The Commercial Products of the Vegetable Kingdom / Considered in Their Various Uses to Man and in Their Relation to the Arts and Manufactures; Forming a Practical Treatise & Handbook of Reference for the Colonist, Manufacturer, Merchant, and Consumer, on the Cultivation, Preparation for Shipment, and Commercial Value, &c. of the Various Substances Obtained From Trees and Plants, Entering into the Husbandry of Tropical and Sub-tropical Regions, &c.

by P. L. Simmonds

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 1½ 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.