The Commercial Products of the Vegetable Kingdom by P. L. Simmonds

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Next day the different kinds of tea are picked, and on being
separated they are again placed in the conical baskets and heated.
During this process the baskets are frequently removed from the
choolah in order to turn the tea, so that the heating may be general
and uniform. In doing this a flat basket is always placed on the
floor, as on the former day (and a flat basket, too, is placed on
the top to confine the heat), to receive the conical one, which
receive one or two blows to open the pores of the sieve. What passes
through is replaced amongst the tea. When it is perfectly dry it is
ready for finally packing.

The kinds of black tea at present manufactured are--Souchong,
Pouchong, Flowery Pekoe, and Bohea. The Flowery Pekoe is
manufactured in September.

_Method of manufacturing Green Tea_.--On the young and fresh leaves
being plucked they are spread out on the ground of the airing room
and allowed to cool. After remaining for about two hours, or (if
brought in late in the afternoon) during the night, they are removed
to the green tea room. The pans being properly heated, the leaves,
as in the case with the black tea, are thrown into the pans and kept
either with the hand or two forked sticks in constant motion for
three or four minutes, and are then removed to the rolling table,
and then rolled in the same manner in balls as the black tea. They
are then scattered most sparingly on large flat baskets and exposed
to the heat of the sun. If there is no sun the baskets are arranged
in frames, which are placed over the choolah, heated with charcoal.
During the drying the leaves are frequently made into balls and
rolled in the flat baskets, in order to extract the juice. The
drying process continues for about two hours, and on the leaves
becoming dry, those contained in two baskets are thrown together,
and then four basketsful into one, and so on until they are all
collected together. In this state the leaves still feel soft, damp,
and pliant to the hand, and are now brought back to the tea
manufacturing-room. Opposite to each of the inclined pans, which
have been properly heated so as to feel warm to the hand by wood
supplied to the ovens underneath, one of the Chinese stations
himself, and puts as many leaves into it as it will hold. He then
moves them in a heap gently, from before backward, making these
perform a circle, and presses them strongly to the sides of the pan.
As the leaves become hot he uses a flat piece of wood, in order that
he may more effectually compress them. This process continues for
about two hours, the leaves being compressed into at least half of
their bulk, and become so dry that when pressed against the back
part of the pan in mass, they again fall back in pieces. The tea, as
by this time it has assumed this appearance, is now placed in a bag
made of American drill or jean (the size depending on the quantity
of tea), which is damped, and one end twisted with much force over a
stick, and thus it is much reduced in size. After being thus
powerfully compressed and beaten so as to reduce the mass as much as
possible, the bag is exposed to the sun until it feels perfectly
dry. If there is no sun it is placed in the heated pan, and there
retained until it is so. This finishes the first day's process.

On the second day it is placed in small quantities in the heated
inclined pans, and moved up and down against the sides and bottom
with the palm of the hand, which is made to perform a semi circle.
This is continued for about six hours, and by so doing the colour of
the tea is gradually brought out.

The third day it is passed through sieve baskets of different
dimensions, then exposed to the winnowing machine, which separates
the different kinds of green teas. The winnowing machine is divided
into a series of divisions, which receive the different kinds
according to their size and weight. 1st. Coarsest Souchoo. This tea,
owing to its coarseness, is not marketable. 2nd. Chounchoo. This is
a large, round-grained tea. 3rd. Machoo. This is also a
round-grained tea, but finer than the former. 4th. Hyson. 5th.
Gunpowder Hyson. 6th. Chumat. This kind of tea consists of broken
particles of other kinds of tea.

On being separated, the different kinds are placed in baskets and
picked by the hand, all the old or badly curled and also
light-coloured leaves being removed, and others of different
varieties, which by chance may have become mixed. To make the bad or
light-colored leaves marketable, they undergo an artificial process
of coloring, but this I have prohibited in compliance with the
orders of the Court of Directors, and therefore do not consider this
tea at present fit for the market[13]. On the different teas being
properly picked, they are again placed in the heated inclined pans,
and undergo separately the process of being moved violently up and
down and along the bottom of the pan for three hours in the manner
already described. The color is now fully developed. If the tea
feels damp, it is kept longer than three hours in the pan. The tea
is now ready to be packed.

_Packing_.--As soon as the tea is prepared, boxes lined with sheet
lead ought to be ready to receive it. On being packed it is to be
firmly pressed down, and the lead is then to be soldered. Before the
sheet lead box is placed in the wooden one it is covered with paper,
which is pasted on to prevent any air acting on the tea through any
holes which might exist in the lead. The box is then nailed, removed
to the godown, papered, stamped, and numbered. It is then ready for
sale.

From what I have just stated, it will be perceived that box makers
and sheet lead makers are essential to form a complete tea
establishment. With reference to the box making it is unnecessary
for me to make any remark, further than that care is to be taken in
selecting wood for making boxes, as it ought to be free of all
smell. All coniferous (pine) woods are therefore unfit for the
purpose. In the hills the best woods are toon and walnut, and at
Deyrah the saul (_Shorea Robusta_).

_Manufacture of sheet lead_.--Sheet lead making is a much more
complicated process, and therefore requires more consideration. To
make sheet lead, the manufacturer mixes 11/2 to 3 seers of block tin
with a pucka maund of lead, and melts them together in a cast metal
pan. On being melted, the flat stone slabs, under which it is his
intention to run the lead, are first covered with ten or twelve
sheets of smooth paper (the hill paper being well adapted to the
purpose), which are pasted to the sides, and chalked over. He then
places the under stone in a skeleton frame of wood, to keep it firm,
and above it the other stone. On the upper stone the manufacturer
sits, and gently raises it with his left hand, assisted by throwing
the weight of his body backwards. With his right hand he fills an
iron ladle with the molten matter, throws it under the raised slab,
which he immediately compresses and brings forward (it having been
placed back, and thus overlapping the under slab by about half an
inch) with his own weight. On doing so, the superabundant lead
issues in front and at both sides; what remains attached to the
slabs is removed by the iron ladle. The upper slab is now lifted,
and the sheet of lead examined. If it is devoid of holes it is
retained; if, on the other hand, there are several, which is
generally the case with the first two or three sheets run, or until
the slabs get warm, it is again thrown back to the melting pan.
After having run off a series of sheets the slabs are to be
examined, and, if the paper is in the least burnt, the first sheet
is to be removed, and the one underneath taking its place, and thus
securing an uniform smooth surface, is then to be chalked. According
to the size of the stone slabs used, so is the size of the sheet
lead. Those now in use are 16 inches square by 2 inches in
thickness, and are a composition, being principally formed of lime.

To make sheet lead boxes, a model one of wood (a little smaller than
the box for which the lead is intended) is formed, which has a hole
in the bottom, and a transverse bar of wood to assist in lifting it
up, instead of a lid. The lead is then shaped on this model and
soldered. This being done, the model is removed by the transverse
bar, and by pressing, if necessary, through the hole. The lead box
is then papered over, in case there should be any small holes in it,
to prevent the action of air on the tea, and, when dry, transferred
to the wooden box for which it was intended.

_The manufactory_.--The rooms of the manufactory ought to be large
and airy, and to consist of--1st, a black tea manufactory; 2nd, a
green tea manufactory; 3rd, winnowing room; and 4th, airing room. At
Almorah the black tea manufacturing room is 53 feet long by 20
broad, and the other three, 20 by 24. The walls are 18 feet in
height.

_Implements required in manufacturing_.--In the body of this report
I have noticed all the different kinds of implements required, I may
however, again briefly notice them, and give a short account of
each. Cast-iron Pans--In the manufactory there are two kinds in use,
one received from China, the other from England. Both are considered
equally good by the tea manufacturers, though in firing green tea
they prefer the Chinese ones, as they are thinner, and are thus by
them better able to regulate the heat. The Chinese pans are two feet
two inches in diameter, and 10 inches in depth, by about one-eighth
of an inch in thickness.

The English pans are two feet two inches in diameter, and eight
inches in depth, and rather thicker than the Chinese.

The oven for making black tea is made of kucha brick. In height it
is two feet nine inches, in length, three feet, and in breadth three
feet one inch. Door one foot five inches in height, and 11 inches in
breadth. The base of the oven is 10 inches elevated above the floor
of the manufacturing room.

The oven with double pans for manufacturing green tea, is also built
of kucha bricks. It is three feet in height and three feet in
breadth; base of oven one foot in height. Door one foot six inches
in height, and 10 inches in breadth. The pans are placed
horizontally.

A brush made of split bamboo, used in sweeping the tea leaves out of
the pans.

A basket for receiving tea from the pan when ready to be rolled. It
is 2 feet long, and 11/2 feet broad, and gradually increases in depth
from before backwards to 6 inches. It is made of bamboo.

The mat made of bamboo for placing on the table when the tea leaves
are about to be rolled. It is 8 feet long and 4 feet broad.

A flat basket made of bamboo for spreading out the tea leaves when
they have been rolled on the mat. These flat baskets are of various
sizes, varying from 3 to 5 feet in diameter.

A flat sieve basket of 2 feet in diameter, made of bamboo, upon
which the rolled tea leaves are placed, and which is deposited in
the centre of the double-coned basket.

Double-coned baskets. The height of these baskets varies from 2 feet
2 inches to 2 feet 6 inches, external diameter 2 feet 8 inches. In
the centre there are some pegs of bamboo to support the flat sieve
basket on which the tea rests.

Forked sticks for turning leaves.

Choolahs. These are formed of kucha bricks, and are 10 inches high,
101/2 inches deep, and generally about 2 feet in diameter.

Funnel made of bamboo to allow the heated air from the choolahs to
pass through the tea; it is seldom used; the Chinese tea
manufacturers preferring one made in the tea basket by the hand.

Oven for firing green tea made of kucha bricks. The pans are
inclined at an angle of 50. In front the oven is 3 feet 2 inches in
height, behind 4 feet 8 inches, length 51/2 feet, breadth 3 feet. Door
10 inches from the base, 1 foot 2 inches high, and 7 inches wide.

Frames for placing baskets. The first being inclined.

Baskets for collecting leaves.

Shovel, &c., used in regulating the fire.

Winnowing machine. This is a common winnowing machine, with a box 2
feet 10 inches in length, 1 foot 2 inches in breadth, and 1 foot 3
inches in depth, attached to the bottom of the hopper, and closely
fitted into the middle of the circular apartment which contains the
fanners. This box is entirely closed above (unless at the small
opening receiving the hopper) and at the sides. At the base there
are two inclined boards which project from the side of the machine 6
inches, and are partly separated from each other by angular pieces
of wood. The end towards the fanners is open, the other is partly
closed by a semicircular box which is moveable.

I shall now give the dimensions of the different parts of this
machine, which may be useful to parties wishing to make up similar
ones to those employed in the manufactories.

External frame 7 feet 2 inches in length, 18 inches in breadth, and
5 feet 8 inches in height. Hopper 2 feet 10 inches above, and 1 foot
8 inches in depth. Frame of box for fanners 3 feet 9 inches in
diameter. Hopper frame 2 feet 7 inches. Semicircular box, in length
2 feet 5 inches and 7 inches in depth. Inclined plane at base, first
15 inches, second 13 inches.

I may briefly state how this machine acts. With the right hand the
fanners are propelled by the crank, and with the left hand the
bottom of the hopper is opened by removing the wood. The flat piece
of wood (the regulator) is held in the hand to regulate the quantity
of tea that passes down. An assistant then throws a quantity of tea
into the hopper which escapes through the apartment, and there meets
the air. The first kind of tea falls down the inclined plane into
one box which has been placed to receive them, the second are
propelled further on, and fall into another box, and the lighter
particles are propelled on to the semicircular end, and fall into a
third box.

_Note on the culture of the tea plant at Darjeeling, in 1847, by Dr.
A. Campbell, Superintendant_.--About six years ago I received a few
tea seeds from Dr. Wallich; they were of China stock, grown in
Kumaon. I planted them in my garden in November, 1841, and had about
a dozen seedlings in the month of May following, which were allowed
to grow where they had come up, and rather close together. The
plants were healthy from the commencement, and up to May, 1844, had
grown very well; at this period the ground passed into other hands
(Mr. Samuel Smith's), and I lost sight of them until last August,
when Mr. Macfarlane, from Assam, who was acquainted with the tea
plant in that province, arrived here. Being desirous of ascertaining
how far the climate and soil of Darjeeling were suitable to the tea,
I took him to examine the plants, and begged of him to record his
opinion on their growth and qualities, with reference to their age,
and his experience of the plant in Assam. The result was quite
satisfactory. Encouraged by this result, I determined to give an
extended trial to the plant, and through the kindness of Major
Jenkins and Captain Brodie, of Assam, I procured a supply of fresh
seed in October and November last, which was planted in November and
the early part of December.

The seed was of excellent quality. It commenced germinating in
March, a few plants appeared above ground in the early part of May,
and now I have upwards of 7,000 fine healthy seedlings in the
plantation.

For the information of those who may desire to try the tea culture
in this soil and climate, I have to state the mode of planting
pursued by me, and other particulars. The ground is a gentle sloping
bank, facing the north and west; the soil is a reddish clay mixed
with vegetable mould. After taking up a crop of potatoes, and
carefully preparing the ground, I put in the seeds in rows six feet
apart and six feet distance in the rows. The seeds were placed about
three inches under the surface, five in number, at each place about
four inches apart--thus : . : On an average, two out of five have
come up. The seedlings commenced appearing above ground early in
May, and continued to show until the end of July. The earliest were,
therefore, six months in the ground; the latest about eight months.

The seed was of China stock, grown in Assam, and of the Assam plant
mixed. I am anxious to have the China stock only, and purpose
separating the plants of the Assam stock as soon as I can
distinguish them, which Captain Brodie informs me can be readily
done as they grow up; the China plants begin of a darker color, and
smaller than the Assam ones.

I hope to have a supply of the seed of China stock from Kumaon next
November, and with it to cause the extension of the experiment at
this place.

I think that it is reasonable to expect quite as good tea to be
produced here as in Kumaon.[14] I have not tasted the Kumaon tea,
but, from the opinion expressed on it in England, I am satisfied
that it is a very drinkable beverage, and that with similar success
here, the tea will be a valuable addition to our products. I have
recently tried two kinds of the Assam tea presented by Mr. Stokes to
a friend. They are excellent teas, and I shall be well content to
have an equally good article manufactured here.

Mr. A. Macfarlane's report on the tea plants in Mr. Smith's ground is
annexed:--

"According to your request I have the pleasure of transmitting you
my opinion of the tea plants in your garden in this place. The two
larger plants have made very good progress, considering their
closeness to each other, which prevents them from throwing their
branches freely in every direction, but as they have attained so
great a size I would not recommend their being transplanted, because
let it be done ever so carefully, the roots must receive more or
less injury, and should the injury be great the death of the tree is
certain.

The smaller ones on the contrary are much stunted; this is caused by
their confined situation, being completely choked up by the rose
trees, which prevents their receiving a proper supply of light and
air, so necessary to vegetation. They are also planted too closely,
and, as the plants are still small, by availing yourself of the most
favourable season, and using great care in the operation, they might
he transplanted with safety, and should then be placed at a distance
of not less than six feet apart. The difficulty of transplanting is
occasioned by the depth to which the root penetrates, as it
generally grows downwards, and in a large tree is principally in the
subsoil. The larger plants should be pruned of their lower branches
to allow a free current of air. This operation is generally
performed in November, but any time during the cold season or before
the rains, while the plant is at rest, would answer: as I have no
knowledge of this climate, I would leave it to more experienced
persons to judge of the proper season. To conclude, the plants are
in a very healthy condition, and had they been in the hands of a
cultivator, would now have been giving a very fair supply of
produce.

The small sample I tried was of a very good flavor, but on account
of the defective manner of manufacture, for want of proper
materials, no proper judgment can be formed." (Simmonds's Col. Mag.,
vol. xvi. p. 44.)

Report upon the Tea Plantations of Deyra, Kumaon and Gurhwal, by
Robert Fortune, Esq., addressed to John Thornton, Esq., Secretary to
the Government, North Western Provinces, dated Calcutta, September
6th, 1851:--

KAOLAGIR TEA PLANTATION.

1. _Situation and extent_.--The Deyra Doon, or Valley of Deyra, is
situated in latitude 3 deg. 18 min. north, and in longitude 78 deg.
east. It is about 60 miles in length from east to west, and 16 miles
broad at its widest part. It is bounded on the south by the Sewalick
range of hills, and on the north by the Himalayas proper, which are
here nearly 8,000 feet above the level of the sea. On the west it is
open to the river Jumna, and on the east to the Ganges, the distance
between these rivers being about 60 miles.

In the centre of this flat valley, the Kaolagir tea plantation has
been formed. Eight acres were under cultivation in 1847. There are
now 300 acres planted, and about 90 more taken in and ready for many
thousands of young plants raised lately from seeds in the
plantation.

2. _Soil and culture_.--The soil of this plantation is composed of
clay, sand, and vegetable matter, rather stiff, and apt to get
"baked" in dry weather, but free enough when it is moist or during
the rains. It rests upon a gravelly subsoil, consisting of
limestone, sandstone, clay-slate, and quartz rock, or of such rocks
as enter into the composition of the surrounding mountain ranges.
The surface is comparatively _flat_, although it falls in certain
directions towards the ravines and rivers.

The plants are arranged neatly in rows 6 feet apart, and each plant
is about 41/2 feet from its neighbour in the row. A long, rank-growing
species of grass, indigenous to the Doon, is most difficult to keep
from over-topping the tea-plants, and is the cause of much extra
labor. Besides the labor common to all tea countries in China, such
as weeding, and occasionally loosening the soil, there is here an
extensive system of irrigation carried on. To facilitate this, the
plants are planted in trenches, from four to six inches below the
level of the ground, and the soil thus dug out is thrown between the
rows to form the paths. Hence the whole of the plantation consists
of numerous trenches of this depth, and five feet from centre to
centre. At right angles with these trenches a small stream is fed
from the canal, and, by opening or shutting their ends, irrigation
can be carried on at the pleasure of the overseer.

3. _Appearance and health of plants_.--The plants generally did not
appear to me to be in that fresh and vigorous condition which I had
been accustomed to see in good Chinese plantations. This, in my
opinion, is caused, 1st, by the plantation being formed on _flat
land_; 2nd, by the system of _irrigation_; 3rd, by too early
plucking; and 4th, by hot drying winds, which are not unfrequent in
this valley from April to the beginning of June.

GUDDOWLI PLANTATION (NEAR PAORIE).

1. _Situation and extent_.--This plantation is situated in the
Province of Eastern Gurhwal, in latitude 30 deg. 8 min. north, and
in longitude 78 deg. 45 min. east. It consists of a large tract of
terraced land, extending from the bottom of a valley or ravine to
more than 1,000 feet up the sides of the mountain. Its lowest
portion is about 4,300 feet, and its highest 5,300 feet above the
level of the sea; the surrounding mountains appear to be from 7,000
to 8,000. The plantation has not been measured, but there are,
apparently, fully one hundred acres under cultivation.

There are about 500,000 plants already planted, besides a large
number of seedlings in beds ready for transplanting. About 3,400 of
the former were planted in 1844, and are now in full bearing; the
greater portion of the others are much younger, having been planted
out only one, two, and three years.

2. _Soil and culture_.--The soil consists of a mixture of loam,
sand, and vegetable matter, is of a yellow colour, and is most
suitable for the cultivation of the tea-plant. It resembles greatly
the soil of the test tea districts in China. A considerable quantity
of stones are mixed with it, chiefly small pieces of clay-slate, of
which the mountains here are composed. Large tracts of equally good
land, at present covered with jungle, are available in this district
without interfering in any way with the rights of the settlers.