About the Emrok Tea Factory
The Emrok Tea Factory is one of Kenya's most modern tea processing factories. We are only the second factory in Kenya to house a fully-automated production line.
During factory design, paramount importance was placed on delivering a consistent quality product. We worked with our chosen machinery suppliers towards automating our processes.
For CTC tea production, two main lines are housed inside a 6000 sq. feet building with an inline floor layout. The space is optimized to provide good working space around and between each process area.
In 2015 and 2016 we added new orthodox tea production lines.
To counter the effects of withering, we have incorporated state-of-the-art technology in our Green leaf reception and Withering sections to eliminate manual handling of the tea leaves. The result is an end-product with an exceptional quality and consistency, meeting the world's highest safety standards.
Being in an Export Processing Zone (EPZ), we are ideally suited for export of both bulk tea and value-added packages. We take pride in being able to meet the rigorous requirements of the export market.
Our growing team of 120 employees is dedicated to delivering world-class products meeting the highest safety standards. All of our employees undertake regular in-house training geared towards the implementation of Good Manufacturing Practices and food safety.
CTC and Orthodox Teas
Every day we produce up to 20,000 kilograms of black CTC teas. Our daily production capacity on commercial orthodox teas are 4,500 kilograms with a wide assortment of grades. Most of our green leaf is sourced from the Ogirgir Estate and in partnership with other farms in the surrounding area.
Throughout the day, fresh, green, tea leaves are brought to the factory from our farm, as well as from neighboring farms. The tea quality process starts right at the field where those picking it are trained to selectively pick only the finest two leaves and a bud. At the factory, we rigorously check that each and every delivery meets the required standard.
Upon meeting quality standards and weights, the green leaf is loaded mechanically onto an automated bulk withering machine that holds the leaf for a period of about 14 hours. This initial process involving controlled air passage and critical temperature monitoring culminates in the achievement of the chemical aspects of withering. The withering stage is followed by a controlled rapid moisture loss process that preconditions the green leaf to the predetermined moisture content.
Our automated withering minimizes handling of the green leaf as well as fluctuations of moisture content of withered leaf typical in a manual system. This forms the basis for our consistent quality product. We have a four cut CTC process monitored closely to ensure the evenness of the final product. The modern automatic milling and chasing machine eliminates human errors, resulting in good cuts.
Our continuous fermenting is geared towards consistently achieving bright infusions. The factory has a high roof that's lined with foil and a cyclone system that ensures perfect temperature control through the various seasons of the year. We also have a vibrating fluid bed drier giving an output of 400kg per hour.
Our sorting line is comprised of stalk and fibre extractors and a vibroscreen sorter. CTC grades include BP1, PF1, PD, DUST1, PF2 and DUST2. Commercial orthodox grades include SFTGFOP, TGFOP, GFOP, FOP, OP, Broken and GREEN. Custom orders are possible
Specialty Orthodox Tea
The specialty orthodox line was commissioned in 2015 resulting in the production of specialty orthodox tea, the first of its kind in Kenya. Cultivated from specially selected hybrid plants, this involves labor-intensive picking of 1 leaf/1 bud, specialized equipment and expertise. Available grades are SFTGFOP1, FTGFOP1 and FTGOP1 and PURPLE.
Emrok superfine specialty orthodox was recently awarded Best Specialty Tea from Kenya at the 2015 GOLD MEDAL TEA COMPETITION FOR SPECIALTY TEAS held in San Antonio, Texas and organized jointly by the American Tea Association and the Canadian Tea Association.