Sprouts are one of the most difficult crops to grow, and also to harvest, involving a lot of expensive manual work. Brothers Jan and Ronald Herbert grew up with sprouts. They made a venture capital investment in the future of sprouts and their company. The very first fully automatic Brussels sprout picking robot, developed by machine builder Tumoba, is working hard this season at the harvest. In this way, sprouts will remain profitable and affordable for the company that has now been in existence for 25 years and is competing for the title of Agricultural Entrepreneur of the Year.
Ronald, left, and Jan Herbert, right
Mechanisation
Harvesting sprouts is very labour-intensive; if the process had not already been partly mechanised, sprouts would have been unaffordable by now. In the past, each sprout was picked individually and by hand from the stump. In the 1980s, this was semi-automated by the sprout harvester with a knife system that cuts the stumps and a picking head with knives that cuts the sprouts from the stump. The step in between is still done manually with 4 men who put the cut stumps in the picking heads. Tumoba has succeeded in replacing this human handwork with robot arms. These can take over the monotonous work and are also not bothered by the changing weather conditions and the (often wet) sprout stumps.
The sprout harvesting robot in action, Source Agrifoto
Jan and Ronald have witnessed the mechanisation of the sprout harvest from the very beginning. The history of the company goes back to the early seventies when the company was founded by their father in Zoetermeer. Twenty-five years ago, they jointly took over the company and grew into one of the largest sprout growers in the Netherlands in Zeewolde. This year they cultivated 336 hectares of conventional/Planet Proof and in collaboration with ERF BV organic sprayers. They also grow cauliflower and kale. They have been part of The Greenery from the very beginning. Dutch retail is supplied through The Greenery. Sales to German retail outlets are handled by Weyers and others.
Ronald Herbert with Joost Rouwhorst (l) of The Greenery
Venture capital investment
Picking sprouts is hard work. When they were young, the Herbert brothers dreamed of fully automating the harvest. Three years ago, they made the final push to make it a reality. To support the development of the picking robot, they made a venture capital investment, with limited support from The Greenery's Product Fund for Brussels sprouts. They purchased the robot before it was even built.
Detail of the sprout picking robot, sensors locate the sprout plant after which it is cut.
This allowed the second generation of Tumoba, who specialise in designing open field harvesting machines, to make headway. Three years ago they figured out how the robotic arms could replace the human arms. These clamp the cut stump, make a 180 degree turn, lift it up and put it in the cutting head. The mechanical system must work flawlessly with the sensors and software.
Ronald shows one of the robot arms. The arm clamps the cut sprout plant, turns backwards and puts the plant in the cutting head.
"Tumoba's strength is that they are strong in software as well as in design," says Ronald. The Herbert's were very closely involved in the development. With some delay, the robot was ready at the end of the 2020-2021 season. This season they are working with the robot from the beginning and confidence is growing. "We paid a lot of money to learn, but 80% of the learning process is done. It's going to be all right," says Ronald.
The Brussels sprouts picking robot harvests four riding at once
The venture capital investment was made against the background of an uncertain future. All around them, R. and J. Herbert see growers ceasing to grow sprouts. On the one hand due to a lack of successors, on the other hand because it is difficult to make the cultivation profitable. There are also concerns about the disappearance of crop protection products, for which there are not yet any good alternatives. Expansion of scale is necessary in sprout cultivation, but according to Jan this cannot continue indefinitely.
Detail of the sprout harvesting robot, the underside of the sprout plant has been put into the cutting head.
"I can't see anyone growing more than 500 hectares of sprouts. The costs per hectare have increased enormously. It is estimated that the cost price per ha will rise between €1000 and €1250 this year. However, the sprout price is still the same as 20 years ago. We would like to provide healthy and food-safe food, but by banning crop protection products for which there is no (green) alternative yet, food production is at risk. For many growers it is not sustainable. Retailers are paying more attention to this issue, but we do not yet see this reflected in a better payout price."
A view of what is happening in the robot by means of computer screens
Robot vs man
In the short term, the use of robots will not contribute to a reduction in cost price. The big advantage now is the flexibility that the robot gives, which reduces the pressure on the employees. In the December month, the demand for sprouts peaks. Because the picking robot was being used, there was no need to hire extra personnel.
Cut sprouts roll over a conveyor belt towards the tipping truck
The robot arms can work almost as hard (approx. 10 plants per minute) as 4 experienced workers (approx. 12 plants/minute). The expectation is that in the future the robot can work 24/7 on the field and will then pay for itself. One worker is still needed to control the harvesting robot and ensure that it can make the turn at the end of the row. Compared to a traditional 4-row harvester, this saves three man-hours, and the robot makes the work safer and less strenuous.
Not a single stalk is lost. An extra cutting head on the side of the robot makes it possible to harvest sprout plants that the robot arms did not pick up
R. and J. Herbert have already made plans for the coming season. They are certainly not cutting back on staff. The 18 sprout pickers will certainly be able to work there next season. "People remain the basis of our company, without good personnel we would be lost. We are very proud of the fact that we have been working for a long time with 25 Polish and Romanian employees (in the high season) and 10 Dutch, including ourselves. Machines are secondary," the brothers conclude.
Ronald inspects the rows of sprout plants
Detail of the field through which the sprout-picking robot drives
The sprout-picking robot drives entirely independently, but can be steered
The use of manned sprout harvesters, as seen here in the distance, remains necessary
Full tipper truck is ready to leave for the processing shed of R. and J. Herbert. There, Brussels sprouts are sorted and packed according to the customer's wishes
A clip from Boerderij about the nomination of Agrarische Ondernemer (Agrarian Entrepreneur) 2022
For more information:
Jan en Ronald Herbert
R. en J. Herbert
Zeewolde
Tel. +31 (0) 36-5228296
[email protected]
FB R. en J. Herbert