In the Netherlands and Belgium developments relating to new harvesting methods and equipment have not stood still. Where pickers thirty years ago were still using ladders, modern growers can choose from a staggering array of trolleys, platforms and lifts, that move with ease between the high, tiered shelving systems. Fed by the urge to increase picking performance and create improved labour conditions, these innovations are quickly embraced by the mushroom growing industry. Innovations which cannot be seen in isolation to changes in the areas of logistics and harvesting techniques. Various systems will undoubtedly attract a great deal of public attention at the coming Mushroom Days. This article gives you a taste of what's to come.

It's maybe hard to imagine but until the 1970s ladders were still used in the Netherlands by mushrooms pickers - and we are talking about progressive thinkers here! The most common working practice was to stand in the central corridor, legs akimbo, picking from both beds. This was possible as corridors were narrower then. The down side of this method using ladders was that the pickers working at lower levels were often hindered, the posture used was far from ideal and the use of picking trolleys, except for the upper beds, was difficult. Improvements in the shape of a shallow gutter in the floor as a guide and folding ladders increased manoeuvrability.

In the 1980s the first picking trolleys were introduced in the Netherlands. They were quite narrow so they fitted into most existing growing rooms. The wooden platforms were not an ideal choice from a hygienic point of view and quickly became slippery. However, it did mean racks could be used to place empty and full containers and punnets and picking rates increased. Grading at picking also became a reality, as the different grades could be placed on the same trolley.

In smaller growing facilities it was still a question of fitting everything in, and trolleys didn't always have enough space to pass on the same bed. Picking posture was still not optimal due to the large height differences. Increments of 25 centimetres in height were usual.

These types of picking trolleys were later succeeded by winch driven, height adjustable versions, which in turn lead to the development of hydraulic, height-adjustable trolleys.

Another method was placing a kind of mezzanine staging so the upper two or three beds could also be picked standing. This method was very popular in the UK and America during the 80s.

Anno 2004

If we inspect the currently popular systems, they can be divided into two groups - picking trolleys and picking platforms. Both are electrically driven and hydraulically height adjustable. The choice of system depends on the growing rooms, the harvesting method and which advantages or disadvantages the grower finds most important.

If installed correctly both systems allow all the beds to be picked from the same place. The upper beds are harvested standing and the lower sitting down. Certain versions allow the picker to work from a sitting position on all the beds, if wished.

The investment in these systems is quite similar and lies between € 7.500,- and € 8.500,- per full time equivalent picker.

Picking trolleys

Hydraulically adjustable trolleys are currently available with electric drive with variable speed. This system resembles a normal trolley so pickers quickly become familiar with how it works. The advantage of this system is that it can still be used while pickers are harvesting the two lower beds. The trolley can easily pass them.

A possible disadvantage is the lack of space to carry many containers, which means more frequent unloading and driving up and down. They can be used in most types of growing rooms, but require a fair deal of space for manoeuvring in and out. The meticulous cleaning required takes up a lot of time as well and should preferably be done in a separate area to avoid congesting the main working area.

With the first models adjusting the height of the shelf holding the containers was quite a problem, which caused some irritation among the pickers.

Picking platforms

The hydraulic adjustable platform is also propelled by an electro-motor and continuously speed variable. The special wheel configuration means the platform stays in place, so pickers don't have to constantly pull the platform as close as possible to the beds.

The drawback with these platforms is that they run along the floor so can form an obstacle for pickers working on the lower beds. They can however transport a large number of containers or boxes, so less time is wasted swapping full containers for empty ones. As with picking trolleys, cleaning is a demanding task and should also be done in an area where the platform doesn't get in the way.

Adjusting the height of the picking rack was a bit tricky with the first models- this has been solved in later versions. Picking from the lower beds is possible, but in order to increase the performance here certain companies have raised the lower bed (and therefore all the tiered shelving ).

Tray lift for existing picking trolleys

The lifting platform is the ideal device to lower full containers of mushrooms to the ground. It saves time and labour on the fifth and sixth bed in particular as full trays don't have to be handed down one by one. The pickers can concentrate on picking while the supervisor collects the filled containers. The picker only has to lower the contents to ground level - the supervisor comes by with a hand truck every  three quarters of an hour or so and takes the stack of filled containers away. The lift rises again and so on.

Pickers can also have more empty packaging with them, have more space on the trolley and no more problems taking away full containers and coming back with empty ones. Everything goes in one smooth- and more natural- movement. Each time a full container is placed on the picking rack, the lift drops slightly so the right working height is retained automatically for the picker.

This lift for containers can be attached to existing trolleys and works using air pressure stored in the frame. The weight depends on the number of beds - and varies between 20 and 23 kg.

Investment costs are approximately € 1.500,- and the first experiences in trials are very positive.

Johan Hoekstra is manager at mushroom growers I.C. in Adegem, Belgium. He's confronted by working practices on a daily basis and had long been racking his brains to come up with a solution for the constant bother with containers in the growing rooms. After nine months of development and trials the infant tray lift has ‘come of age' and is ready to go into production. The lift is new on the market and a patented design.

Hoekstra:”A tray lift for existing picking trolleys improves labour conditions and increases performance as pickers are freed up to concentrate on their main task - picking mushrooms! Pickers harvesting seated from the lower and second bed no longer have to take along any trays or boxes - which makes picking more comfortable. The picking performance here has risen by some 10 to 15 %. The pickers are really enthusiastic and wouldn't miss the lift for the world. The lift's simple design make it practically  breakdown and maintenance free. The ideal investment for growers working with traditional picking trolleys. A full return on investment can be achieved in a space of between six months and one year.”

Points to remember

If either of these systems is introduced, bear certain points in mind. Firstly, pickers will have to switch to a totally different method of harvesting. Selective harvesting several times a day is a must. The room mustn't show uniform growth and the trolleys and platforms must constantly be on the move. This is difficult to learn, but special training courses are being developed.

Pickers must also be motivated enough to want to adapt to a new system. The new systems are quickly seen as simply a method to improve productivity, while in fact it's just a ‘different’ approach to work that's required. If the idea behind the new equipment is not explained properly, the result will be discontented personnel and  a lower picking performance than expected.

All the other conditions must be right too. Logistics at the growers must be well planned. Too many long distances and frequently crossing paths cancel out all the other advantages. The members of the picking team may change, and the different harvesting technique could result in a different time frame for cropping. The team will comprise a small group working for an extended period on a certain flush. Periods when harvesting is 'idle' in a particular growing room should be as short as possible. As a consequence the actual working hours may change and the team members accordingly.

These are all aspects that growers should discuss in detail with their advisor or supplier before making any drastic decisions. Rectifying mistakes afterwards is very difficult, just causes frustration and is costly.

Training

AdVisie gives training sessions about manual harvesting in relation to high frequency picking with self-propelled trolleys. Individual training for each picker in the growing room follows the theory session for the whole group. Helpful comments and praise from an outsider can do wonders. Often neglected aspects such as picking technique and posture are also examined. Questions such as what is the ideal speed, why mustn't the trolley stand idle and what is the greatest advantage of picking the same room more than once are dealt with. A course for every grower, but certainly those thinking about changing to selective harvesting with self-propelled trolleys or platforms.

The economic side

Actual, hard figures for comparison or calculation are unavailable. An example can go a long way to giving a better impression. Imagine we have a farm with 12 growing rooms of 300 square metres. The owner invests in 16 hydraulically driven trolleys or self-propelled, hydraulically height adjustable platforms. Cost per item including other modifications: € 8.000,-. Writing off in four years, average interest rate 3.15% and maintenance 4%. The farm uses a six-week schedule and harvests three flushes. The first and second flush manually and the third flush mechanically. Production 33 kg/m2 and a picking performance of 31 kg/hour.

Using these figures, the picking performance must improve by 3.3 kg/hour, which converts to 11 %. At that moment the grower will earn his investment pay after four years.

However, the motivation to invest is not to earn back the original expenditure but to improve overall results. An even higher picking performance than 3.3 kg/hour, and any improved quality, all adds up to profit. If the quality I percentage rises by 2 % in this situation the revenue is € 15.000,- annually, and each kilogram of performance higher than 3.3 kg/hour supplies € 12.500,- .

As well as the financial figures, improvements in health and safety conditions are also important- and can equally supply long-term financial benefits.

Coen Verkooijen mushroom grower in Ospel

"When we were expanding our company in the autumn of 2003 the self-propelled hydraulic picking lift played a crucially decisive role. We didn't construct five beds high as intended initially, but six high. This gave us an additional growing surface area of 60 square metres per room. Each week we fill an ‘old’ room of 300 and a new one of 360 square metres. We harvests using a five-week schedule and pick two flushes. When constructing new buildings make the new rooms wide enough (6.80 metres) to get optimal use of the 71 centimetre wide trolleys, which actually take up quite a bit of space. We can't use this equipment in the old rooms as they are too narrow (6.00 metres). We're shortly going to introduce hydraulically height adjustable and propelled picking trolleys. When we've reached that stage all our pickers will have the ideal conditions.”

Rene van Dongen mushroom grower in Zeeland

“I've rarely made such a huge investment that paid itself back as quickly as this. In spring 2004 we invested in 24 self-propelled hydraulic picking lifts on our farm of 12 growing rooms of 420 square metres. Before the investment, I calculated a increase in production of 1 to 1.5 kg/m2, an improvement in quality of 2 % and picking performance improvement of 5 kg/hour.

The production increase by selective picking is not so obvious after three months. On the other hand, better quality and higher picking performance is. Until now we achieved an improvement of 15 %. We're trying to optimise this by continuing to improve the organisation - which will take on a different form.

On my own company this means I can recover my investment in two years and that's not counting the COM-subsidy we received! As well as the financial aspects, we've also made conditions for the pickers considerably better - something that's just as important as the monetary gain."

Cris de Brouwer mushroom grower in Goirle

“The decision whether to invest in new equipment is not an easy one in today's unfavourable climate for the sector. All around colleagues are ceasing business and I'm on the brink of laying out nearly € 200.000,- in harvesting equipment, a total contrast. The decision to take the risk was partly motivated by the COM-subsidy granted via a trial project organised by The Greenery. We have to continue to grow, but I see this more a step on the road towards further optimisation and mechanization. On my company with fourteen rooms covering 244 square metres with tiers of five beds, we now use 24 hydraulically height adjustable, electrically driven picking trolleys. I chose picking trolleys as the middle corridor doesn't allow enough space for two self-propelled picking platforms to pass, and because I still want to be able to pick the second bed  ‘normally'. My beds are only 18 metres long, so I try to only use four picking trolleys per room and one picker for the second bed. In the peak during the first flush I use more picking trolleys. Regarding working conditions, the hydraulically driven trolleys are a great advance. Always at the correct height, the pickers no longer have to physically move the equipment, the railings guarantee safety and we never have to manually hang the platforms. I'm happy and my pickers are too.”

Suppliers

Picking platforms and picking trolleys:

Christiaens construction,            Tel:             +31(0)77-3999540        Mushroom Days stand nr. 50.

Picking platforms:

Traco               ,                       Tel:             +31 (0)412401946       

Picking trolleys:

Limbraco,                                  Tel:             +31(0)77-3983359        Mushroom Days stand nr. 55.

Picking lift:

International Cultivate,               Tel:              +32-937-83579                         Mushroom Days stand nr. 58.

Organisation and harvesting instruction:

AdVisie Tel:               0475-537161        in co-operation with

Alles voor groene Arbeid,           Tel: +31(0)900-1001280             Mushroom Days stand nr. 19.