Sport and Work on the Nepaul Frontier. James Inglis
rel="nofollow" href="#fb3_img_img_eed2ff7b-0a88-5b6d-9fb8-38fc2c12e892.jpg" alt="Indigo Beaters at Work in the Vats"/> Indigo Beaters at Work in the Vats
During the beating, two processes are going on simultaneously. One is chemical—oxygenation—turning the yellowish green dye into a deep intense blue: the other is mechanical—a separation of the particles of dye from the water in which it is held in solution. The beating seems to do this, causing the dye to granulate in larger particles.
When the vat has been beaten, the coolies remove the froth and scum from the surface of the water, and then leave the contents to settle. The fecula or dye, or mall, as it is technically called, now settles at the bottom of the vat in a soft pulpy sediment, and the waste liquor left on the top is let off through graduated holes in the front. Pin after pin is gradually removed, and the clear sherry-coloured waste allowed to run out till the last hole in the series is reached, and nothing but dye remains in the vat. By this time the coolies have had a rest and food, and now they return to the works, and either lift up the mall in earthen jars and take it to the mall tank, or—as is now more commonly done—they run it along a channel to the tank, and then wash out and clean the vat to be ready for the renewed beating on the morrow. When all the mall has been collected in the mall tank, it is next pumped up into the straining room. It is here strained through successive layers of wire gauze and cloth, till, free from dirt, sand and impurity, it is run into the large iron boilers, to be subjected to the next process. This is the boiling. This operation usually takes two or three hours, after which it is run off along narrow channels, till it reaches the straining-table. It is a very important part of the manufacture, and has to be carefully done. The straining-table is an oblong shallow wooden frame, in the shape of a trough, but all composed of open woodwork. It is covered by a large straining-sheet, on which the mall settles; while the waste water trickles through and is carried away by a drain. When the mall has stood on the table all night, it is next morning lifted up by scoops and buckets and put into the presses. These are square boxes of iron or wood, with perforated sides and bottom and a removeable perforated lid. The insides of the boxes are lined with press cloths, and when filled these cloths are carefully folded over the mall, which is now of the consistence of starch; and a heavy beam, worked on two upright three-inch screws, is let down on the lid of the press. A long lever is now put on the screws, and the nut worked slowly round. The pressure is enormous, and all the water remaining in the mall is pressed through the cloth and perforations in the press-box till nothing but the pure indigo remains behind.
The presses are now opened, and a square slab of dark moist indigo, about three or three and a half inches thick, is carried off on the bottom of the press (the top and sides having been removed), and carefully placed on the cutting frame. This frame corresponds in size to the bottom of the press, and is grooved in lines somewhat after the manner of a chess-board. A stiff iron rod with a brass wire attached is put through the groove under the slab, the wire is brought over the slab, and the rod being pulled smartly through brings the wire with it, cutting the indigo much in the same way as you would cut a bar of soap. When all the slab has been cut into bars, the wire and rod are next put into the grooves at right angles to the bars and again pulled through, thus dividing the bars into cubical cakes. Each cake is then stamped with the factory mark and number, and all are noted down in the books. They are then taken to the drying house; this is a large airy building, with strong shelves of bamboo reaching to the roof, and having narrow passages between the tiers of shelves. On these shelves or mychans, as they are called, the cakes are ranged to dry. The drying takes two or three months, and the cakes are turned and moved at frequent intervals, till thoroughly ready for packing. All the little pieces and corners and chips are carefully put by on separate shelves, and packed separately. Even the sweepings and refuse from the sheets and floor are all carefully collected, mixed with water, boiled separately, and made into cakes, which are called 'washings.'
During the drying a thick mould forms on the cakes. This is carefully brushed off before packing, and, mixed with sweepings and tiny chips is all ground up in a hand-mill, packed in separate chests, and sold as dust. In October, when mahye is over, and the preparation of the land going on again, the packing begins. The cakes, each of separate date, are carefully scrutinised, and placed in order of quality. The finest qualities are packed first, in layers, in mango-wood boxes; the boxes are first weighed empty, re-weighed when full, and the difference gives the nett weight of the indigo. The tare, gross, and nett weights are printed legibly on the chests, along with the factory mark and number of the chest, and when all are ready, they are sent down to the brokers in Calcutta for sale. Such shortly is the system of manufacture.
During mahye the factory is a busy scene. Long before break of day the ryots and coolies are busy cutting the plant, leaving it in green little heaps for the cartmen to load. In the early morning the carts are seen converging to the factory on every road, crawling along like huge green beetles. Here a cavalcade of twenty or thirty carts, there in clusters of twos or threes. When they reach the factory the loaders have several vats ready for the reception of the plant, while others are taking out the already steeped plant of yesterday; staggering under its weight, as, dripping with water, they toss it on the vast accumulating heap of refuse material.
Down in the vats below, the beating coolies are splashing, and shouting, and yelling, or the revolving wheel (where machinery is used) is scattering clouds of spray and foam in the blinding sunshine. The firemen stripped to the waist, are feeding the furnaces with the dried stems of last year's crop, which forms our only fuel. The smoke hovers in volumes over the boiling-house. The pinmen are busy sorting their pins, rolling hemp round them to make them fit the holes more exactly. Inside the boiling-house, dimly discernible through the clouds of stifling steam, the boilermen are seen with long rods, stirring slowly the boiling mass of bubbling blue. The clank of the levers resounds through the pressing-house, or the hoarse guttural 'hah, hah!' as the huge lever is strained and pulled at by the press-house coolies. The straining-table is being cleaned by the table 'mate' and his coolies, while the washerman stamps on his sheets and press-cloths to extract all the colour from them, and the cake-house boys run to and fro between the cutting-table and the cake-house with batches of cakes on their heads, borne on boards, like a baker taking his hot rolls from the oven, or like a busy swarm of ants taking the spoil of the granary to their forest haunt. Everywhere there is a confused jumble of sounds. The plash of water, the clank of machinery, the creaking of wheels, the roaring of the furnaces, mingle with the shouts, cries, and yells of the excited coolies; the vituperations of the drivers as some terrified or obstinate bullock plunges madly about; the objurgations of the 'mates' as some lazy fellow eases his stroke in the beating vats; the cracking of whips as the bullocks tear round the circle where the Persian wheel creaks and rumbles in the damp, dilapidated wheel-house; the-dripping buckets revolving clumsily on the drum, the arriving and departing carts; the clang of the anvil, as the blacksmith and his men hammer away at some huge screw which has been bent; the hurrying crowds of cartmen and loaders with their burdens of fresh green plant or dripping refuse;—form such a medley of sights and sounds as I have never seen equalled in any other industry.
The planter has to be here, there, and everywhere. He sends carts to this village or to that, according as the crop ripens. Coolies must be counted and paid daily. The stubble must be ploughed to give the plant a start for the second growth whenever the weather will admit of it. Reports have to be sent to the agents and owners. The boiling must be narrowly watched, as also the beating and the straining. He has a large staff of native assistants, but if his mahye is to be successful, his eye must be over all. It is an anxious time, but the constant work is grateful, and when the produce is good, and everything working smoothly, it is perhaps the most enjoyable time of the whole year. Is it nothing to see the crop, on which so much care has been expended, which you have watched day by day through all the vicissitudes of the season, through drought, and flood, and blight; is it nothing to see it safely harvested, and your shelves filling day by day with fine sound cakes, the representatives of wealth, that will fill your pockets with commission, and build up your name as a careful and painstaking planter?
'What's your produce?' is now the first query at this season, when planters meet. Calculations are made daily, nay hourly, to see how much is being got per beegah, or how much per vat. The presses are calculated to weigh so much. Some days you will get a press a vat,