Development Progress
Development Progress – Anyone interested in increasing harvesting efficiency, crop yield and profit should read this.
Explanation / Introduction
Over the past 12 months the Mushroom Machine Company has kept a low profile about its actual development progress. This was due to a few reasons:
1. We were very busy completing and methodically testing our Gamechanger software developments on different farms, with numerous container variations, different mushrooms sizes and with different users.
2. The new Articulated Floor Supported Lift had taken significant time to develop and perfect.
3. We didn’t want our potential competitors to know how much progress we have made.
4. Our customers had agreed to hang back until we got the New Lift perfected.
5. We needed to learn how to better implement mechanisation in farms, rather than leave it with reluctant and obstructive project managers.
6. We needed to develop more options for implementing 2 handed picking for bulk picking and developed the new Gamechanger Cord Box.
7. We needed time to get a perfect product before expanding into mass production.
This process began about 12 months ago and we started out with some very specific requirements.
The Requirements
The Gamechanger Pro is a combination of more than 15 machines in 1. This makes the design and software more complex as it introduces numerous mechanical, electrical and software combinations as well as many input variables.
The requirements of the Gamechanger Pro were:
1. Handle and weigh basically every size and type of container, which includes plastic punnets, cardboard punnets, boxes, trays, numerous punnet combinations inside trays, loaded via a de-nester or in the conveyor tray.
2. Harvesting and placement of all sizes of mushrooms, small, medium, large, brown or white button mushrooms into the containers with optimum presentation. The ability to switch between these formats easily several times per day.
3. Operate in basically any type of existing farm or shelving layout, with minimum or no adaptions. Easily moved from room to room and also be able to get into the outside aisles, with limited space at shelf ends, with the Articulated Lift. The ability to pick from both sides of the trolley and comfortably pick the bottom shelf.
4. Usability to the extent of “Idiot proof”, reliable and easily swapped from configuration to configuration. Access to numerous language options are available providing audio and visual prompts.
5. Adjustable and accurate stalk cutting complimented with minimal cleaning requirements to ensure optimum hygiene and absolute disease control using NutriSoap spray.
6. 6. Doubling of the picking rates, increases in yield through crop grazing and minimal or no infrastructural investment should mean that the savings could be achieved quickly, providing a very quick Return on Investment (ROI). The equipment costs should equate to cost savings equivalent to approximately one year’s wage in Europe.
The Actions
Over the past 12 months specific upgrades and amendments were carried out in accordance with our observations and user suggestions:
Gamechanger Pro
1. Selection menu for specific products to setup the machines with regard to weights and punnets.
2. Able to adjust selection menu to move commonly used products to the top.
3. Ability to delete unwanted products.
4. Add product descriptions.
5. Improved aerial positioning for better wireless range particularly when providing remote support.
6. We included a “large mushrooms” software option with complimentary placement adjustment.
7. Further Increased the number of drop positions to further improve presentation options.
8. Now we have the ability to handle mushrooms in excess of 80mm.
9. Extend the Pick & Place distance by 50mm to allow mushrooms to be placed in bottom of the punnet rather than dropping the mushrooms from a greater height.
10. Amended sucker cleaning system to accommodate the large trays as well as small punnets.
11. Software changed to more accurately reflect tray weight discrepancies caused normally by damaged trays and variations on tray movements.
12. Advanced troubleshooting help now built into the Software.
13. Strengthening of weighing brackets and weighing module to reinforce rigidity.
14. Reduced user interaction at software prompts.
15. Weighing modules increased to cater for heavier trays, now approx. 80kg.
16. More shelf space with detachable shelf extensions.
17. Improved stalk cutting blade attachment that allows 3-way adjustment and enhances the pickup position of the mushrooms.
18. Improved access to blade system.
19. Improved sensor protection and lowering sensor profile.
20. Improved design of removeable panels for cleaning.
21. Adjustable, detachable hard stop fitting for container positioning.
22. Enhanced roller system for punnet slide.
23. Cutter system allowing cutting stalks off the oversize and undersized mushrooms, that may require different punnets or trays other than those in the Gamechanger.
24. Optimised system settings tested over time.
25. Improved battery runtime by allowing the use of 1 or 2 battery sets.
26. Ability to hot swap batteries while in operation.
27. Attachment to keep air tunnels from touching sharp edges.
28. Improved visibility of sensor lights for troubleshooting.
29. Elements to reduce possibility of water ingression.
30. Increased Pick & Place performance.
31. Elimination of dirt ingression into moving parts using extended use of covers.
Gamechanger Punnet
1. Reduce sensors in line with advances made in the Gamechanger Pro.
2. Make mechanical changes to compliment changes.
3. Software upgraded to bring into line with Gamechanger Pro upgrades.
Articulated Floor Supported Lift
1. Prototyped a 5 level Floor Supported Articulated Lift.
2. Redesigned protype Lift with significant amendments.
3. Added auto-levelling system to ensure level operation at higher levels.
4. Modular design on electronics to allow quick replacement or diagnosis of problems in the future.
5. Simplification of cabling connections with easily identifiable connectors.
6. Changed horizontal gearing to allow slower grazing speeds, useful in the first few weeks of picking training.
7. Improved safety systems.
8. Slippery floor adaptor to ensure traction even on extremely slippery floors.
9. Added floor dirt scrappers to ensure dirt is moved from under the wheels.
10. Swapable attachment allowing picking from either side, allowing the picking up one side and back down the other.
11. Addition of covers allowing easy access points for maintenance – oiling and greasing.
12. Scissor Lift for picking the lower shelf has been lowered, thus lowering the Gamechanger.
13. Scissor Lift with improved stability while lowering and raising for picking normally or on the lower shelf.
14. Enhanced bin system.
15. Enhanced corrosion resistance coating for the Stainless-Steel frame.
16. Easier removal of waste stalks.
17. Improved battery runtime by allowing the use of 1 or 2 battery sets.
18. Stability adaptor for linking to high level rail, only needed for levels 6 & 7.
19. Designed an attachable module to allow easier movement in every direction.
Gamechanger Cord
1. We have tested and prototyped a cord conveyor for the shelf system.
2. Improved cord system to allow expansion of the prototype.
3. Development of a cord packing device for punnets.
4. Development of an inexpensive cord harvesting system for packing into boxes or large containers.
5. Development and test of “undisclosed” 2 handed picking device.
6. End of shelf development for the Gamechanger Pro
Training
Initially we depended on the on-site farm staff to handle the training of the pickers on the Gamechanger, but we slowly came to realise that change requires a more direct approach.
We have since learned how to ensure the correct use of the Gamechanger Pro and Lift to ensure optimum results. We have developed training procedures, support procedures and management requirements that greatly enhance the speed, and results off the implementation experience.
We have developed training aids that help ensure the smooth transfer to 2 handed picking, graze picking and yield optimisation without changing the successful growing strategies developed over many years.
Developments In Progress
We have several existing development projects in various stages of progress, with each being completed within the coming months.
1. Gamechanger Deluxe allowing packing into large crates holding 2 levels of punnets (In Progress)
2. 6 & 7 levels lift development (In Progress)
3. Auto-belt cleaner (In Progress)
4. Waste handling options
5. Further “undisclosed” developments
Investments
We have made significant investment in precision engineering and fabrication equipment. We have developed software, electrical and electronic technology expertise. We also have expanded our staff to include CAD designers and some with other relevant expertise.
Conclusion
After months of development and testing we can now proceed to a stage of full production and implementation of the improved, reliable, flexible and useable Gamechanger Pro and a fully integrated Floor Supported Articulated Lift with an option of an inexpensive Cord solution for bulk picking.
We will be working on the 6 & 7 level lifts in the next few weeks and we will be running all our machines with the latest amendments on farms immediately with several more installations being completed over the coming weeks and product being despatched to several locations worldwide within the coming weeks.
Thanks
Significant progress has only been made by listening to the helpful suggestions and comments of many people on the farms. We would like to acknowledge our sincere thanks in helping us to perfect our machines. We are only sorry it has taken so long.
The Gamechanger is the only viable harvesting solution for existing mushroom farms.
To view more information and video please click the following links for the Gamechanger Pro or Floor Supported Lift.
If you have any questions you can contact us on email or whatsapp or by using the form below.
