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NL: How the automated delivery process at the new location of Gebr. Valstar leads to optimal space utilization

Recently, We Prove Solutions (WPS) visited the new location of Gebr. Valstar in Bleiswijk to see their installation in action. WPS provided the complete automation of the delivery process in this nursery. By automating almost the entire process, Valstar optimizes the use of available space and requires less labor compared to a manual process. The decision to invest in automation was a logical step, given the experiences Gebr. Valstar has gained at other locations. Raimond Hagedoorn from Gebr. Valstar enthusiastically guided them through the entire process.

Step by step
The route the plant takes through the automated process is as follows: the plant arrives on tables from the greenhouse, where employees clean it. Weeds and damaged leaves are manually removed—one of the few manual interventions still required. Next, the plant is placed in the Oval Plant Carrier (OPD) and moves toward the camera cabin. There, the plants are assessed based on specific characteristics, which is necessary for sorting them further in the process.

The tray destacker

The plants then arrive, distributed over two conveyor belts, at the two Smart Picking and Placing robots. The Tray Destacker sends a tray to the robot at the right moment, and the robot picks up the plants and places them in the tray. Based on input from the Order Control System (OCS), the robots determine how many and which plants go into each tray. Once a tray is full, it is moved along a wider conveyor belt. The empty OPDs are returned via another belt to the start of the process for reuse.

The Smart Picking and Placing Robots in action

Plant Spray Unit integrated into the conveyor buffer system
The trays then proceed to the Plant Spray Unit (PSU), which activates the correct spray settings based on the pot size registered on the RFID tag. After watering, the tray is sent to the appropriate buffer, where it remains until the order is collected. Valstar cultivates a wide variety of green plants, which requires numerous conveyor buffer systems to ensure the process runs smoothly. If a tray waits longer than usual to be included in an order, it is automatically sent back to the watering machine to keep the plant healthy.

The plant watering system in action

Efficient order processing
The operator enters the order into the Order Control System (OCS), which then identifies which trays need to be sent to the packing stations. The system is accessible not only on screens but also on handheld devices used by employees to direct orders to the packing stations. The order appears on the handheld device, and the employee then goes to the indicated buffer(s), scans the tray, and releases it to start its journey to the packing station.

The handheld OCS

The packing stations are among the few areas that require manual labor, aside from plant cleaning. Automating this step is challenging due to the large volume of labels Valstar processes. However, WPS has worked to make this step as efficient as possible to save time and reduce costs for the grower. Additionally, WPS helped develop a conveyor solution to maintain a large stock before a colleague places the trays on the Danish cart. This conveyor gently rolls the trays to the end, minimizing unnecessary walking.

Trays with RFID tags
The trays used in the automated system were designed in collaboration with Valstar. Equipped with RFID tags, these trays can be tracked throughout the entire automated process. The system includes readers that scan the RFID tags, allowing for the identification of each tray and the plants contained within. The Order Control System (OCS) monitors and manages the actions required for each tray. After packing, the trays are sent to the Tray Stacker, where they are stacked and prepared for reuse.

The Order Control System

WPS's automated systems streamline the entire process—from plant cleaning to order packing. Automation not only enhances efficiency but also creates a more flexible, faster, and cost-effective workflow, reducing reliance on manual labor. The innovative integration of the OCS, automated transport, and robotics ensures that Valstar is well-prepared for the future. At WPS, they remain committed to collaborating with partners to innovate and deliver solutions that advance the horticulture and plant research sectors.

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