Posted: 2022-10-15 22:04:08

Just a short drive from lakes and beaches in the New South Wales Great Lakes region lies a lush pocket of farming land. 

A 60-hectare property covered in 20-year-old native tea tree plants is among the farms in the area.

For Allan and Jane Hutcherson, purchasing this property fulfilled a long-held dream. 

"We have a contract manufacturing business … and one of the things we always wanted to do was to create our own brand," Mr Hutcherson said.

For almost three decades, the couple has been making soap for big companies in their factory in Sydney's Northern Beaches.

But the tea tree farm presented the chance to finally start their own skin care line, using essential oils produced from the plants on the property. 

"It's totally vertically integrated," Mr Hutcherson said.

"We're actually producing oils from all of these wonderful botanical plants, and we're using them in our manufacturing facility."

A long-distance shot of a man in blue jeans, top, gum boots, cap, on his tractor towing a trailer full of shredded teat tree.
After the tea tree is mechanically harvested, Mr Hutcherson takes it to the shed to be processed.(ABC Rural: Keely Johnson)

Regenerating the farm

The couple purchased the property in 2018 and have spent the past four years regenerating it. 

"It was a little bit run down, but we've given it a lot of love and planted a lot more trees and introduced new species," Ms Hutcherson said.

The pair have expanded to include lemon myrtle, old man saltbush and kunzea to the mix, and they are not stopping there.

"At the moment, we are working on preparing an area for about 4,000 Melaleuca ericifolia, which a lot of people know as Rosalina," Mr Hutcherson said.

"We see that as one of our new oils and new products we'll launch in probably 12–18 months' time."

Two images side by side. The first shows overgrown grass the second a paddock filled with essential oil plants.
The farm in 2018 compared to now.(Supplied: Amy Dempsey)

Mr Hutcherson studied food science at university and later did a horticulture course.

He said the farm allowed him to put his skills into action.

"It's just great for me because I love it," Mr Hutcherson said.

"I grew up on a farm, and I missed it when we didn't have it."

From farm to factory

The plants are mechanically harvested and processed on the farm. 

The essential oils are extracted from the trees and poured into large barrels, which Mr Hutcherson transports about three hours south of the property to his factory in Sydney.

They also have 10 beehives on the farm to create manuka honey, another ingredient used in their products.

A large shed with a big, steel steaming device and barrels under it.
The tea tree is extracted at the farm.(ABC Rural: Keely Johnson)

The business is a family affair involving their children and their partners, who manage sales and marketing, human resources, and operations at the factory with a staff of 50.

The Hutchersons' son-in-law Grant Dempsey oversees contract production, as well as that of about 40 of their own products that incorporate essential oils from the farm. 

"It's pretty rare to actually produce a product from scratch, basically from the raw materials first," Mr Dempsey said. 

Five pouches filled with yellow liquid hand wash are on a rotating table with a worker packing them into a box.
Lemon myrtle and manuka honey handwash pouches being made in the Northern Beaches factory.(ABC Rural: Keely Johnson)

Small businesses work hard to succeed

The Hutchersons' goal was always to get their products on supermarket shelves.

Their son Sam Hutcherson, who is the business's sales director, helped make that happen but said competing with global brands was a constant battle for the family.

"It was a difficult process getting in there [supermarkets] and getting in the door … and I guess the hardest thing is staying in there," he said.

"Being a small business and being at the mercy of big businesses is hard. It's stressful, but we back ourselves because our product is really good quality.

Smiling woman wears hat, light top, jeans, holds child, man in t-shirt, jeans, carries child in front of lemon myrtle plants.
Annie Hutcherson manages accounts and human resources, while Sam Hutcherson is in charge of sales.(ABC Rural: Keely Johnson)

"We don't have millions and millions of dollars to pump into marketing like the multinationals [international companies] do, and so you really are fighting for your life."

Business sustainability

The Hutchersons' daughter and business manager Amy Dempsey said ensuring their company was sustainable was important.

"We've recently just launched our refillable glass bottles and our soap pouches. These save about 80 per cent of plastic, and you can re-fill your bottle twice with them," she said.

Handwash also comes in clear glass and plastic bottles, which can be recycled, and online orders are sent in plastic-free packaging.

A bunch of products in a tray including: soap bars, essential oils, hand creams, body scrubs, hand wash.
The family has developed about 40 products in their hair and body wash line.(ABC Rural: Keely Johnson)

Recycling is just as important on the farm.

"Once we finish cooking the tea tree or the lemon myrtle, we have the biomass which we compost," Mr Hutcherson said.

"We put it back onto the plantation, and so we reuse it."

A smiling couple with their three children standing in front of salt bush plants, man wears cap, blue shirt, woman white shirt.
Grant and Amy Dempsey are also involved in the business.(ABC Rural: Keely Johnson)

Ms Hutcherson said she felt lucky to have her family help run the business.

"Having our kids come on board has been fantastic," she said.

"They've brought their own skills to the business, and their partners have also been able to join our business, bringing a completely different set of skills."

A group of men and women some wearing hats, jeans with the kids smiling on the farm.
The family often enjoy the school holidays together on the farm.(ABC Rural: Keely Johnson)

Family is at the heart of this farming business, but it's the farm that is its essence.

"The soul of our business is this wonderful farm and using the botanicals that we produce here in our products," Mr Hutcherson said.

Watch this story on ABC TV's Landline at 12:30pm on Sunday, or on ABC iview.

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