CHAPTER 1 INTRODUCTION

INTRODUCTION
Name of the Tea Estate Address Location Year of Acquisition Features : Sholayar Estate : Sholayar Estate , Sholayar Post, Valparai 642 124 : Anamalai Hills, Coimbatore Dist, Tamilnadu, India : 1946 : Cultivation of Green Leaf & Tea Manufacturing

Area under cultivation of tea : 395.79 Area under irrigation Gross yield Awards and Achievements Certificates Awarded : Nil : 3570 : Award for highest yield in 1971 : FIRST ISO 9002 IN PLANTATION & FACTORY

Jay Shree Tea & Industries Ltd. is the third largest tea producer in the world. It has 22 Tea Estates spread throughout India with total area of 9407 hectares under tea plantation. We have five Gardens in Upper Assam, five in Catcher, four in Dooars & Terai, six garden in Darjeeling and two in South India. The company also has two tea processing factories which manufacture tea exclusively from tea leaves procured from other gardens. With the latest acquisitions in Africa, we now have the best teas the African Continent produces. The company is one of the largest tea manufacturer-exporter of India having exported teas of Rs.76.57 corers in FY 2009-10 and already achieved export turnover of Rs.45.40 corers in the half-year ended Sept 30, 2010 and expected to cross Rs.100 corers in the current financial year. The company has produced 234 lac kgs last year and have already produced 156.50 lacks kgs up to 30th September 2010 as compared to 149.47 lac kgs in the same period last year. The current year-end target is 251 lac kgs of black tea.

THE COMPANY Incorporated on 27th October 1945, Jay Shree Tea & Industries Ltd. is a part of well diversified conglomerate of B.K Birla Group. B. K. Birla Group has been in the forefront of industrialization in the country since Independence. An inspiration for generations of Indian
2

entrepreneurs, the Birlas are looked upon as the First Family of India Inc., reflecting quality, reliability and leadership. Besides tea, Jay Shree Tea & Industries Ltd., is manufacturer of Single Super Phosphate & Sulphuric Acid. It recently made foray into Sugar Industry by acquiring 100% stake in M.P.Chini Industries Ltd. It also provides Tea Packaging and Warehousing facilities at Kolkata and Kochi. The company is also engaged in real estate business having developed several properties at prime locations of Kolkata and Bengaluru. The core business of the company is Tea accounting for 75.56% of the gross turnover with Chemicals & Fertilizers at 23.52% and others 0.92% during the half-year ended 30th September 2010.

KEY HIGHLIGHTS 1. It is the only tea company in India having tea estates in all the major tea growing areas of the country. All the teas of India under one roof!! 2. One of the few Indian tea companies to have tea estates abroad. 3. Contributing around 3% of the national tea output. 4. Contributing around 11% of the total Darjeeling tea, considered Champagne of teas.

FINANCIAL HIGHLIGHTS 1. 91% of the present paid-up Share Capital is represented by Bonus Issues. 2. First Group to return money to shareholders in the years 2001 and 2002 under buyback scheme of shares. 3. Uninterrupted track record of paying dividend since inception of the company in 1945. Last 5 years average payout is 33%.

NEW ACQUISITIONS As per the strategic tie up with Assam Tea Corporation Ltd. the company is procuring green leaf of Longai and Ishabheel Tea Estates and operating its Longai Tea Factory to manufacture 6 lac kgs of tea per annum from the current season.

The Parvati Tea Company Pvt. Ltd. acquired by it at Makum (Tinsukia) in the State of Assam is likely to manufacture 6 lack kgs. of black tea during the current year. The Company through its investment arm, Birla Holdings Ltd., UAE has acquired 100% stake in Kijura Tea Co. Ltd. and Bondo Tea Co. Ltd., having tea estates, producing around 14 lac kgs of tea per annum in Uganda (East Africa). Under a joint venture arrangement, it has acquired 60% stake of Mata Tea Co. Ltd. & Gisakura Tea Co. Ltd., Rwanda. The companies own tea estates in the best quality tea producing belt of East Africa producing 42 lack kgs of tea per annum. The cost of producing Tea in East Africa is lower as there is not much need for application of fertilizers and pesticides in the field because of the better soil condition. Further, the social cost for the laborers is the responsibility of the local Government.

DIVERSIFICATION IN SUGAR The company has acquired 100% stake in M.P.Chini Industries Ltd.having a sugar factory at Majhaulia in Bihar with a capacity of 4600 TCD, which is being enhanced to 5500 TCD. The factory has co-generation facility of 6 MW and its own sugarcane plantation of around 1000 acres. This is one of the best maintained factories in the State of Bihar and will enable the company to leverage its experience and expertise in managing agro based industries.

WELFARE ACTIVITIES:

Incentive for excellence in work: Apart from their normal incentive, extra incentives are given to meritorious workers. This encourages other workers also to fall in the line of good performers. Workers turning up regularly to work (outturn), workers plucking highest green leaf in a year and those workers plucking more than 100 kg daily are given special prizes.

Best line maintenance: A sort of competition program is organized for improving the sanitation and maintenance of the labor lines. Best lines are awarded with prizes and above all, Chairman, Managing Director, President visit and share a cup of tea with the awardees. An unbelievable and thrilling event for a worker.

Health awareness program: These are conducted periodically on a continued basis to inculcate a culture among the workforce for preventive measures against normal ailments. Present Executives and their contact details.

S.K.Kardile, Group Manager Phone: 04253-221026, 04253-221030

Awards and Achievements : 1966 -1967, 1978 & 87 Tea Board Trophy for highest yield per hectare in India 1968 Federation of Indian chamber of commerce and Industry Award for outstanding achievement in the field of agriculture for highest yield of tea in India. The award was presented by the Hon'ble prime Minister of India, Smt. Indira Gandhi on March 15, 1969 1987 Tea Board Chairman's Challenge Trophy for highest all India average yield Award for highest price in 1975

Certificates Awarded: FIRST ISO 9002 IN PLANTATION & FACTORY

Welfare Activities:

Incentive for excellence in work: Apart from their normal incentive, extra incentives are given to meritorious workers. This encourages other workers also to fall in the line of good performers. Workers turning up regularly to work (outturn), workers plucking highest green leaf in a year and those workers plucking more than 100 kg daily are given special prizes.

Best line maintenance: A sort of competition programme is organized for improving the sanitation and maintenance of the labor lines. Best lines are awarded with prizes and above all, Chairman, Managing Director, President visit and share a cup of tea with the awardees. An unbelievable and thrilling event for a worker.

Health awareness programme: These are conducted periodically on a continued basis to inculcate a culture among the workforce for preventive measures against normal ailments.
5

Present Executives and their contact details :

S.K.Kardile, Group Manager S.N. JAGETIYA, Commercial Manager

ACTIVITIES INVOLVED IN THE MANUFACTURING OF TEA The main activities carried out here are Procurement of raw materials Withering Cutting Fermentation / oxidation Drying(firing) Sifting Grading Quality evaluation Packing Distribution

CHAPTER 2 COMPANY PROFILE

COMPANY PROFILE
LOCATION : Valparai (Near Pollachi in Anamallai Hills) YEAR OF ACQUISITION : 1946 AREA UNDER TEA GROSS YIELD : 689 hectares : 3405 kg/hectare

What is Tea? Tea is a product obtained by processing the young tea shoots of tea plant. It is a good beverage which has a great market demand all over the world, mainly in Russia . Tea contains a small amount of necessary vitamins and minerals. It is a very good source of antioxidants which helps in strengthening the immune system of the body

FEATURES: Sholayar Estate & Kallyar Estate is the earliest purchased property of B.K. Brila Groups. These two units (Sholayar & Kallyar) were purchased from the Managing Agents M/s Harrisons & crossfield. The total planted area for both these estates put together is 1730.05 acres, most of it planted during the First World War time from 1914 to 1918. We are carrying on with the original planted bushes and only a small area of around 90 acres was newly planted by our company sometimes in the early 1950s. Sholayar Group is also the recipient of FICCI Award for excellence in agriculture. Sholayar group was the first Tea Garden in the Indian Tea Industry to be certified ISO 9002. To counteract high acidity and low ph due to prevalent fertilizer practices, application of agricultural lime and dolomite to soils was carried out in these two estates as early as 1963-64. As a leading player in innovation and development these estates also introduced Split Fertilizer application and the using of Zinc and a higher dose of potash. The Tea Research Institute, UPASI, later recommended these. The group employs 1,501 permanent workers and has been receiving awards continuously for the highest yield/Hectare in this region. This unit consists of two factories; Workshop (MV & CTC), Hospital and School. There are 6 units of Estates for Jayshree Tea & Industries Ltd other than Sholayar & Kallyar

OVERVIEW OF THE COMPANY

Today with technology changing at a pace beyond any previous expectations, and the world becoming a rapidly

emerging market under global economy, Jay Shree Tea & Industries Limited - a B.K Birla Group Company, stands to create the most dynamic form of conducting business by going online. As most in steady a leading business house catering for the best possible teas at the

competitive prices, it has already created its own niche in the market. Not only India but also in Germany, Japan, U.K, Middle East and the CIS it has a consumer - oriented presence. Today by effectively harnessing the promising

aspects of the Internet , and by addressing every possible tea related market segment with newer value propositions and transferring its services across geographical borders, it aspires to develop further, creating brighter prospects for its customers. A new century is at the doorstep. Jay Shree Tea & Industries Limited chooses to respond to it thus confirming yet again its penchant for thinking swiftly and innovatively. Indeed, its functioning mantra has always been balanced on Strong Foundation, Sustained Growth, and Proven Leadership.

JAYSHREE TEA & INDUSTRIES LIMITED

LOCATION

: Valparai (Near Pollachi in Anamallai Hills)

YEAR OF ACQUISITION

: 1946

AREA UNDER TEA

: 689 hectares

GROSS YIELD

: 3405 kg/hectare
9

FEATURES: Sholayar Estate & Kallyar Estate is the earliest purchased property of B.K.Brila Groups. These two units (Sholayar & Kallyar) were purchased from the Managing Agents M/s Harrisons & Crossfield. The total planted area for both these estates put together is 1730.05 acres, most of it planted during the First World War time from 1914 to 1918. We are carrying on with the original planted bushes and only a small area of around 90 acres was newly planted by our company sometimes in the early 1950s. Sholayar Group is also the recipient of FICCI Award for excellence in agriculture. Sholayar group was the first Tea Garden in the Indian Tea Industry to be certified ISO 9002. To counteract high acidity and low ph due to prevalent fertilizer practices, application of agricultural lime and dolomite to soils was carried out in these two estates as early as 1963-64. As a leading player in innovation and development these estates also introduced Split Fertilizer application and the using of Zinc and a higher dose of potash. The Tea Research Institute, UPASI, later recommended these. The group employs 1,501 permanent workers and has been receiving awards continuously for the highest yield/Hectare in this region. This unit consists of two factories; Workshop (MV & CTC), Hospital and School. There are 6 units of Estates for Jayshree Tea & Industries Ltd other than Sholayar & Kallyar. "Perfection in a tea cup is what we achieved here at Jay Shree Tea" ~ Mr. B.K. Birla ( Chairman ) "Our craving for excellence has been translated into success in terms of higher productivity and better quality; we have reached out to the world by our commitment and endeavour to bring the best to our consumers" ~ Director) "Technological upgradation and modernization is a continuous process. Factories and packing units have ISO 9002 and HACCP certification." ~ Mr. D.P. Maheshwari ( Managing Director) Mrs. Jayashree Mohta, Director (

10

PHOTO GALLERY:

SHORT STORY OF THIS GARDEN: These estates are located in the picturesque Anamallai Hills 110 Km from Coimbatore and 150 Km from Cochi. The average elevation of these estates is 3500 to 4000 feet above MSL and the annual rainfall varies between 110 150 inches. The minimum temperature falls to 60C and the maximum temperature goes up to 290c during summer. Anamallai Dist is the highest tea yielding district in the whole of India and most of the gardens are managed by big corporates. This district has two growing season, April to June and Oct to Dec. Sholayar / Kallyar is the earliest purchased properties of our company. These south units were purchased in the year 1946 from the Managing Agent M/s Harrisons & Cross field. The total planted area for both these estates put together is 1730.05 acres, most of it planted during the First World War time from 1914 to 1918. Sholayar / Kallyar estates were the first to introduce CTC type of manufacturing in South India during 1958. Sholayar / Kallyar Estates are the first recipients in the world of the coveted ISO 9002 Certificate for a composite unit of plantations and tea factories

TEA ESTATES Towkok Tea Estate Manjushree Tea Estate Sibsagar, Assam
11

Mangalam Tea Estate Nahorhabi Tea Estate Meleing Tea Estate Dewan Tea Estate Burtoll Tea Estate Labac Tea Estate Kalline Tea Estate Jellalpore Tea Estate Risheehat Tea Estate Tukver Tea Estate Aryaman Tea Estate Ananyashree Tea Estate Jalpaiguri, West Bengal North Dinajpur, West Bengal Darjeeling, West Bengal Cachar, Assam Jorhat, Assam

CHEMICALS & FERTILIZERS Jay Shree Chemicals & Fertilizers has two factories. One factory is located in Khardah, near Kolkata and another in Pataudi, Haryana. The Kolkata unit manufactures Sulphuric Acid and Single Superphosphate and the Pataudi unit manufactures Sulphuric Acid. We are marketing the Single Superphosphate (SSP) under our Brand Annapurna. The company has manufactured 76,256 MT of SSP and 39,162 MT of Sulphuric Acid in the FY 2009-10 and in the current year it targets 90,000 MT of SSP and 82,000 MT of Sulphuric Acid. The Company has kept pace with development of technology in its field and has continuously adopted new technologies in its processes by continuous revamping & modernization of its plants.The process of manufacture of Sulphuric Acid was modified to adopt latest DCDA Technology which resulted in lowest emission levels. Similarly, both the SSP Plants as well as Granulated Fertilizer Plant were revamped and modified with a view to reduce emission levels and improve productivity. The Company has undertaken effective energy conservation measures by installing a suitable Turbo-Alternator which utilizes the surplus steam available from both the Sulphuric Acid Plants.

CHEMICAL & FERTILISERS UNITS The Jay Shree Chemical & Fertilisers
12

Unit I & II @ West Bengal & Unit III @ Haryana

OTHERS Jay Shree InfoTech Consultants Kolkata, West Bengal Warehousing & Tea Export Dept. Kolkata, West Bengal Tea Warehouse & Sales Dept Kochi, Kerala

ALL THE TEAS OF INDIA UNDER ONE ROOF:

Jay Shree Tea & Industries Ltd. is an outstanding crescendo in the composition that is the Birla Group. Besides tea, the Company is also actively involved in chemicals & fertilizers,sugar and education. Jay Shree Tea has gardens spread all over the tea growing regions of India, some nestled in the frosty slopes of Darjeeling, a sprinkling of them rolling languidly over the hot and humid valleys of Assam and Cachar, yet others tucked away in the lower Himalayan reaches of the Dooars and the Terai and a few dotting the undulating Annamalai hills. From Darjeeling comes the Champagne of teas, teasing the connoisseur with their richyet-subtle essence, with flavors and aromas so rich that one of our Darjeeling gardens fetched a record price of Rs.10,000 a kg. From Assam comes the hearty, full-bodied teas, invigorating the sipper with their smooth malt pungency. The Blue Mountains of the Nilgiris down South yield brisk liquors, with their tantalizing fragrance and fine flavors. Jay Shree Tea also specializes in packaged tea, sold under the umbrel la Birla Tea. It also offers customized packaging as well as designs to meet the needs of various clients, at home and abroad. Today, not only is it a leading producer, trader and exporter, but it is also one of the biggest producer of specialty teas, and a proud member of the Specialty Tea Institute, USA.

13

Jay Shree Tea packs its teas right in the gardens to preserve their fresh aromas. Its gardens have constantly won accolades in terms of price and productivity and several awards over the years for quality. Instant acceptance across the globe in countries like Australia, Japan, Pakistan, Russia, Ukraine, Kazakhistan, Iran, Saudi Arabia, UAE, Egypt, Tunis, Germany, Netherland, Ireland, UK, USA, Canada and in even tea producing countries like China and Sri Lanka. The well-diversified company has been enjoying the unwavering trust of a faithful customer base for the last three decades. At the root of its success lies its commitment to achieve 100 percent customer satisfaction.

SOCIAL RESPONSIBILITES: Tea industry is an extremely labor intensive one with plantation workforce hardly having decent literacy levels. A major part of the work-force live on the estates with their families and therefore the total population residing and directly dependent on the tea estates is quite large. The company has to deal with many unions and hence efficient human resource management is the key to survival and success of the company. We have excellent relations with all the unions and the labour work-force which is proved by the fact that we have not had any labour unrest in any of our estates. The company takes pride in looking after its own people and has set-up facilities to provide better living conditions for its workforce. We provide them with hygienic living conditions, subsidized electricity and rations, schools for their children, handicraft centres for providing vocational training, medical facilities not only to provide basic medical care but also to take care of emergencies with subsidized medicines. There are community areas for hosting entertainment programs etc. We also have full-fledged hospitals in a couple of gardens with fully equipped operation theatres. In Darjeeling , the best-equipped hospital in the district is in the Puttabong estate, which has a 52-bed hospital, while the Dewan group of estates in Cachar has a 110-bed hospital with a fully-equipped operation theatre. Not just this, the Sholayar and Kallyar estates in South India also have a 50-bed hospital with OT and facilities like ECG, X-Ray, incubator, bedside monitor and a complete clinical laboratory.

14

Jay Shree Tea is concerned with the health of its employees. Medical centres at Jay Shree Tea's various estates are doing commendable work, holding regular eye check camps, dental care camps, pulse polio programs, blood donation camps, family planning camps, routine immunization, snake bite treatments and maternity care.

Nature Conservancy Jayshree Tea is proud to be eco-friendly. Its inexorable pursuit of technology has not been at the cost of nature. The management at Jay Shree Tea is equally wedded to the preservation of environment. Our afforestation programme has met with a huge success, with thousands of timber trees being planted along roadsides. We are constantly upgrading our technical knowhow so as to effectively utilize our natural resources. With special educational programmes being undertaken on a regular basis for the tea garden workers and their families, they are constantly being briefed on the importance of ecology and conservation of natural resources. Jay Shree Tea is supported by other respectable concerns and organizations. Voluntary organizations too, together with the management, have taken up various projects to clean village drains and sewage; a drive for cleaner water has also resulted in fewer ailments among the labour force. Our top management is hands-on and is very closely involved in companys activities from the grass-root level ensuring the success of every task is undertaken. Our office work-force is a dedicated lot and the company is not affected by the problem of attrition which is the bane of all industries across the country.

NEW DEVELOPMENTS: The company has entered into an agreement with Assam Tea Corporation Limited for purchase of green leaf of Longai & Ishabheel Tea Estates and to operate its Longai Tea Factory having a capacity to manufacture around 10 lacs kg of tea per annum w.e.f. the season commencing March, 2010. The company has also entered into a Memorandum of Understanding to acquire shares of a company having a tea factory near Makum, Tinsukia, Assam with annual production capacity of around 11 lacs kg. per annum. This should help the company to increase its production by around 2 million kgs. from the year 2010 11.
15

SUGAR The company has acquired 100% stake in M.P.Chini Industries Ltd. having a sugar factory at Majhaulia in Bihar with a capacity of 4600 TCD, which is being enhanced to 5500 TCD. The factory has co-generation facility of 6 MW and its own sugarcane plantation of around 1000 acres. This is one of the best maintained factories in the State of Bihar and will enable the company to leverage its experience and expertise in managing agro based industries and harnessing the same for growth of all its stakeholders.

OVERSEAS ACQUISITIONS FOR TEA The company has entered into a joint venture agreement with Rwanda Mountain Tea SARL,Rwanda in East Africa and has formed "Tea Group Investment company Ltd."(TGIC) at Dubai through its offshore investment arm "Birla Holdings Ltd." at Dubai to acquire 60% stake in Mata Tea Co. Ltd., and Gisakura Tea Co. Ltd.,Rwanda, East Africa which was owned by OCIR-THE, the Government of Rwanda.The said companies owns two tea estates namely 'MAta' and 'Gisakura' in Rwand, the best quality tea producing belt in East Africa producing 4.1 mn. kgs. of tea per annum.The Government of Rwanda has recently issued the notification for allotment of the said two tea companies to TGIC and the process for acquisition shall be over within a month's time. The company has also entered into a marketing tie-up with Rwanda Mountain Tea SARL, Rwanda for the sale and marketing of around 6mn.kgs. of tea from its existing tea estates whereby it shall utilize its international marketing network to drive better value for Rwandan teas. Both these acquisition and tie-up shall be in long term interest of the company. The company through its investment ,Birla Holdings Ltd.,Dubai has entered into a share purchase agreement with the owners of Kijura Tea Co. Ltd.and Bondo Tea Co. Ltd., to acquire 100% stake in the said companies having tea estates producing around 1.2 mn.kgs.of tea per annum ar Uganda in East Africa. The total investment for the aforesaid acquisitions in Rwanda Nad Uganda is to the tune of US$ 6.5 million (equivalent to Rs.29.25 crore only)for control of around 11.3mn.kgs.in East Africa.

16

CHAPTER 3 ORGANIZATIONAL CHART

17

ORGANIZATIONAL CHART:
GROUP MANAGER

SHOLAYAR

KALLAYAR

ASSISTANT MANAGER

OFFICE MANAGER

SALES MANAGER

FIELD OFFICER

18

ASSISTANT FIELD OFFICER

SUPERVIOUSOR

LABOUR

SHOLAYAR/KALLYAR COMPARISION:
Sholayar / Kallyar estates are being run with a thin & lean management structure. The total permanent workers including non-staff is 871, Supervisors-74, Staff-55 and Officers 9 (including 1 Doctor).

19

CHAPTER 4 PRODUCTION DEPARTMENT

20

PRODUCTION PROCESS
PROCESS FLOW CHART: Obtaining the raw materials directly from the field

Reducing the moisture content(12-18hrs)

Cutting the withered leaves into finer material

Fermentation and oxidation takes place

Dired to remove the moisture and to obtain keeping quality and black Colour

Graded depending on the material size

Quality evaluation

Packing and dispatches

21

PLANTING OUT IN FIELDS

Tea plants establish This is a very delicate operation and needs adequate planning and proper supervision. Correctly planted in the field quickly, grow vigorously and come into full bearing earlier. On the other hand, a slight error during planting can cause high percentage of mortality or permanent setback to the plants.

NURSERY: Polythene sleeves of 150 g may be used in the nursery. It is recommended to use a 10 cm lay-flat polythene tube of 30 cm length. The lower three-fourths of the sleeves may be filled with jungle top soil with appropriate proportions of sand to make it a sandy loam. The top one-fourth portion of the sleeve should be filled with the rooting medium. Both the soils should have a pH of 4.5 to 4.8 and EC below 0.05 dsm-1. Single nodal cuttings and the grafted plants are prone to pestalotia attack for the first to six weeks after planting. Contact fungicides like mancozeb at the rate of 30 g in 10 litres may be applied for protecting the rooting cuttings from pestalotia attack. Planted cuttings should be inside the nursery 'Pandal' for six to eight months and then transferred to the open space for hardening.

TIME OF PLANTING: June and August are the recommended seasons for planting for the areas receiving south west and north east monsoon season respectively. Periods of heavy rains should be avoided. One year old plants are planted in pits with a dimension of 30 X 45 cm. Double hedge system with a spacing of 135 X 75 X 75 cm ( plant population 13,000 / ha ) is recommended. The selected plants for planting should have 14 to 16 healthy mature leaves and the root system should have reached the bottom end of the sleeves at the time of planting. The stem at the collar region should be about pencil thick and brown.

TYPE OF PLANTS USED FOR PLANTING: Only healthy plants 40-60 cm high with at least 12 good mature leaves and of pencil (0.5 cm) thickness (at collar) should be taken for planting in field. In general, 9 to 12 month old
22

plants attain this stage. Sub-standard plants should be discarded. Before plants are removed from nursery, they should be hardened by gradual exposure to full sun. Transportation of the plants to the planting site in field should be done with utmost care and only after proper labeling.

TYPE OF PLANTING (PROCEDURE FOR GROWING PLANT):

There are two types of planting, i.e., pit planting and trench planting.

PIT PLANTING: This method is followed when spacing between plants is wide enough to allow digging of individual pits of proper size and without much difficulty. Pits should be about 45 cm wide and 45 cm deep, circular and straight walled. Smaller pits restrict root growth and retard shoot growth and development. The excavated soil is conditioned by mixing with 4-5 kg welldecomposed cattle manure or 150-200g well-decomposed oil cakes and returning the soil into the pits. No other manure is used except 30 g rock phosphate and 30g SSP at the time of planting.

TRENCH PLANTING: This method is adopted for closer spacing and in heavy soils. Trenches 30 cm wide and 45 cm deep are dug along the rows. The excavated soil is conditioned and returned back as in case of pits and tea is planted directly on the trenches.

METHOD OF PLANTING ( PROCEDURE FOR CREATING PLANT ): There are two methods of planting, for plants raised in nursery beds. They are bheti planting and stump planting.

BHETI PLANTING: Here, the plants are lifted along with the bheti and the roots intact from the nursery bed. This is convenient with plants grown in ploythene sleeves, which reduces difficulty in transportation, reduce root damage and gives a very high percentage of survival. The polythene is removed carefully by slitting the tube and the bheti is held in the pit half-filled with the conditioned soil in such a manner so that the top of the bheti is flushed with the ground surface. 30g rock phosphate is added at the bottom of the bheti and the pit is filled with soil with
23

adequate ramming. At about 5 cm depth 30g SSP is added around the bheti and the pit is filled up to the collar of the plant with soil. Adequate ramming is necessary to prevent sinking of the pit level later, which will cause localized water logging. The same method can be used for plants grown in sleeves.

STUMP PLANTING: Plants are lifted from the nursery bed without having any soil around the roots. The shoot portion is cut off 15-20 cm from the collar and the excess roots trimmed off before putting them into the pits. This method is generally followed with overgrown nursery plants and has the advantage of easy transport and reduced chances of withering after planting. However, the percentage of survival is much less than bheti planting.
PLUCKING: Plucking round describes the time interval in days between consecutive plucking. The plucking rounds should be maintained at around 10 days during the high cropping months and at about 15 days interval during the low cropping months

STANDARD OF PLUCKING: Black plucking removes all above tipping level, except unopened buds. Standard plucking leaves buds and small one and buds on the bush, remainder plucked to tipping level.
Coarse plucking leaves buds, one and buds and small two and buds on the bush, remainder plucked to tipping level.

24

SYSTEM OF PLUKI: PESTS: Major Tea Pests

Sucking Pests

Chewing Pests

Insect pests

Mite pests

Caterpillar a. Looper

Tea Mosquito bug Thrips Jassids Tea seed bug

Red Spider Mite Scarley Mite Pink Mite Purple Mite

b. Bunch c. Red Slug d. Red stem borer e. Flush worm

Beetles a. Cockchafer Beetle b. Metallic Green Beetle c. Orange Beetle d. Cerambycid Stem e. Borer f. Cerambycid root borer Termites a. Live wood eating b. Scavenging

25

STEPS TO MINIMIZE PESTICIDE RESIDUES IN TEA: Monitoring and early detection of pests Integrated pest management Use of safer pesticides, botanicals and bioagents Avoid repeated spraying of the same pesticide Allow sufficient waiting period between spraying of pesticides and plucking Spot treatment MANURING: Fertilizers should be applied only when the tea bushes are ready to utilize them. As a general rule, the best time for fertilizer application is after the first rain in spring has moistened the soil to a depth of 45 cm and there is some new growth in case of unpruned tea. In case of pruned and skiffed teas, the fertilizers should be applied after the bushes have produced two new leaves. A weed free clean ground is desirable at the time of manuring.

STRIPING: Before pruning the field taking the full leaf including coarse from the tea bushes called Stripping

PRUNING: Pruning is one of the most important operations, next to plucking, which directly determines the productivity of tea bushes. It is a necessary evil in the sense that it has to be carried out periodically in spite of huge crop loss it results. If pruning is delayed, in other words as the age of wood from pruning increases, the size and weight of growing shoots on plucking surface decreases. To maintain the vegetative growth, pruning is necessary. The objectives are: To renew the wood. To provide stimulus for vegetative growth. To divert stored energy to production of growing shoots. To correct past defects in bush architecture. To maintain ideal frame height for economic plucking. To improve bush hygiene. To reduce the incidence of pests and diseases.
26

 To regulate the crop. To facilitate consolidation by infilling of vacancies.

SIFTING FLOW CHART:

DRIER

Bulk to
1000 Kgs Vibro with 24 mesh to separate to BOPF
Fines to 5-T Stalk Extractor

Batch Weigher

3-T Stalk

1000 Kgs of Vibro with 10 mm perforated sheet to separate the bulk and fines

MIDDLET ON

Middleton fall thorough to Chottamore over 8 mesh GFOF Chottamore over 12 mesh FBOP Chottamore over 18 mesh TGBOB

Fall through to Middleton passed through chottamore over 8 FCP through 8 GFOP

Middleton

Spill of Middleton for OPS

The spill of the Googi is passed through Middleton with 6 mesh

Spill of the Middleton passed through Hex Googi 10/8 mesh to

27

MECHANIZATION: Cultural operations such as pitting, pruning and harvesting are now being mechanized. We recommend the use of machines for increasing the productivity of the workers. The STIHL BT 120 C earth auger can increase the productivity of the worker nearly three times when compared to manual method. Pruning machines with spinning discs are nearly four times more efficient than the manual method.

Types of pruning:
LIGHT PRUNE:
Tea bushes are usually pruned every 3 or 4 years at 4 -5 cm above the last pruning cut. This type of pruning is called light prune (LP). The time period from one light prune year to another is called one pruning cycle and LP is a thus, natural sequence given at the end of a pruning cycle. It helps to renew the wood, regulate crop distribution, reduce pests and diseases and maintain ideal frame height of the bushes.

HEIGHT REDUCTION PRUNE AND MEDIUM PRUNE:

However, when the tea bushes grow tall and plucking becomes difficult, they are brought down to an optimum height by height reduction prune (HRP) at 60-70 cm, or medium prune (MP) at 45-60 cm above ground. Both HRP and MP help in rejuvenating the tea bushes that have become old and their yields have started declining. MP removes the knots and unproductive excess woods and facilitate consolidation by infilling of vacancies. Medium pruning thus provides opportunity for taking many corrective measures for improving the health and production capacity of old tea sections. Such sections are brought back to the normal 3-4 year pruning cycles in about 4-5 years.

28

SKIFFING:
DEEP SKIFF: Deep skiffing (DS) of tea bushes is done normally between 12-15 cm above the last LP mark. The DS helps to regulate crop distribution and to reduce the ill effects of drought, excessive creep and the height of plucking table. MEDIUM SKIFF: Medium skiff (MS) is normally given at 5 cm over last Deep skiff mark. The objective of MS is to regulate crop distribution, reduce the ill effects of drought, reduce the incidence of excessive banji formation and reduce the height of plucking table. LEVEL OF SKIFF AND LIGHT SKIFF: Level of Skiff (LOS) is given 4-6 cm above the tipping mark mainly to level the plucking surface. Light Skiff (LS) is usually given up to 1 cm above the previous tipping height. TIME OF PRUNING AND SKIFFING: In general, pruning is carried out when the tea bush is dormant and there is a good reserve of root starch. Here the pruning is done in the month of July & August. The best time for pruning may differ with cultivars, which can be ascertained by root starch reserve test.
SOME PRACTICES FOR BUSH DEVELOPMENT: Some practices stated below can be followed for encouraging the proper formation of the tea bush: Breaking the stem using thumb and forefinger 25cm above ground in such a way that at least th of the stem is remained in tact. The dried broken branches can be removed just below the broken portion by clean pruning using 7.5cm (3") pruning knife. Decentre selectively between 15-20cm. Debudding by nipping/removing all the growing buds from the main stem/growing shoots above 25cm from the ground. Once the branches below this height are developed, the top debudded portion is removed by clean pruning using a 7.5cm (3") pruning knife TIPPING: The bushes giving leaves after pruning is called as tipping.

29

TEA PRODUCTION PROCEDURE: Black tea manufacturing technology essentially involves disruption of the cellular integrity of tea shoots, thereby enabling the mixing up of substrates (polyphenol) and the enzymes (polyphenol oxidases). This results in the initiation of a series of biochemical and chemical reactions with the uptake of atmospheric oxygen and formation of oxidized polyphenolic compounds that are characteristic of tea along with volatile flavor compounds that impart characteristic aroma to tea. Sholayar/Kallyar estates were the first to introduce CTC type of manufacturing in South India during 1958, which is now followed profitably by the entire industry in South, a big breakthrough for tea gardens of South India. CTC refers to the Crush Tear & Curl process where the withered green leaves are passed in-between two rollers rotating in opposite directions. There is complete maceration of the leaves and the resulting powdery material referred to as "cut dhool" or dust. Enzymatic action is maximum in CTC type of manufacture.

STEPS IN CTC TEA MANUFACTURE: Withering Reconditioning Rolling Fermentation Drying Grading & Sorting Packing

WITHERING: Withering is the first processing step in the factory and is a process in which freshly plucked leaf is conditioned physically, as well as, chemically for subsequent processing stages. Withering Troughs are generally installed in the first floor of the factory. Green leaf is spread over a wire mesh (No.4/16 gauge) which is fitted on plenum chamber. The height of the plenum chamber is 0.6-.76 m (2-2.5 feet) and leaf is loaded over the mesh to.20-.23 m (8-9") height or 89 kg/sq. m. (2.5-3 kg/sq. ft.) of the withering trough.

30

The size of the withering trough is 30.5 m (100') long 1.8 m (6') wider or 22.9 m (75') long and 1.8 m (6') wide. Better withering can be achieved with smaller trough 22.9 X 1.8 m (75' X 6'). The trough should be fitted with a suitable fan to deliver the required quantity of air as per the size of the trough. To achieve proper withering the fan has to deliver 45 CFM air for every one square foot of trough area. For artificial withering hot air from the drier room is bulked with outside air and used. Fans are arranged in such a way that they can draw hot air from the drier and cool air from the atmosphere GREEN LEAF SIFTER: It is designed to remove extraneous matter such as stones, metal pieces etc to avoid damage to CTC rollers. The green leaf sifter consists of a reciprocating tray powered with an electric motor. The reciprocating tray is fitted with a mesh through which leaves are passed and unwanted materials removed. Powerful magnets are fitted in the sifter, which removes iron/steel particles from the green leaf.

GREEN LEAF SHREDDER: It is a pre-conditioning machine. The machine shreds the leaves into small pieces before sending it to the rotorvane. Besides, the green leaf shredder helps to increase the rotorvane capacity and in efficient mixing of RC material to the withered leaf especially in the CTC type of processing. The machine consists of a cylinder in which the main shaft having knives (blades) rotate at a speed of 2500 RPM.

RECONDITIONING: In South India, secondary grades and other residues, which are obtained while cleaning the primary grades, are ground and recycled to the withered leaf. It is known as reconditioning. The primary objective of this practice is to produce grainy grades as well as tea of high density. It also helps to minimize or eliminate secondary grade teas. The quantity of recycled material, known as recondition dust, varies from factory to factory; it depends on the quality of green leaf, the moisture content of the
31

withered leaf and standard of machinery available. The percentage of RC is mostly expressed on the weight of green leaf or made tea basis. However, there is a wide variation in the moisture content of green leaf and thereby the quantity if made tea produced. So quantifying the amount of RC material for the made tea to be produced depending upon the green leaf conditions is difficult. The best practice is that the RC ratio should be calculated on the withered leaf weight basis.

ROTORVANE: It consists of a cylindrical drum of a diameter of 200 cm (8"), 380 cm (15") or 460 cm (18"), depending on the capacity. Inside the circumference of the drum, the resistors are fitted at appropriate distances. The main shaft, which rotates inside the drum, has vanes at equal intervals. There is a worm arrangement in the main shaft, which facilitates forward motion of the leaves into the drum. The leaves are crushed in between the vanes and resistors and discharged through the diaphragm. The RPM of rotorvane ranges from 30 to 35.

CTC-ROLLERS: It consists of a main shaft on which the segments are fixed by heat treatment on a mandrel form. The diameter of the roller is generally 200 cm (8") and the latest senova rollers are of 330 cm (13") diameter. Depending on the capacity of the rollers, their length varies from 600 (24") to 910 cm (36"). Generally two rollers are fixed horizontally and parallel to each other and both rotate in opposite directions. The ratio of speed between the low speed and high-speed rollers is 1:10 depending on the requirement of leaf or dust grade. Note: Depending upon the market demand they can change the grade percentage in the factory.

32

FLOOR FERMENTATION : The rate of fermentation depends on the concentration of substrates in the leaf; availability of oxygen, activities of the enzymes and temperature Floor fermentation is practiced by spreading the rolled leaves on the floor to 5 - 8 cm (2-3") height depending on the weather condition. Floor fermentation is better than drum

fermentation as the former has better air contact with the leaves. Factories producing tea aimed at liquor quality can adopt drum fermentation followed by floor fermentation to achieve good liquor as well as better appearance and density.

DRUM FERMENTATION : It is mostly practiced in CTC tea manufacture in south India. When compared to floor fermentation, drum fermentation results in more density and better granulation, which give better appearance. The fermenting drum is a simple cylindrical drum with conical feeding and discharge ends. The standard drum is 4.8 - 6.1 m (16-20 feet) long and has a diameter of 1.5 m (5 feet) at the cylindrical portion. The total length of the conical segment is four feet. The capacity of the drum will be 5.2 kg of rolled dhool for every square meter area of the drum.

DRYING: The keeping quality of tea mainly depends on the drying technique and the final moisture content in the made tea. The objectives of drying are to terminate the biochemical changes and to remove moisture to achieve better keeping quality. During the process of drying, water is removed from the fermented leaf and its colour turns from coppery red to black and fermentation is arrested.

FLUID BED DRIER : It consists of drying chamber, plenum chamber, airflow damper and dust collectors. The drying chamber is separated by a perforated grid plate through which high pressure hot air from the plenum chamber gets into the drying chamber for fluidisation. The plenum chamber is
33

divided into four zones that have individual air control valves. These valves control the quantity of air to the individual zone and the direction of hot air entering the control dampers. At the top of the drying chamber two centrifugal exhaust fans are fitted with cyclone, one for refiring and the other for dust extraction. When the fermented dhool is fed into the drying chamber in the first zone it gets fluidised. With the help of pressurised hot air, water is removed by evaporation. The inlet and exhaust temperatures for FBD may be maintained at 250F to 260F and 150-160F for achieving better quality.

VIBRO FLUID BED DRIER: It works on the principle of 'vibrating fluidized bed'. It works on pneumatic and mechanical power. The fermented teas are fed through a feed system into the drying chamber. Hot air from the heater is passed from underneath to the drying chamber through the perforated tray carrying wet teas. The tealeaf is effectively fluidised by a combination of air pressure and mechanical vibration.

FIBRE EXTRACTOR: This works on the principles of static electricity. There are 4 to 6 PVC rollers arranged in a row. The PVC rollers brushes against thick pads of felt which imparts a static electricity to develop on the PVC rollers. When tea is fed in to this machine after firing, frictional force takes place between fibre and the rollers. As a result static electricity is produced. The PVC rollers act as positive charge (+) and fibre acts as a negative charge (-), thereby both attract each other and fibre is collected from the PVC roller

AIR HEATER: The air heater basically exchanges the heat, released from the combustion of fuels, indirectly to raise the temperature of ambient air for drying purposes. Tea drying is a high thermal energy consuming operation. Hence it is essential to know the
34

basis of combustion for the efficient operation of heater or stove. Air heaters commonly used in South India are of two types. In the first type, the hot flue gas from the combustion chamber passes through the tubes of a heat exchanger. In the other type, it flows outside the multi tubular heat exchanger. The former is most common and suitable for fluidized bed driers. The selection of the stove should be based on the compatibility with the drier in regard to heat requirement as decided by the fan characteristics such as air volume and total pressure. Any under rating of the air heater implies burning more fuel than the stipulated quantity and results in higher flue temperatures. The efficiency of the heater is mainly determined by the heat transfer area, insulation, type of fuel used, combustion control and design of the furnace itself.

VIBRO SCREEN SORTER:It is a simple machine that is used to grade the bulk tea from the fibre extractor into different grades according to their size. Generally the sorter is fitted with meshes of different size.

GRADES IN CTC TEAS: BOPL Broken Orange Pekoe Large BOP Broken Orange Pekoe BOPSM Broken Orange Pekoe Small BP Broken Pekoe BPSM Broken Pekoe Small PD Pekoe Dust RD Red Dust SRD Super Red Dust SFD Super Fine Dust

WINNOWER:After grading the teas in sorter the final teas are again given one more cleaning in the winnower by this process the
35

teas will be cleaned & stored in different bins. Depending upon the requirement the teas will be taken for packing from the bin

DXN TEAS: Three years back they had entered into a MOU with M/s. Daehsan Trading (India) Pvt. Ltd., Chennai to blend their RG powder (Mushroom powder) in their own tea blend (their Assam + South Indian teas blend) and market the same as DXN Teas in jars. They are getting a clear profit of Rs.35/- per kg on the tea dispatched by them. They have sent so far 28782 kg DXN Teas in which 11473 Kg sent in this year. If this marketing effort becomes successful then they might expand their operation by going in for flavored teas making use of the blending machine supplied free by the Malaysian company.

36

TYPES OF TEA: All types of tea is produced from the plant Camellia sinensis. However, all the different varieties of tea grown worldwide, vary merely by the region it was grown in, the time of year the leaves are plucked, and the method by which they are processed. The process of oxidation is the primary impact of the way the leaves are processed, and the main indicator of how the tea will be classified. The chemical process of oxidation is the natural phenomenon, by which, the enzymes present in the tea leaves are exposed to, and chemically react with, the oxygen in the area, after the leaves' cellular structures are broken. This process can happen quickly, through rolling, crushing or cutting, or may be more slowly through the process of natural decomposition of the leaves.

WHITE TEA: White Tea is the least processed of all teas. The tea leaves are withered to remove moisture and then dried. The name of white tea has been derived from the bleary white 'hairs' appearing on the unopened or recently opened buds of new growth on the tea plant. The white tea leaves also tend to have the highest antioxidant content, as they are comprised of the newest leaves. White tea produces a pale yellow or green liquor. They are the most delicate in aroma and flavour.

GEEEN TEA: Green Tea is subjected to the process of steaming, pan-firing, and/or rolling before being dried to freeze the oxidation process. In most green teas very little oxidation occurs. and they are differentiated from white teas primarily by the extra steps of manipulating or processing the leaf before drying. Green tea produces a green or yellow colour liquor. It has flavours which range from sweet to grassy, mixed with mild astringency.Since ancient times Green Tea has been most enjoyed in China and Japan. In recent years, for its health-giving properties, green tea has also gained popularity among Europeans and Americans.

37

OOLONG TEA: Oolong Tea also undergoes a multi-step process of pan-firing, rolling or steaming. However, in addition, it is also set out and is allowed to 'wither', thus giving the leaf time to get oxidized. Typically, Oolongs are bolder in flavour than the varieties of Green or White teas, and they offer less astringency than either the stronger Black or lighter Green teas. Oolong tea is also referred to as an aromatic tea, and it features popular flavors rich in aroma.Oolong tea is a form of Chinese tea, which is positioned between the green and black teas. Oolong's flavour is sophisticated, and is derived from complex production methods BLACK TEA: Black tea is also not an exception in undergoing similar processing to Green tea or Oolong tea, but the difference is that, it is allowed to oxidize more completely. The liquor brewed from black tea ranges between dark brown and crimson. The different types of black teas deliver the strongest flavours. Black tea is the only style of tea regularly drunk with milk and sugar and is the most popular base for iced-tea, as also used as a delicacy drink mixed with fruits, herbs, spices.One of the features of black tea is its wide array of production areas and methods of drinking. Although the flavours vary, the high-quality black teas abound in natural aroma, flavour and nutrients.

PACKING: Teas are packed in airtight containers in order to prevent absorption of moisture, which is one of the main causes for loss of flavour during storage. Now- a - days teas are packed in laminated jute bags using HMHDPE (High Density Poly Ethylene) liners. Teas are also packed in Vacuum Packing. Corrugated cardboard boxes lined with aluminum foil and paper sacks lined with plastic are also employed.

38

PACKING

CONSIGNMENT / AUCTION DIRECT SALE / CASH & CARY

DXN

CARTON BOX

LAMINATED PACKS

POUCHES

PET JAR

BOOKS MAINTAINED IN FACTORY: Three years back they had entered into a MOU with M/s. Daehsan Trading (India) Pvt. Ltd., Chennai to blend their RG powder (Mushroom powder) in their own tea blend (their Assam + South Indian teas blend) and market the same as DXN Teas in jars. They are getting a clear profit of Rs.35/- per kg on the tea dispatched by them. They have sent so far 28782 kg DXN Teas in which 11473 Kg sent in this year. If this marketing effort becomes successful then they might expand their operation by going in for flavored teas making use of the blending machine supplied free by the Malaysian company. RG I ( Revenue Book I) Personnal Ledger Account Tea Book Green Leaf Payment Book
39

Fuel Consumption Book ( Firewood, Agni, Electricity ) Packing Materials Book Weathering Book

PACKET TEA We are one of the players of Packet Tea Market in India having small market share in states like Punjab, Haryana, Rajasthan, Gujarat, Uttar Pradesh, Madhya Pradesh, Orissa and Himachal Pradesh with brands like Shaandaar, Birla Tea Premium, Birla Gold, Jaandaar, Kalline Gold etc. We are registered supplier to Defence Forces and Indo-Tibetan Border Force. We supply and pack teas for reputed brands also.

ORGANIC TEA Organic teas are nature friendly, naturally grown and naturally made. The organic process involves planting tea bushes along with leguminous plants, using herbal pesticides and natural fertlisers. Utmost care is taken to preserve the natural flavour of tea. No chemical pesticides are used. This is the purest way of enjoying a good cup of tea. Buyers across the world of Darjeeling teas are now demanding Organic tea and keeping in tune with their demands our company has converted three of our Darjeeling Estates, Tukvar, Risheehat and Sungma into 100% organic and another tea estate Singbulli is in the process of conversion and is expected to be converted by March 2012.

SPECIALITY TEA We also produce Darjeeling Green Tea, Assam Tippy Orthodox Tea, Oolong Tea, White Tea,and other speciality Tea which have good demand in global markets. CERTIFICATIONS All our Darjeeling Estates have Hazard and Critical Control Point (HACCP) Certification and we are in the process of getting the certification for our Upper Assam estates. We are also in the process of obtaining Fair Trade Certification for our Darjeeling Estates. Our warehouse in Kolkata is ISO 22000 certified with separate storing and blending facilities for Organic and inorganic teas. We have been recognized as Star Export House by Government of India.

40

BEST QUALITY Our teas have good demand which is proved by our buyers list which includes the key packeters of India and abroad. Our teas fetch higher prices than the district averages across all the key areas like Upper Assam, Darjeeling, Cachar, Dooars/Terai and South India. Our Darjeeling garden Tukvar (Puttabong) was the first to fetch a record price of Rs.10,000/- per kg way back in 1992.

ADVANTAGES OF SCALE After all the acquisitions this year we estimate to produce more than 260 lac kgs tea in India about 60 lac kgs in Africa and 80 lac kgs sourced from others we estimate to touch 400 lac kgs this financial itself. With such large quantity we have the flexibility and control to supply any quality and quantity of tea from any region to satisfy our buyers i.e. all the teas under one roof.

DEDICATED TEAM Employees are our best strength. We have a loyal and dedicated workforce. Our Managing Director is the present Chairman of Tea Research Association and President of Tea Association of India, an organization of all the tea companies of India. One of our VicePresidents is the Chairperson of Calcutta Tea Traders Association. This just shows the faith the tea industry at large has in our company.

LOWER COSTS We have gardens in each of the key tea producing areas in close proximity and we have active inter-exchange of resources between these gardens. Further we have invested large sums of money in last couple of years in our factories and all of them have latest machinery which ensures high efficiency of production. As a result we achieve high economy of scale and our costs per kg of tea are lower compared our peers.

41

CHAPTER 5 HUMAN RESOURCE DEPARTMENT

42

EMPLOYEE DETAILS AND TRAINING REQUIREMENTS

1. Prepare a detailed list regarding the qualification, experience and professional training undergone by individual employees. 2. Based on the above details prepare a plan for training to be given to individual employees. 3. After identification of training needs, communicate the same to respective department dealing with training and development. 4. In house training shall be organized by the Factory in charge

HEALTH BENEFITS: Probably, the world's most popular energy drink, tea is not merely rich in taste and flavour, but it is also a rich source of the health essentials. Tea is a very healthy drink, which offers a multitude of health benefits from anti-aging benefits to helping prevent several types of cancers. In general, teas undergoing the least amount of processing like white teas contain more antioxidants and less caffeine than other teas. Although, the processing time increases from the making of white to green tea, from green to oolong tea, and finally from oolong to black teas, nevertheless, all teas maintain a basic and significant level of health benefits. Tea is free of calories, if taken without milk or sugar and can play a major role in maintaining bodily fluid balance. Tea also has many other health benefits including:

Tea contains fluoride, thus strengthening tooth enamel and can help reduce the formation of plaque. It promotes the health of your teeth.

Antioxidants in varying degrees are very much present in tea (primarily in white and green tea, but also black tea in smaller quantities), which may help to reduce the risk of cancer (specifically, lung, skin and colon cancers).

Polyphenols are also present in tea, the substance which are thought to help inhibit the absorption of cholesterol into the blood stream and help prevent the formation of blood clots.

Caffeine, present as a mild stimulant in tea increases the activity of the digestive juices. Caffeine helps stimulate the heart and circulatory system, which further aids in keeping

43

the walls of blood vessels soft, thus reducing the likelihood of atherosclerosis (hardening of the arteries).

HEALTH BENEFITS OF WHITE TEA: Because of the highest level of antioxidants than any other tea, white tea is great for health. Antioxidant aids in detoxifying the body. Antioxidants are famous for helping fight cancer and increasing metabolism. As an added health benefit, white tea is also good for the skin and helps improve the complexion.

HEALTH BENEFITS OF GREEN TEA: Green tea has multiple health benefits. Green tea has the most of the EGCG complex, which is good for metabolism. Polyphenols are also present in green tea, which the body needs for cancer prevention and has been known to protect against or decrease the spread of bladder cancer, breast cancer, ovarian cancer, lung cancer, skin cancer and stomach cancer, among others. Antioxidant in green tea boosts up the immune system, and helps regulate blood sugar.

HEALTH BENEFITS OF OOLONG TEA: Oolong Tea is mainly responsible to burn superfluous body fat. Drinking oolong tea during or after a high-cholesterol meal has been shown to lower the intake of fat content in the blood. Oolong Tea also contains the most tannic acid, which is good for lowering cholesterol. This tea is great for losing weight, since it burns fat built up in the body.

HEALTH BENEFITS OF BLACK TEA: It has been suggested by medical research that, black tea helps to regulate blood sugar, lower cholesterol, lower blood pressure, and keep the blood vessels soft because of the caffeine present in black tea. Other than this, black tea also has other health benefits like promoting healthy teeth, skin an

44

CHAPTER 6
INFORMATION TECHNOLOGY DEPARTMENT

45

OFFICE: Here both the manual & Systems are used for their accounting etc. They are using Visual Basic as Front End and Ms Access as Back End for their softwares. The Visual Basic software is used for last 5 Years. Previously they were using FoxPro for their works. Here they are using FoxPro for Calculating Company TDS and calculation for Deprecation on Fixed Assets.

They are using software for the following Departments. Payroll Department Purchase / Inventory Department Sales / Despatch Department Accounts Department

PAY ROLL: Wages & payslip for labours and staffs are prepared in the Group Office and the Salary is disbursed at the respective division musters. In the case of staff & managements the salary are deposited directly into the bank account with SBI Valparai. All other payments like SB LWW MB Gratuity, Bonus, and LTC etc are controlled and maintained in the office only. Since this is an exempted unit PF contributions are remitted to Birla Industries Provident Fund at Kolkata. As per the rule the portion of the contribution, say 8.33% is remitted to Government providement fund towards Family pension Scheme and the balance 3.67 will be remitted to PF at Kolkata. The Pf settlements are done by the Birla Industries Providement Fund.

46

CHAPTER 7
PURCHASE DEPARTMENT

47

PURCHASE: Orders for Manure, Chemicals, Pesticides, Machineries & Stationery etc are placed after obtaining and comparing quotations from various parties. Materials are stored in our stores and supplied to divisions timely for their application in the fields. They are not encouraging any local purchase only emergency items are purchased locally. They are maintaining stock register in the stores. In the stores the details are maintained manually. Unless the Store order slip is issued from the office the items cannot be move out from the store.

48

CHAPTER 8
MARKETING DEPARTMENT

49

SALES: They are marketing their teas all over the country except Assam and Orissa. Most of their teas are selling through consignment only. As and when we receive orders for tea we are preparing Despatch Instruction and sending to factories for packing teas. What ever teas are despatched to different destinations, details to the same i.e. invoice no, grads, brand name, bag serial no qty Despatch , price etc are entered in the different registers depending on the type of sale, payment & Form F & Form C details are also mentioned in the respective registers to know the payment position. A separate register is also maintained for stock of teas lying in the factories.

50

CHAPTER 9
FINANCE DEPARTMENT

51

ACCOUNTS: Group office maintains the accounts of all divisions. The accounts are maintained in computers and in the form of books. The account books are maintained perfectly for the purpose of auditing and taxation. The computerized accounts are sent to Head Office through E-mail. The group office sends all report and records of account properly to the Head Office at the end of the every month. Trial Balance, Profit & Loss Account, Balance Sheet, Budget Preparation are processed in this department. In Accounts department they maintain certain books like Cash Book, Bank Book, Journal Vouchers, Ledger Book. Etc.

BALANCE SHEET AS ON- 2007 TO 2012 : Incorporated on 27th October 1945, Jay Shree Tea & Industries Ltd. is a part of well diversified conglomerate of B.K Birla Group. B. K. Birla Group has been in the forefront of industrialization in the country since Independence. An inspiration for generations of Indian entrepreneurs, the Birlas are looked upon as the First Family of India Inc., reflecting quality, reliability and leadership. The core business of the company is Tea accounting for 75.56% of the gross turnover with Chemicals & Fertilizers at 23.52% and others 0.92% during the half-year ended 30th September 2012. Table No : 1 : Income

Years 2007 2008 2008 2009 2009 2010 2010 2011 2011 2012

Amount 191.76 269.47 326.64 338.37 374.58

Index 100% 140.52% 170.33% 176.45% 195.33%

The above table no : 1 shows the Income position from 2007 -2008 to 2011 2012. From 2007 2008 to 2011 - 2012 the Income value shows an increasing trend from 191.76 to 374.58. The Index also increased from 100% to 195.33%.

52

Income
400 350 300 250 200 150 100 50 0 2007 2008 2008 2009 2009 2010 2010 2011 2011 2012 100% 140.52% 170.33% 176.45% 195.33% 191.76 Amount Index 269.47 326.64 338.37 374.58

Table No : 2 : Expenditure

Years 2007 2008 2008 2009 2009 2010 2010 2011 2011 2012

Amount 153.49 224.43 266.13 262.05 284.75

Index 100% 146.21% 173.38% 170.72% 185.51%

The above table no : 2 shows the Expenditure position from 2007 2008 to 2011 2012. From 2007 2008 to 2008 2009 the expenditure value shows an increased trend and during the year 2009 2010 the expenditure value is been decreases lightly and again during 2011 2012 the expenditure value is been increased the Index value also increased from 100% to 173.38% during 2007 2008 to 2009 2010 and it decreased from 173.38% to 170.72% during 2010 2011 and it increased from 170.72% to 185.51% during 2009 2010.

53

Expenditure
300 250 200 153.49 150 100 50 100% 0 2007 2008
100

266.13 224.43
60 40 20 0 80

284.75 262.05
East West North

Amount Index

1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

146.21% 2008 2009

173.38%

170.72%

185.51% 2011 2012

2009 20010 2010 2011

Table : 3 : Pro fit & loss:

Years 2007 2008 2008 2009 2009 2010 2010 2011 2011 2012

Amount 25.30 23.07 36.26 51.10 67.52

Index 100% 91.18% 143.32% 201.97% 266.87%

The above table No : 3 shows the adjusted profit before Tax position from 2007 2008 to 2011 2012. From 2007 2008 to 2008 2009 the value has been decreased from 25.30 to 23.07. then from 2009 2010 to 2011 2012 the value has been in increasing trend from 36.26 to 67.52. The Index value also decreased from 100% to 91.18%. From 2007 2008 to 2008 2009, then the Index value started to increase from 143.32% to 266.87% from 2009 2010 to 2011 to 2012.

54

Profit & loss

70 60 50 40 30 20 10 0 100% 2007 2008 91.18% 2008 2009 143.32% 2009 2010 201.97% 2010 2011 266.87% 2011 2012 25.3 23.07 36.26 Amount Index 51.1 67.52

Table No : 4 : Earnings before appropriation

Years 2007 2008 2008 2009 2009 2010 2010 2011 2011 2012

Amount 43.96 46.11 42.80 31.95 40.41

Index 100% 104.89% 97.36% 72.67% 91.92%

The above table no : 5 shows the earnings before appropriation position from 2007 2008 to 2011 2012. From 2007 2008 to 2011 2012. There is a variations like ups and downs in the value. The Index value has also variation like ups and downs from 2007 2008 to 2010 2012.

55

Earnings before appropriation

50 40 31.95 30 Amount 20 Index 46.11

43.96

42.8

40.41

SHOLAYAR& KALLYAR FACTORY 2010:

10 100% 0 104.89% 97.36% 72.67% 91.92%

2007 2008 2008 2009 2009 2010 2010 2011 2011 2012

TEA ESTATES IN INDIA AREA SL.NO. GARDEN PLANTATION (Hectares) DARJEELING, WEST BENGAL 01 02 03 04 05 06 Risheehat Tea Estate Tukvar Tea Estate North Tukvar Tea Estate Singbulli Tea Estate Balasun Tea Estate Sungma Tea Estate 256 437 195 303 353 273 01.81 02.32 00.97 02.22 00.88 01.36 UNDER PRODUCTION (FY kgs) 2009-10) (lac

UPPER ASSAM 07 Towkok Tea Estate 646 18.46

56

08 09 10 11

Manjushree Tea Estate Mangalam Tea Estate Nahorhabi Tea Estate Meleng Tea Estate

616 105 695 760

14.09 02.26 14.70 16.34

CACHAR, ASSAM 12 13 14 15 16 Dewan Tea Estate Burtoll Tea Estate Labac Tea Estate Kalline Tea Estate Jelalpore Tea Estate 726 686 434 463 367 22.39 20.50 14.51 12.88 08.72

DOOARS BENGAL 17 18 19 20

&

TERAI,

WEST

Aryaman Tea Estate Ananyashree Tea Estate Marionbarie Tea Estate Jayantika Tea Estate

222 237 329 604

08.96 14.11 06.71 13.59

SOUTH INDIA 21 22 Sholayar Tea Estate Kallyar Tea Estate Bought Leaves Factories 401 299 14.68 10.22 11.32

GRAND TOTAL

9407

234.00

57

EDP: In this department they are generating the reports and send to the management level. There are various functions done in this department i.e. Yield Statement, Plucking average, Estimation of green leaf, Distribution of Hands, Manuring Statements, Weeding, DRS (Daily Report Statement). Fuel Efficiency Statement, etc all are compared with the corresponding previous year. Calculation of Company TDS and Salary TDS are prepared. The Income Tax worksheet for the staffs and managements are prepared.

HOUSE KEEPING: Hygiene and cleanliness should be given utmost importance in the rolling room to avoid bacterial contamination. Details regarding factory layout, placement of safety equipment/fire extinguishers and first aid box shall be made into charts and hung in the factory Office. Fire exit signs shall be marked in each room. All Walls inside factory & machinery shall be painted/white washed once a year or earlier with white polyurethane enamel paint/lime. In house training shall be provided on safety & house keeping. Machinery and electrical maintenance shall be done only by qualified persons. Electrical sub DBs shall carry DANGER sign and follow electrical regulations. Packing workers/Pulverize workers shall be given dust masks. Fused tube lights shall be replaced on priority basis. Upper limit of fused tube lights is 10 % in each area. Brooms are specified in withering rolling, dryer & sorting area, with colored ribbons and mix up is prevented. SERVICE RENDED BY MANAGEMENT SOCIAL FORESTRY: For environmental ecology all fallow areas in the Estates have been brought under the cultivation of trees such as teak, kadam, shishom

SOCIAL WELFARE ACTIVITIES:

58

A 50 bed hospital with modern operation theatre and facilities for ECG, X-Ray, Incubator, Bedside Monitor and a complete Clinical Laboratory is maintained in the Sholayar Garden. In Sholayar/Kallyar, there are four primary schools and one middle level school in the Companys own buildings, with the student strength of more than 1,100 students. First in the Anamallai Hills, Sholayar Group has provided education with latest computer equipment to the workers children.

SPIRITUAL UPLIFTMENT: The beautiful Siddhi Vinayaka Temple built at Valparai by the Sholayar group in 1971 is one of the landmarks of this area and a famous tourist attraction. Jay Shree Kalyanamandapam was built in Valparai and handed over to the public for regular use for social, religious and cultural functions.

TRANSPORTING:
Important: Final inspection should be carried out by the Factory in charge before clearance Inspection and testing records shall be maintained in the factory for traceability. Factory In charge should inspect the teas before arranging for transportation. Prepare proper report/invoice. Clean the lorry with Broom stick. Spread tarpaulin sheet at the bottom of the cabin. Record tare weight of the Lorry. Load the lorry with tea bags. While loading do not use hooks. Cover the cabin with tarpaulin. Record the gross weight. Hand over the excise/dispatch documents to the lorry driver before he leaves the Factory.

59

CHAPTER 10 FINDINGS AND SUGGESTIONS

60

FINDING AND SUGGESTION: Link other plantation , jay shree is also facing shortage of labours. Tea crop is mainly dependent on the climatic and timely execution of cultivation operation. Necessary steps could be taken to reduce their overhead charges. The company has good reputation among the customers for its brand quality so they should try to maintain the quality. More care should be taken to improve productivity. New technology/ mechanization should be adopted to labour force. Adequate shortage of labour in the industry. Due to climatic change, yields increased by year by year.

61

CHAPTER 11 CONCLUSION

62

CONCLUSION
The employees who work in this organization are all knowlegeble and skillful in their respective work. The employee of this oraganization treat their work has is workship. It was a pleasure experience. I was able to gain new insights and comprehensive understanding about the real industrial working condition and practices. I have more confidence to enter the industrial world and build my future career.

63