Robots will start harvesting mushrooms soon, but they won’t completely replace humans any time soon – this is the main conclusion that can be drawn from the presentations and discussion of the Mushroom Automation Seminar held on June 11, 2024, in Dublin, organized by Teagasc. Special thanks to Donal Gernon, Mushroom Specialised Adviser in Teagasc for organization.
The seminar was attended by about 80 people, mainly farmers from Ireland and the UK. The speakers and panel discussion participants were companies and projects involved in automating the mushroom harvesting process in one form or another. The companies presented their developments and shared the current situation.
The main questions facing the mushroom industry, farmers who grow mushrooms, and companies developing automation solutions today are:
- Will it be possible to recoup the huge costs of purchasing robots, and will using robots be more profitable than using human labor in the short term?
- Is it worth investing in robots immediately, risking experiencing the ‘teething problems’ of technology on your own, or is it better to wait and implement robots when they prove their effectiveness on other farms?
- Should you try to adapt the robot to the design of existing farms, or is it more promising to build farms specifically designed for robots?
- Should you invest immediately in comprehensive solutions that automate the entire process, including packaging, or break it into parts such as automating the decision-making process of which mushroom to pick, actually picking the selected mushrooms from the shelf, cutting the stem, sorting, packaging, and logistics of containers?
Almost all participants mentioned working with AI in their presentations, expressing confidence that with the help of artificial intelligence, it is possible to understand the decision-making principles and work of the best pickers and ‘transfer’ this knowledge to robots. Thus, the yield of mushroom farms can be significantly increased.
Moreover, by obtaining a huge amount of data during the mushroom harvesting process using automation tools, it is possible to better understand the opportunities for increasing yields, further processing this data with tools that were previously unavailable.”
The seminar commenced with an opening speech by Dermot Callaghan, the Head of the Horticulture Development Department at the Teagasc Research Center in Ireland. Callaghan’s made a comprehensive overview of the mushroom industry’s evolution in Ireland and the critical role of automation in its future.
Historical Context and Industry Evolution
Callaghan began by reflecting on the evolution of mushroom farming in Ireland. He highlighted the significant transformation from the mid-1990s to today. During the late 90s, there was a substantial investment in Phase 3 production, leading to a consolidation of the industry. From an initial setup involving 800 growers using a bag system, the industry has now consolidated to about 30 growers operating 34-35 sites across Ireland. Despite this consolidation, the volume of Irish mushrooms has remained consistent, with approximately 66,000 tons produced annually, predominantly for the UK market.
Callaghan referred to this progression as moving through different “versions” of mushroom farming: starting with smaller-scale operations (Version One), transitioning through significant modernization with Phase 3 compost implementation (Version Two), and now entering the current phase of automation and technological integration (Version Three).
The Challenge of Labor Costs
One of the central themes of Callaghan’s address was the impact of labor availability and costs on the mushroom industry. He pointed out that labor costs have always dictated the pace of development in the sector. During the late 90s and early 2000s, Ireland’s booming economy made it challenging to attract workers to the mushroom industry, which led to the introduction of the first permit scheme to stabilize the workforce. Fast forward to recent years, labor costs have surged dramatically. Callaghan cited that labor now constitutes 46.3% of input costs, with a significant increase in recent years. This rise in labor costs underscores the necessity for automation to enhance productivity and reduce reliance on manual labor.
The Future of Mushroom Farming
Callaghan emphasized that the future of mushroom farming in Ireland hinges on embracing automation. He highlighted Teagasc’s commitment to supporting the industry through research and development of advanced technologies. Callaghan stressed that automation is not just about replacing human labor but also about improving efficiency, consistency, and quality in mushroom production. By integrating automation into various aspects of farming, the industry can overcome labor challenges, reduce costs, and meet the growing demand for mushrooms in both local and international markets.
One of the most comprehensive and promising developments in the field of mushroom farm automation was presented by Wim Van Vugt from Christiaens. Van Vugt provided an in-depth look at the company’s innovative solutions aimed at optimizing various aspects of mushroom cultivation and harvesting.
Key Areas of Development
- Separation of Growing and Harvesting Processes: Van Vugt emphasized the importance of separating pinning and harvesting rooms for logistical and hygienic reasons. This approach optimizes workflow without increasing the overall farm area.
- Logistics Solutions: Efficient logistics are crucial for delivering boxes and punnets to the growing room and transporting harvested mushrooms out. Christiaens has developed systems to streamline these processes, enhancing overall efficiency.
- Blue Belt System: Initially developed in 2002, this system allows harvesters to use both hands for picking mushrooms. Despite some disadvantages, it remains a significant step in automation.
- Drawer System: This innovative system centralizes the harvesting process by moving mushrooms to the harvesters rather than the other way around. It uses conveyors to transport empty crates and punnets to the harvesters and filled ones out of the room.
- Harvesting Disc: The picking disc introduced by Christiaens optimizes the harvesting process by separating the actual harvesting from the task of placing mushrooms into boxes. This allows one person to serve two pickers, significantly enhancing efficiency and reducing labor requirements. This system is particularly effective in farms with separate pinning and harvesting rooms and represent best alternative to Blue Belt System.
- Robotic Harvesting: The ultimate goal is to replace human labor with robots. Christiaens is set to install the first commercial mushroom-harvesting robot in the Netherlands in July. The robots use fingers instead of suction to minimize damage to the mushrooms, and are equipped with AI and vision systems to accurately identify and pick mushrooms.
The Drawer System from Christiaens, combined with the picking disc, offers a more optimized harvesting process by allowing two-handed picking and precise packaging. Wim Van Vugt highlighted the benefits of these systems, such as improved ergonomics, reduced labor requirements, and enhanced efficiency.
Christiaens’ robotic harvesting solution represents a significant advancement. Initial experiments showed that suction methods damaged mushrooms, leading to the development of finger-based robots. These robots, equipped with AI and vision systems, can accurately identify and pick mushrooms, further reducing labor costs and improving efficiency. The first commercial installation will feature a robot with multiple arms to handle the delicate task of harvesting without damaging the mushrooms.
Van Vugt emphasized the significant advantages of Christiaens’ automation solutions. The drawer system, combined with the picking disc, reduces labor requirements by a third in compare to Blue Belt system. The implementation of robots will further decrease labor costs and improve efficiency. Christiaens is also focusing on utilizing AI and big data to optimize yields by analyzing data from the best-performing crops and replicating successful growing conditions.
Sean O’Connor, the Director of 4AG Robotics from Canada, briefly discussed his company’s development of automated solutions for mushroom harvesting. He highlighted the importance of practical and effective solutions and the transition from rule-based systems to AI-driven solutions. O’Connor shared insights into their robots’ operational success and financial stability, showcasing their capabilities in picking mushrooms with minimal human intervention.
Alan Doake, the Director of Axis Harvesting from the UK, provided a brief overview of the technological advancements in his company’s harvesting systems. Doake highlighted the evolution from the first-generation harvesting system to the current innovations, including a conveyor system for efficient mushroom handling and processing. He emphasized the improved harvesting speed and flexibility of their solutions.
Jack Lemmen, the Director of GTL from the Netherlands, discussed the integration of automation in mushroom farm management. He highlighted the separation of growing and packing areas, shelf configurations, and the use of AI to enhance the picking process. Lemmen also explored different packing solutions and the future potential of detachable robots for increased flexibility and efficiency.
Jan-Emiel Tuck, the Director of TLT Automation from Belgium, outlined his company’s four-step approach to automating mushroom farming. He emphasized simplifying the picker’s task, efficiently removing mushrooms from the picking room, utilizing automation in external processing areas, and implementing data systems for performance tracking. Tuck highlighted the benefits of their innovative farm design and automated systems in reducing labor costs and improving efficiency.
