then thin out to 20'× 20' ). The planting hole should be 1'-
1½', 225 g of dolomite was applied to the hole before planting. 1 ½ ' length of stick should
placed under the hole while 4 ½ ' and remain above the ground level. Without the upper most
feet, the planted stick were coated with lime to prevent the bud break from lower areas. The
top end of the sticks about 1.5' was covered with polythene to prevent dieback. Lopping of
dadap was done with the regular intervals (1-2 times per year) and lopping were used as
green manure for tea plants.
Gravillia seedlings, where initially raised in poly bags at nursery can be planted as high shade
at 20'×20' spacing as initial shade (then thin out to 40'× 40' ). The planting hole should be 2'-
2 ½' depth. 1 kg of Dolomite was applied to the each planting hole.
Once a year, pollarding of high shade trees was done to make a well spread canopy at the
height of 20'.

30. Plate 2.14 : Establishment of shade trees
2.2.9 Lining, Pegging, Holing and Planting of Tea
After cutting mana grass to the ground level, lining and pegging has to be done on contours
between the original grass rows to enable holing operation. Planting hole should be 45cm
(18”) deep and 30cm (12”) as open diameter. Plants are usually planted at the inter rows of
mana. Top soil is filled up to 2/3 of the hole and 7g of Carbofuran was applied to prevent
white grubs‟ infestation.
2.3 Plucking
Picking of young tea shoot having two or three leaves and soft dormant shoot (banjhi) is
known as plucking. Plucking is the most important field practice which affect the final
quality of made tea and it is the highest single component, which accounted more than 1/3 of
cost of production (COP), which involved in harvesting tender apical shoots and also it is the
most labour intensive field operation in tea plantation.

31. Well balanced plucking policy enhances the yield and optimizes the labour usage without
affecting the quality of made tea. Stressed overgrown bushes (flowered bushes) were skipped
during the plucking activity and it is called clearing of field. The appropriate plucking style
should be selected by considering the prevailing weather pattern, bush vigour and labour
availability. Plucking styles can be categorized as follow.
 Light plucking : Leave one mature leaf, fish leaf and scale leaves
 Hard plucking : Leave the fish leaves and scale leaves.
Plate 2.15 : Tea shoot
2.3.1 Manual Plucking
Manual plucking refers the removal of tender apical shoots with human power without using
any mechanical devices. And this is the best method to practice selective plucking. Usually 2
leaves and bud were removed. But “Immature banj”, 3 leaves and a bud and selected
immature leaves are plucked by considering the duration of plucking round.

32. Plate 2.16 : Manual plucking
2.3.2 Mechanical Harvesting
2.3.2.1 Shear Harvesting
Shear harvesting was practiced by using the hand held shears (TRISTH) as a selective
harvesting technique. Shears are convenient with the well leveled bushes and less sloppy
lands because if it a well leveled land it cause to minimized the physical damages to the
leaves and it prevent the early fermentation of tea leaves on tea bush. Main purpose of shear
plucking is to overcome the labor shortage in tea estates, mainly during the rush crop season.
2.3.2.2 Machine Harvesting
Machine plucking was practiced by using Hand held Motorized harvester. Hand held
Motorized harvester is used for both harvesting and clearing of fields. This method is suitable
for low and medium sloppy lands to be practice the non-selective harvesting. Two labors
were needed per hectare and they could be able to harvest more than 100-120kg per day.
2.3.3 Transport of Green Leaves

33. Plucked fresh green leaves are transported to the factory by Lorries, tractors and on foot as
soon as possible, in order to take them for manufacturing.
2.3.4 Weighing of Green Leaves
 Check roll weight- Plucked leaves are weighed at the field by reducing some amount
of weight for moisture and bag weight (lowest end)
 Field weight–All the pluck leaves are collected and they were weighted in front of
field officer (highest weight)
 Factory weight- This weighing is done at the factory and recorded in the green leaf
statement book (lower weight than field weight)
2.3.5 Plucking Norm
Plucking norm is the number of kilograms of green leaves that has to be plucked by each
plucker, in order to be qualified to receive the daily wage. Plucking norm could vary with two
factors namely the type of tea and the season of the year and it is mainly govern by the
existing crop at the field.
2.3.6 Leaf Counting Process to Obtain Best Leaf
Weighted tea leaves were selected and got in bulky. 200 g of leaves are normally selected for
this process. Then leaves are categorized under 4 stages as two leaves and a bud, imature
banji, mature banji and coarse leaves

34. If 2 leaves and a bud and Normal banji are more than 75%, they are best for manufacturing
process and mature banji also use for manufacture. But now most of estates are practiced on 2
leaves and bud plucking in order to achieve high quality tea.
2.4 Pruning
Pruning is the removal of leaf bearing branches from the tea bush at a given height. Main
objectives of pruning are to,
 Maintain a convenient height of the plucking table for easy harvesting
 Stimulate vegetative growth for sustaining productivity
 Remove old, decayed ,pest-infected and diseased branches for maintaining a healthy
frame and effectively utilize the land area
Usually 1/4 of the entire estate extent is pruned annually by dividing that extent evenly in to 3
categories. Pruning is done in 4 year gaps or sometimes in 3 years. The pruning period is
depending on rainfall pattern, wind, vigor of tea bush, category of field and available starch
reserves.

35. Plate 2.17 : Pruning
Table 2.3 : Types of pruning
Type of pruning Height Frame sanitation
Clean pruning 25-40 cm Partial-complete
Rim lung pruning 40-55 cm Partial-complete
Cut across pruning 55-75 cm Nil
2.4.1 Clean Pruning
This is a hard pruning system which remove the all branches at a height of 25-40 cm. Clean
pruning usually results in late or poor recovery ability due to absence of foliage and adequate
starch reserves to support the bud break and subsequent growth of shoots.
However clean pruning is adopted at high elevations, because the soil and weather conditions
are conductive for growth and adequate starch reserves are available in the tea bush is in the
desirable level for better recovery after pruning.

36. 2.4.2 Rim-lung Pruning
Foe the Uva region rim lung pruning was recommended. Rim-lung pruning was practiced by
keeping 3-4 vigorously grown shoots with 200-300 leaves at a height of 40-55 cm. Other
shoots were removed at a height of 1.5' without keeping any unsuitable portions (pinnal-
vadhu, muddhichi-vadhu and asimbuvadhu) by using a pruning knife. Pruned surfaces should
be sharped and sloped to prevent die back.
2.4.3 Cut-across
Prune the upper most layer of the bush at a height of 55-70 cm. In this type of pruning,
cleaning up of old debilitated branches was not practiced and therefore it can lead to poor
frame development.
2.4.4 Starch Test
Starch test was conducted before pruning for identify the recovering ability. Thumb sized
root samples were taken randomly from selected tea bushes (20bushes/ha).Roots were
washed and splited into 2 halves lengthwise. Few drops of iodine solution were applied to the
splited surfaces of the roots. Colour changes were observed after 1 minute.
Dark bluish colour : Starch content is greater than 15%
Pale bluish colour : Starch content in between 10 – 15%
No colour change : Starch content less than 10%

37. It is not necessary rested the field, if more than 75% of dark bluish roots.
Plate 2.18 : Starch test
2.4.5 Frame Sanitation
Pruned leaves were kept on the tea bushes to avoid sun scorching of remaining stems just
after pruning. Mossing and ferning is another important post pruning practice and it is done
manually with 15 labours per hectare. Chemicals were not used to those activities to
minimize cost factor.
2.4.6 Burying of Pruning
Pruned branches were buried in shallow trenches in alternate tea inter-rows in a staggered
manner. This post pruning practice has a great impact on enhancement of organic matter
content and to recycle plant nutrients which are available in soil.

38. Plate 2.19 : Burring of pruning
2.4.7 Tipping and Plucking in
Tipping was practiced by keeping 4 leaves at the bottom from the pruned cut, after it is
covered 75% of the bush frame and grown shoots with 8-10 leaves and it refers the removal
of other leave. The purpose of keeping 4 leaves is to give support for root (2 leaves) and
shoot growth (2 leaves). Side branches should not be tipped and over grown shoots should
removed by using a knife. This is usually taken 3 months and pluckable leaves are taken as
the harvest.
But recovery of bush is very poor by this knife cut tipping practice. So TRI is recommended
“plucking in” practice which done in same way as tipping manualy when the stem of bush in
green stage. Recovery of bush frame better than tipping.
2.5 Fertilizing of Tea
Total fertilizer requirement of each tea field has to be calculated based on the potential yield
of individual field. Where favorable weather conditions prevail, frequent applications of

39. fertilizer are desirable. If it is applied during periods of dry or heavy rain, the fertilizer
adsorption will be ineffective.
2.5.1 N-fertilizer Requirement
The calculation of annual N-fertilizer requirement for a given tea field is based on the
“potential yield”. The annual potential yield is defined as the highest yield achieved in the
previous pruning cycles at the same age of that cycle, and it based on the immediate past 3
cycles. Then it was estimated to get more than 10% from the potential yield. Application of
fertilizer to mature seedling or VP fields is calculated according to the potential yield. Cycle
ratio is counted from last prune into to-date value, 12 months ratio was counted for last 12
months while season ratio is counted with January to present month.
N ratio = (Total input of N / Total yield) x 100%
Table 2.4 : Recommended Basal Mixtures for Seedling Tea
Region
Nutrient requirement
as Recommended
Source of Nutrients
Mixture
N P2O5 K2O Urea ERP MOP
Up/Mid 90 25 70 196 87 117 ST/UM 400
Low 90 25 50 196 86 83 ST/LC 365
Uva 90 25 90 196 89 150 ST/UM 435
Table 2.5 : Recommended Basal Mixtures for VP Tea
Region
Nutrient Requirement
Source of
Nutrient
Mixture
Recommended Basal Mixtures for VP Tea

40. N P2O5 K2O Urea ERP MOP
Up/Mid 270 35 120 587 123 200 VP/UM 910
Low 270 35 100 587 126 167 VP/LC 880
Uva 270 35 140 587 125 233 VP/UVA 945
2.6 Draining
2.6.1 Construction of Leader and Lateral Drains
In tea field, there are two types of drains called leader and lateral drains. Leader drains are the
main drains which constructed on natural drainage lines to convey the water from lateral
drains. The types of leader drain should be reverse slop type. All the lateral drains are gently
sloped towards the leader drains.
Leveled land is pegged along the contour at a gradient of 1:120 to slope towards the leader
drain by using “A-Frame” and “Road tracer” to make a lateral drain. After observation from
road tracer and pegs were connected with a nylon rope and finally smoothed the drain line
with more pegs. The space between lateral drains is depended on the slope of the land and
amount of rain fall (usually it is taken 20-40 m).
1 3
2 0.5 1.5 width 2.5'
3 10 6 9 1 Reverse slope Check dam
Figure 2.1 : Lateral drain with lock & spill Figure 2.2 : Leader drain
2.7 Forking

41. Forking is practiced once in a pruning cycle. Because compaction of the soil is caused to
decrease the number of macro pores in the soil. Excessive forking may be damaged to the
feeder roots and it could be harmful to the tea bush.
2.7.1 Deep Forking
Deep forking was undertaken with a garden fork which having 3-4 tines, 38-45 cm long.
2.7.2 Envelope Forking
Envelope forking was practiced by using garden forks with 3-4 tines along the tea inter rows
and having 22-30 cm interval. Soil is just opened and leaf litter was put into it while
maintaining a gap of 9-12'' between tea stem and hole.
2.7.3 Time of Forking
Normally forking was practiced done after pruning when there is the sufficient new foliage
on the bush and soil moisture is in a acceptable level. Forking can practiced with more than 2
intervals, when alternative rows are forked each time.
2.7.4 Frequency of Forking
It is recommended to carry out the forking only once a cycle in the up and mid country and
once in 2 cycles in low country.
2.7.5 Forking in Related to Weather
Forking during prolonged dry weather should be avoided. When forking is carried out in such
dry periods, the soil surface is exposed to wind and sun light which resulting the evaporation
of soil moisture. And forking could be avoided in heavy rainy days to prevent the soil
erosion.
2.8 Weeding

42. 2.8. 1 Importance of Weeding
Simply a weed is an unwanted plant in the cultivation, which compete with the main crop for
moisture, space, sunlight and nutrition. They are holding diseases and pests which harmfully
affect for tea cultivation. Also weeds are disturbed to many field operations like plucking,
fertilizing, draining etc (thorny weeds and creeper weeds). Therefore weeding at tea field is
played vital role in estates.
2.8.2 Weed Control Method – Manual/Chemical
 Manual- Hand pulling and slash weeding
 Chemical- Use of pre-emergent, contact and systemic weedicides
Residual weedicide- Those that are applied to the soil and are mainly root absorbed. They
are relatively persistent and transmit mainly through the xylem. Also called pre-emergent
weedicides. E.g. Diuron.
Contact weedicide- Those that are applied to the foliage and do not move far from the point
of application. They kill only tissues with which they come in to contact. E.g. Paraquat.
Systemic weedicide- Those that are applied to the foliage and can move from the site of
application to other parts of the plant. Their action is systemic and movement is principally
through the phloem. E.g. Glyphosate.
2.8.3 Time of Applications of Chemicals

43. When weed are in an active stage of growth with tender leaves and 8-10 cm in height, it will
be effective to use herbicides. Select a calm day for spraying, as wind could carry the spray
drift away from the intended area of spray. Also avoid the very hot period of the day for
spraying (It is done with 3 labours per hectare)
2.9 Tea Manufacture
2.9.1 Tea Manufacture – Orthodox
The orthodox manufacturing of tea produced highly profitable leafy grades such as Pekoe
types, OPA, OP and flowery grades. Following steps were engaged with the pure orthodox
manufacture.
2.9.1.1 Withering
Withering is the removal of excess moisture in green leaf under controlled conditions using a
mixture of conditioned air and ambient air. Turning and loosening practices were done with
the help of workers in order to have better uniform wither. A worker should spreads 4500 kg
of leaves per day.
2.9.1.2 Rolling
Rolling was done after withering in order to get dhool. The objective of rolling is to twisting
and size reducing of the leaf matter (by applying pressure). Rolling was done for first batch
of withered leaves (420kg) with the help of workers.
2.9.1.3 Roll Breaking

44. The main objectives of roll breaking is to separate dhools from rolled leaf, prevent over
fermentation of dhools, to cool the bulk of leaf and breaking of lumps. Reciprocatory roll-
breakers are used in orthodox manufacture to get leafy grades.
2.9.1.4 Fermentation
The dhools were spread on the fermenting beds, and they were kept until the temperature
attained to 84° F. At this temperature, chemical Reactions are started.
2.9.1.5 Drying/Firing
Drying is a C.C.P (Critical Control Point) and it helps to arrest the fermentation at the
optimum time by exposing the particles to higher temperature and also to bring down the
moisture content to about 3% to facilitate storage and packing. It also inactivates microbial
activities in tea, and checks further loss of soluble matter which takes place during
fermentation. ECP dryers were commonly used at the drying.
2.9.1.6 Sifting and Grading
Sifting is helps to get different grades of tea by the separation of particles into various sizes.
Leafy grades are available as highest particle sizes and lowest particle sizes. Sifting is also
help to clean the tea from iron particles, fibers and stalks.
2.9.1.7 Packing
Packing is a one of C.C.P (Critical Control Point ) in tea manufacturing. Paper sacks and
container sacks were commonly used in packing. Container sacks were used for leafy grades
and paper sacks were used for non-leafy grades like broken grade teas.

45. 2.9.1.8 Dispatching
The loading of teas from factory to were house/private sale refers as dispatching it was done
in related to invoice of dispatch and sent them to warehouses/private sales is called tea
dispatching. Normally vehicle should contain about 200-220 tea bags.
2.9.1.9 Tea Tasting and Moisture Testing
The main objective of tea tasting is to find out any defect of the process by assessing general
appearance of tea, liquor characteristic and infusion. For factory purposes 2.5-2.8g of tea
sample was taken from daily sample and let it brew for 5 minute with hot boiled water. After
separating liquor and infusion it is ready for tasting and testing. But at professional level of
tea tasting, 5.5g of tea sample was boiled in 217ml of water to make a tea tasting cup.
The main objective of moisture testing is to check moisture level of fired tea and graded tea
before packing. Moisture level should below than 7%. This will help to factory staff to adjust
temperature level of drier and to take decision about re-firing process. The moisture testing
equipment is Infra-Red moisture teller where 2g of graded tea can be placed on balance plate
and adjust it to zero and supply power for 5 minutes. Then calculate the moisture level before
packing .
2.9.2 Tea Manufacture – Rotorvane
The main objective of rotor vane type tea manufacturing is to produce of high percentage of
broken grades and to maintain quality manufacturing at specially quality season.
Manufacturing process is same as the orthodox manufacturing but rolling is done by using

46. rotovane rollers and roll-breaking process is done by using rotary roll breaker with the sizes
of No.2, No.3, No.4, No.6, No.7 and No.8 meshes.
The deviated step of rotorvane tea manufacture is the engagement of rotorvane roller which
consists of barrel, feed hopper, feed worm, vanes, resisters and an end attachment. A 10HP
gear motor is needed for operation.
2.9.3 Familiarizing with Raising of Samples, Cataloguing and Marketing Process
2.9.3.1 Raising of Samples
Tea sampling- At ex estate sale all teas are in factory and authorized body is taken 1kg from
one package and total of 4kg randomly taken by covering all packages according to the
related invoice number. This type of sampling specially performs during quality season with
rotovane teas.
Special sampling- Perform during quality season where air bid takes place. 250g of tea in an
Aluminum foil pack is sent through air mail to foreign country for those who are willing to
buy at there. This type of sampling is also performed by broker.
2.9.3.2 Cataloguing and Marketing Process
The all dispatched teas except for ex-estate should be in Colombo warehouses. Then check
whether recommended number of lots are available and catalogue (Picks the lower invoice
numbers first) under Uva name category.
Then at the auction, teas are being bided by buyers and highest price bid fetch the invoice.
But for ex-estate sale, all teas are at factory while other procedures for selling are same.

47. Objectives of ISO 22000:2005Food Safety Management Policy
ISO 22000:2005 is stand for food safety management policy is to minimize chemical,
physical and biological hazards to the system. Factory food safety management system
documentation requirement are Documented statement of food safety policy and related
objectives, Documented procedures and records required by the standard and Documents
required for development, implementation and updating of food safety management system.
2.10 Maintenance of Estate Records
2.10.1 Estate Record Books
2.10.1.1 Name of Books in Estate Head Office
1. Cash book- All the details of salary, available income in bank, value of stocks details
are recorded
2. Stock books- All the available stocked goods details are included
3. Amalgamation- The book which included all the check roll details of entire field
4. Goods received book- All the details about received goods like manure, machineries
are included
5. Worker register- All the details of each and every worker and records their day to day
details which help to work out worker wages

48. 6. Budget book- Mainly budget estimate on crop, revenue from made tea, total
expenditures and profit on sale of made tea. Based on estimation next year works are
carried out
7. Retirement gratuity book- All the details of gratuity for the labors are recorded
8. Estate vehicle running expenses book- All the details of estate vehicles are recorded
(Fuel, spare parts, tires, grease, oil, painting, repairing etc.)
9. Check List- Records details like date, EPF No, name, task and time duration of task
which need for check rolling
10. Requisition book- All the required goods details can be included in this book
11. Tea valuation book- All details of auctioned teas are recorded (Dispatch tea, quantity,
gross weight, net weight etc.)
12. Tea infilling inventory book- All the details of infilling activities in the field are
recorded in each year
2.10.1.2 Name of Books in Factory
1. Tea book - All the details from the field to factory are recorded (Rainfall, Plucking,
and Withering to Dispatching)
2. Yield books- All the details of yield fertilizer, pruning cycles in each divisions are
recorded
3. Cycling yield book- All the details of yielding after each pruning cycle are recorded
by Superintendent and Assistance superintendent
4. Withered leaf book- All the details of withering are recorded
5. Rolling room book- All the details and types of rolling are recorded

49. 6. Fired tea weighing book- All the details about drying and output quantities are
recorded
7. Sifted tea account book- All the details of grading and sifting are recorded
8. Bin card- Details of graded teas for dispatching from the bin are recorded. 1 Bin card
is used to record the details of 1 tea grade (1 for BOPF grade)
9. Dispatch book- Dispatched grades, broker details are recorded
10. Check roll book- Worker wage details are recorded
11. Bought leaf weighing book- Weight of bought leaves are recorded
2.10.1.3 Name of Books in Estate Division
1. Tools book- All the details of tools in each divisions are recorded
2. Master diary - Details of plucking, labors and other divisional details recorded
3. Maternity book- Details about child birth in each division and record details for the
salary calculation
4. Sick leave book- Details of sick leaves of workers during the work period are
recorded
2.11 Welfare Activities
The welfare activities of tea sector is in desirable level in compare to developed rather than
any other industries. Initially the labors also have their rights, therefore all the facilities

50. including infrastructure, accommodation and food had to be given by the estate. Currently,
rather than those fundamental facilities, education, medical facilities, EPF, ETF , family
problems solving, sanitary and other welfare facilities are also provided.
2.11.1 Welfare Staff and Responsibility
Estate Medical Assistant  Issuing medicines as necessary
 Cure patients and direct them to the hospital as needed
 Consulting regarding sanitary issues
 Take care on pregnant mother‟s pre delivery, delivery and post-
delivery
Midwife  Infant and child conservation
 Counseling on family planning, oral health, environmental
health and youth health
Plantation family welfare
supervisor
 Change dependent mentality of estate workers
 Line maintenance, co-operative services, toilet and sanitary
services, health and education program
Child Development Officer  Taking care of children who need a protection
 Counseling for parent
 Conduct programs for child development and health

51. In addition to these responsibilities, educational programs on drug addictions, social diseases
preventing programmes , demonstrations on liquoring and smoking related to their immoral
effects are conducted.
CHAPTER 3
PROBLEMS IDENTIFIED AND SUGGESTIONS
3.1 Labor shortage.
The labor problems are difficult to manage by the estate management. Because the human
resource power is very important in the estate. Therefore we have to handle them carefully,
otherwise there may be troubles, strikes, labour migrations, etc.
Suggestion: Should give maximum benefits to the labours. Then it will make more labour
attraction to the tea plantation. And also the estate management should be consider on new
invention such as Shear plucking and Machine plucking. And also increase in welfare
services may be reduce the migration of labors from the estate.
3.2 Cost of production is another important topic in plantation.

52. The cost of production directly effect to the profit margin with Net Sale Average (NSA) in
the estates. The COP is increased because of several reasons; high cost for the labor wages,
high electricity cost, etc.
Reduce to 0% is not possible, but can reduce up to 50-60%.
Suggestion: labor cost can be reduce by using Shears and Machineries for plucking.
Replanting is not suitable for current situation, because it required high investment. Direct
sales and Forward contract of made tea also help to earn profit while take part in Public
auction. Reductions of unnecessary machineries also help to minimize the cost.
3.3 Lack of equipment to the field practices
Suggestion: Always try to use the well maintained modern equipments and estimate budget
for equipment related to field activities is required.
3.4 Problems and Suggestions Regarding Nursery
 Watering to nursery plants is cost consume process: Sprinkler system or Drip
irrigation can help to overcome this situation
 Pest and Disease problems: Practice proper land management practices and keep
the nursery site free from pest and disease area

53. 3.5 Problems and Suggestions Regarding Plucking
Always try to use new techniques and standard ways to do the plucking and also inform
the pluckers and all the coworkers about them.
3.6 Problems and Suggestions Regarding Replanting
 Labor shortage and Time consumption process: Use machineries such as
Backhoes, loader and rollers
 Soil erosion problems: Watering to tea plant before uprooting, watering before
forking and leveling the land.
3.7 Problems and Suggestions Regarding Pruning
 Improper pruning and bush sanitation maintenance: Proper supervision in the
field by a field officer and contract system also minimize those problems and
machinery pruning can practice by skilled labors
 Improper post pruning activities: Skilled labors should allow for those practices
3.8 Problems and Suggestions Regarding Chemical Weeding
 Improper spraying of weedicides and wastage of chemicals: Assist, advise and
explain the purpose of weeding to the labors and use skilled labors
 Continuous weedicide spraying lead to resistance ability on weeds: Practicing
alternative methods to overcome those problems like Integrated Weed Management
practices

54. 3.9 Problems and Suggestions Regarding Manufacturing
 Maintenance of machinery is at poor level: Maintenance is lead to avoid cost of
production and balance the labor shortage
 Reduce the percentage of refuse tea by standard plucking and use the excess of
refuse tea as manure for tea land
 Reduce the wastage of electricity by off the machines which are not working for
the manufacture process fix some energy serving equipments such as VSD,
capacitor banks is also a good suggestion.
 Color shorter should remove the tips in Flowery grades. So proper sifting can
minimize the need of color shorting process.
3.10 Quality of the end product
Both the local and the export market prices depend on the quality of the made tea. The
final quality mostly depends on the plucking leaf standards.
Solutions: Should always be careful to use standard methods and machineries in all the
plantation operations, plucking, manufacturing and distribution of tea. As suggestions you
can obtain,
 Should have the careful supervision
 Adopting of GAP, GMP (Good agricultural practices, Good manufacturing
practices)
CHAPTER 4

55. CONCLUSIONS AND RECOMMENDATIONS
Tea Technology and Value Addition is the one of four year special degree program in Uva
Wellassa University. Practical aspects regarding the theories leant in Tea Technology and
Value Addition degree programme were applied in the field training programme which was
conducted from 22nd
of September 2014 to 17th
of October 2014. This training program was a
great opportunity for us to gain valuable knowledge and skills and to understand the
appropriateness of the theoretical knowledge when applying them into the practical
situations. It directed us to combine our knowledge with the practical aspects. Through this
training programme, we were able to gather most of the real experiences in Sri Lankan Tea
industry, able to familiarize with the estate culture which will be affected for developing our
future carrier, and understood the importance of the attitudes, disciplines, team work spirit,
leadership qualities and the problem solving strategies.
But we couldn‟t get enough practical knowledge about tea marketing process during this
training program. And also in some factories scheduled works are not enough for 1 week
period while some scheduled works are overload for 1 week.
Viva voce and spot test can do in the period of training to get better result and discussion
from students.
As more experience become more perfect, I would like to suggest to lengthen the duration of
this training for about 2 months and finally, it can be concluded this training program is a
valuable, excellent and great opportunity for all the undergraduates of Tea technology and
Value Addition degree program.

56. REFERENCES
 Britannica Tea Cultivation. Retrieved June 2007.
 Kathiravetpillai A. and Kulasegaram S., 2008. Nursaery and Nursery Practices, In :
„Handbook on Tea‟(Eds.A.K.N.Zoysa)pp. Tea Research Institute of in Sri Lanka,
Talawakelle, Sri Lanka.
 Premathilake K.G.,2003.Weed Management in Tea Lands. In: Twentieth Century Tea
Research in Sri Lanka (Ed.) W.W.D.Modder, Tea Research Institute of in Sri Lanka,
Talawakelle, Sri Lanka.63.
 Sivapala P.,Gnanapragasam N.C. and Kathiravetpillai A.(1995).Field Guild Book(Tea
Research Institute of in Sri Lanka, Talawakelle, Sri Lanka).
 T. R.I. ADVISORY CIRCULARS 2004/2005, Tea Research Institute of in Sri Lanka,
Talawakelle, Sri Lanka.