New ways and means to increase tea production

TRI Selective Tea Harvester

Although there are many hand held shears and motorized machines for tea harvesting, the biggest problem with them is the non-selective harvesting and loss of crop. Under such a system of harvesting quality of the end product (made tea) is also adversely affected.

The new innovation (TRI Selective Tea Harvester) is a light weight shear harvester without long handles as found in the hand shears used in other tea growing countries.

This selective tea harvester is made up of a plastic tray and a small handle coupled together with cutting blades to give a precise shearing of tea shoots above a step of about one inch. With the elimination of long handles and metal box, its weight has been reduced by more than two-thirds of the ordinary shears used in other countries.

Further, absence of long handles, less weight and small size of this harvester has made it worker friendly and more selective in harvesting of shoots.

After designing and fabricating the harvester, it was further improved and jointly patented by the Tea Research Institute and P.P.P. Jinadasa Pvt Ltd. It has the potential of doubling the output of workers in plucking and estates using the harvester has achieved more than 50% increase in plucking intake.

About 30-40% saving of labour is expected with the proper use of this harvester especially during rush crop (high cropping) periods. The use of the harvester not only increases the output of workers, it also reduces the shoot damage thus improving the quality of made tea.

Further, use of this harvester minimises discolouration and the damage to fingers of manual pluckers, one of the social problems leaving youngsters away from plucking.

The introduction of the harvester will change the attitude of workers and attract younger generation of workers to the plucking fields.

In most of the up country estates, the shear harvester is given to the men pluckers who are not well trained and bring poor quality leaf by manual harvesting.

The use of selective tea harvester has not only improved their out put but also brings good quality leaf ensuring the bush health too. In many estates using the harvester, men pluckers finish their norm or pluck shoots above the daily norm by around half day.

This shows that innovations help reduce the drudgery of field operations and save time for workers satisfaction and leisure. In addition, use of this harvester allows to maintain plucking surface in good condition and improve the appearance of the field.

The TRI Selective tea harvester is commercialised and sold by P. P. P. Jinadasa. Presently, possibilities are being investigated in motorising the harvester to improve the out put and for convenient operation.

Collapsible tea plucking basket

Well woven cane or bamboo baskets were used as an essential plucking gear in the past for shoot collection while harvesting.

Due to rising costs, lack of production and some difficulties to use in well covered tea fields, it has now been disappeared from many tea growing regions. Workers are using such baskets now for carrying leaf to weighing points or to the factory only. Use of such baskets reduce, leaf damage and preserved the quality of harvested crop in the past.

However, the poly-sacks used at present is not the ideal alternative to bamboo baskets as it can damage shoots and also reduce worker output.

Further, the rope used to rest the sack on the head is also not good for the worker's health. It has been observed that due to such bags being used, pluckers tend to keep a large number of harvested shoots in their hands thus damaging or bruising the leaf ruining the quality of harvested crop. Moreover, use of shear harvesters has also been restricted due to an absence of a suitable leaf-collecting basket. Taking these factors into consideration a new collapsible basket was designed. The collapsible (foldable) frame of the innovative basket was made of PVC pipes and a removable cloth sack was attached to the frame.

The basket is worn using belts as a back-pack like a school bag. However, some female workers preferred wearing the basket on the head and hence, that it further modified as a basket with a cap to rest on the head. Use of this basket reduces leaf damage and helps pluckers to move freely between tea rows.

The collapsible basket was also patented in Sri Lanka. The innovative basket was further improved to reduce cost and change its appearance in collaboration with C.K.P. Chandra Enterprises, Rathgama and commercialised.

The innovative basket is very lighter and compatible with shear harvesting. Further, basket and selective tea harvester will secure the dignity of workers and implant positive attitudes towards plucking of tea.

Hand Pruner: Pruning of tea is also an important field operation in tea. Usually, pruning is done by manual workers using knives. This is also identified as a fatigue field operation that needs greater knowledge and skill. Due to labour shortage, pruning is also not done properly and as a result productivity of fields are greatly affected. Therefore, some estates are presently using bush cutters for pruning of tea the out put of which is around 3-4 times higher than knife pruning.

However, recommended type of pruning is difficult with these machines and there are other limitation to use machines in our tea fields.

Therefore, a hand-held motorised pruning machine (hand pruner) was designed to use with electricity. Few units can be operated by a small household generator.

The beauty of this machine is that it can prune branches of tea bushes at any level selectively as recommended by the TRI.

Although, this electrical hand pruning machine was designed and patented, so far it has not been to commercialised due to the absence of a suitable manufacturer. This machine can also be used for pruning other crops such as Cinnamon.

Deep Fertiliser Applicator Fertiliser application for tea is at present, done manually. This always leaves a question with farmers whether distribution of fertilisers by manual application is even and also whether surface application does not lead to more wastage in heavy rainfall areas where tea is usually grown. This is particularly true in young tea fields where the ground is open and surface is liable to soil erosion.

Therefore, a Deep Fertilizer Applicator was designed to be used for young tea plants.

The unit allows to measure and apply fertilisers to the root zone few inches below the ground, directly.

The applicator was designed using a garden fork by fixing a plastic box with a measuring unit for filling with fertilisers and measure required quantity of fertiliser before directing to the ground through PVC tubes connecting the fertiliser box and tines of the fork.

This applicator is manually operated and reduces body movements of workers as in manual application.

Further, it can be used for other perennial crops which needs frequent application of fertilisers.

This fertiliser applicator was also patented in Sri Lanka which is available to be manufactured by a prospective company.