A nearly 40-year collaboration between GP Graders and Reid Fruits has led to the introduction of a new gantry-style bin tipper as part of the AirJet® cherry grader upgrades for the 2024/2025 cherry season in Tasmania. The development of this system aims to enhance efficiency in the grading process by automating fruit loading, reducing labor requirements, and improving overall workflow.
Previous challenges in the grading process
In past seasons, cherries destined for grading on one of the two processing machines were manually loaded into a receiver tank by a team of five or six operators. This method posed several challenges, including labor-intensive handling and a physical limitation on how much fruit could be fed into the grading line. With processing volumes reaching between three and four million cherries daily, the need for a more efficient system became evident.
The need for automation
The objective was to introduce an automated system that would reduce the manual loading team to a single forklift operator and one coordinator. Additionally, with the AirJet® grader being expanded from six to ten lanes and extra exits added, increasing the input volume of cherries became necessary to match the machine's grading capacity.
The new system needed to accommodate up to four quarter-tonne bins at a time, allowing for a smoother workflow without frequent interruptions for reloading. This adjustment ensures the ability to load up to 10 tonnes of cherries per hour, aligning with the grader's capacity to analyze up to six tonnes per hour while providing room for future expansion.
Development and implementation
GP Graders designed and built the bin tipper to fit Reid Fruits' specific operational requirements. The system was developed with a durable chassis, high-quality motors, gearboxes, chains, castors, and an integrated electronics system to ensure reliable performance during peak harvest seasons.
The tipping process has been carefully programmed to handle cherries gently while ensuring all fruit is efficiently transferred from the bins. Each bin is partially submerged into the receiver tank to facilitate smooth transfer while minimizing impact on the fruit. The system is fully electric, eliminating the need for hydraulic actuators and pumps, which reduces maintenance and avoids the use of synthetic fluids in a food processing environment.
The full cycle—picking up, transferring, tipping, and returning all four bins (equivalent to 1,000 kilograms)—is completed in approximately five minutes. Smart sensors have been incorporated to optimize workflow, allowing new full bins to be loaded while the last emptied bin is still being placed down. This feature helps maintain efficiency without compromising operator safety.
Impact on labor and efficiency
Previously, six workers manually loading cherries had to handle approximately 165 lugs per hour each to keep up with grading demand. This system removes the variability associated with manual labor, such as fatigue or absenteeism, ensuring a continuous and efficient workflow.
For more information:
gpgraders
Tel: +61 3 9585 9444
www.gpgraders.com