The engineering of unblended character.
At Sundarpur, tea manufacturing balances dynamic agronomy with industrial precision. We process our harvest within a unified single-estate workflow. By avoiding external sourcing, we guarantee complete leaf traceability across our entire production timeline.
Every morning, raw leaves are monitored to measure environmental cell hydration. From early plucking cycles to final multi-deck mechanical grading, each step is optimized to lock in the bold, malty characteristics that define authentic Upper Assam tea.
The Five Stages of CTC Mastery
Cultivation
Terroir OptimizationOur bushes thrive in the rich alluvial soils of the Brahmaputra basin. The local monsoon climate and high humidity support steady, uniform leaf growth. Field teams combine generational agricultural expertise with modern soil analytics to ensure the crops receive balanced nutrients year-round.
- Alluvial river loam
- High ambient humidity tracking
- Indigenous soil preservation
Fine Leaf Plucking
Harvest Selective ControlHarvesting teams select only the finest two leaves and a bud during peak flushes. This precise hand-plucking process isolates top-tier foliage, ensuring high enzyme content, excellent clarity in the cup, and a well-developed golden tip profile across our commercial invoices.
- Strict "Two Leaves & A Bud" selection
- Morning cell-hydration field sweeps
- Integrated logistical transport
Withering
Moisture ExtractionArriving leaf batches are spread uniformly across specialized open troughs. Atmospheric air is circulated precisely through the beds to reduce internal leaf moisture by 30% to 35%. This controlled chemical and physical wither softens the leaf structures, preparing them for uniform cell breakdown.
- Monitored automated cross-flow ventilation
- 35% target moisture reduction
- Polyphenol preservation tracking
Processing & CTC
Cell Disruption MacerationWithered leaves pass through synchronized high-speed rollers to undergo the Crush, Tear, and Curl (CTC) process. This deliberate mechanical maceration breaks open leaf cells, releasing essential juices and initiating natural oxidation. The process develops the signature deep color, intense liquor strength, and rich character of Sundarpur tea.
- High-precision multi-stage roller arrays
- Continuous ambient oxidation tracking
- Fluid bed drying temperature control
Grade & Dispatch
Mechanical Density SortingProcessed granules are sorted into specific trade designations using multi-deck vibrating screen sifters. The resulting grades—ranging from bold leaf particles to fine fannings and dust—are evaluated by our head tasters, packed in secure moisture-barrier bags, and prepared for global bulk distribution.
- Vibrating multi-deck sifting systems
- Rigorous pre-shipment tasting protocols
- High-barrier hermetic industrial packaging
The visual language of large-scale processing.
Take a look inside the active facilities of our estate. Our processing floors combine classic manufacturing techniques with modern quality controls to process our entire annual yield under strict safety standards.
