The Rwandan tea sector is largely under-exploited. Experts estimate that, given perfect conditions (climatologically and use of fertilizers), it should be possible to reach yields of 3 tons of black tea per Ha in the marshlands and 2,5 T on the hills. For most factories this means twice the actual production, which implicates, off course, that their capacity will have to be extended as well.

Below is the process used in Rwanda tea production

1. PLUCKING

The plucking height of tea bushes varies from 60 cm during the “Tipping-in” process to the normal plucking at 120 cms. Plucked leaf consists of the BUD and the FIRST TWO leaves on the plucking shoot. Plucking being a delicate operation, it is done by skilled operators who are capable of fast and exact work to produce good quality leaf for the factory. After plucking, the leaf is taken to the nearest leaf shed for individual quality control and weighment. Then the leaf is sent to the factory.

2. WITHERING

On arrival at the factory, the leaf from the field is weighed once again and spread onto special troughs for withering. The duration of withering varies from 15 to 18 hours, until the leaf has lost 30 % of its moisture. This process is helped by large fans pushing air through the leaf below. When the leaf is flaccid it is ready for further processing.

3. ROLLING

The withered leaf is passed through machines that cut, tear and curl (CTC) into small particles. The finer the cut leaf the better pungency in the black tea.

4. FERMENTATION

From the rolling machines, the leaf is fed into fermenting machines where the colour changes from green to coppery on the contact with air. The process takes around 90 minutes.

5. DRYING

From the fermenting units the leaf is passed onto the drying machines where hot air dries the teas to 3 % maximum and turns them black.

6. SORTING

From the firing machines the tea is passed over pre-sorters, sorters and stalk extractors to produce a variety of grades. The leaf is passed through a series of vibrating wire meshes which produce the required grades according to the demands of the tea markets.

7. PACKING

The finished product of black sorted tea is packed by separate grades into double strong papers sacs lined with aluminium sheeting and white paper, the average weight of each packed sacs is around 70 kgs.