Perry Luckett, CoffeeMan1

I’m keeping my eye on several major developments for the coffee industry in 2024, having blogged about a number of these areas during the past two years. A major trend for coffee growing is better use of technology and automation throughout the supply chain. In the next three blog posts, I’ll overview how three key technologies continue to improve coffee production in 2024 and beyond.

• automated coffee harvesting technology

• artificial intelligence (AI)-driven quality control

• blockchain technology to make coffee supply chains transparent and traceable

Let’s begin here with machines that aid automated harvesting, including mechanized harvesters and drones equipped with sensors that help monitor crop health, optimize irrigation, and manage pests. We’ll cover artificial intelligence for quality control and blockchain technology for coffee supply chains in the next two blogs.

Automated coffee harvesting technology may cover labor shortages and costs

Although still in the early stages of development and adoption, automated coffee harvesting has gained increasing interest and investment because of labor shortages, rising labor costs, and the need to improve efficiency and productivity in coffee farming.

One of the industry’s key innovations is the use of robotic automation, which is transforming the way coffee is produced. These robots can do things—such as harvesting, sorting beans, and packing them—that previously required manual labor. Using robotics not only saves time and money but also improves quality control, ensuring only the highest-quality beans reach consumers.

Automated coffee harvesting technology typically involves the use of robotics and machinery to harvest ripe coffee cherries selectively while leaving unripe ones on the plant. This technology aims to reduce reliance on manual labor for harvesting, especially in regions where labor is scarce or expensive.

Several companies and research institutions around the world have been developing and refining automated coffee-harvesting technology. These efforts include developing robotic harvesters equipped with cameras and sensors to identify ripe cherries, using robotic arms or suction devices to pick the cherries, and apply advanced software algorithms to control the harvesting process.

Brazil and the United States are two key countries that are developing or testing coffee-harvesting technology.

Brazil uses automation to enhance growing and harvesting

As one of the world's largest coffee producers, Brazil has been at the forefront of adopting new technologies in coffee farming. Several research institutions and coffee farms in Brazil have been exploring automated-harvesting solutions to address labor challenges and improve efficiency in coffee production. Three key automation methods enhance coffee harvesting:

• Using mechanized harvesters

• Terracing for unilateral harvesters

• Deploying drones and sensors

Mechanized harvesters for flat areas of coffee plantations

Brazil employs large-scale mechanical harvesters that can navigate relatively flat areas of coffee plantations. These machines are designed to efficiently collect coffee cherries, significantly reducing the need for manual labor. A single machine can replace up to 150 workers, lowering costs per hectare by about 30%.

Automated harvesters for coffee cherries are designed to streamline harvesting by making it more efficient and less labor-intensive. These machines can cover large areas quickly and greatly reduce the time needed for harvesting. They also can make farmers less dependent on manual labor, which often is in short supply in some regions. Finally, they offer more consistent harvesting by selecting coffee cherries more uniformly, which can lead to higher quality coffee.

Automated harvesters have several common components and mechanisms:

Shaking mechanism: The harvester has arms or tines that shake the coffee trees from side to side, causing the ripe coffee cherries to detach from the branches. Farmers can adjust the shaking frequency and intensity to harvest only the ripe cherries and limit damage to the plants and unripe cherries.

Collection system: Below the shaking mechanism are catcher plates or conveyors that catch the falling cherries. These plates are typically angled to guide the cherries to a central collection point. After catching the cherries, conveyor belts transport them to a storage bin or container on the machine.

Sorting and cleaning devices: Some harvesters have built-in sorting mechanisms that can help separate leaves, twigs, and other debris from the cherries. Usually, this “debris” gets expelled to the side by a separate conveyer or forced- air blower. More sophisticated harvesters can further sort and clean the coffee cherries, although these tasks often fall to manual laborers working over large racks.

Self-propelled or tractor-mounted: Self-propelled harvesters are standalone machines that can move through the coffee plantation on their own, driven by an operator. Tractor-mounted harvesters are attachments that workers can connect to tractors for mobility and power.

Adjustable for size of coffee plants and terrain: Many machines can adjust their height and width to match coffee plants’ different sizes and shapes. Some harvesters can navigate varying ground heights, making them suitable for plantations with uneven ground.

Able to use automation and control: Advanced machines may operate sensors and cameras to detect the ripeness of cherries for more effective harvesting. In most cases workers can operate machines from their cabins or with remote controls, adjusting settings as needed for best performance.

Automated harvesting brings challenges to coffee producers, as well. Automated harvesters are expensive, so they’re less accessible for small-scale farmers. Even for larger farms, these machines require regular maintenance and repairs, which add to farmers’ operational costs. Then too, not all coffee varieties and plantation setups are well suited for mechanical harvesting, so adjustments or further manual work may yet be necessary.

Still, automated harvesters represent a significant technological advancement in coffee agriculture, offering a blend of efficiency and precision that can enhance productivity and quality when used properly.

Terracing for unilateral harvesters on steep slopes

In regions with high slopes, such as the southern part of Minas Gerais, coffee farms have been adopting the microterraces system, a technique that reduces the slope’s effect by moving the soil between the crop lines. This adaptation allows machinery to operate on steep slopes, where traditional methods wouldn’t be practical, thereby increasing harvesting efficiency. [TEA]

Adopting microterraces allows coffee farmers to efficiently mechanize areas previously resistant to machine harvesting by using unilateral harvesters with bag storage. These special harvesters can efficiently collect and temporarily store coffee crops. They’re designed to operate on one side of the crop row, making them suitable for terraced field layouts.

Unilateral harvesters are compact and maneuverable, making them ideal for terraced areas with limited space. They also can use flexible power sources, including a tractor's power take-off, an onboard engine, or electric motors. User-friendly controls and easy maintenance access add to their value.

Unilateral harvesters can partially replace manual labor, equaling the service of 23.68 manual workers—or 10.55 manual workers in a semi-mechanized system. Producers can tailor their cutting blades, gathering arms, and other mechanisms to the type of crop being harvested, and harvested beans go directly into bags for storage. These bags can be easily removed and replaced, ensuring continuous operation.

Deploying drones and sensors

Drones are increasingly used in Brazilian coffee farming to monitor crop health, improve irrigation, and manage pests. They can access hard-to-reach areas and collect precise data that helps in managing large plantations more effectively.

Once a drone captures images of affected crops, agronomists visit that part of the farm and collect plant samples to verify the nature and extent of pest attacks. This approach combines the best of people and machines working together through drone photography or videos. [DV]

Aerial imaging: Drones equipped with high-resolution cameras and multispectral sensors capture detailed images of coffee plantations. These images help farmers identify areas affected by diseases, nutrient deficiencies, or other stress factors. [HCV]

Analyzing data: The data collected by drones is analyzed to assess plant health. By detecting variations in plant coloration and growth patterns, farmers can pinpoint problem areas and take corrective measures promptly.

Precision mapping: Drones create precise maps of the terrain, highlighting variations in soil moisture levels. This information is crucial for developing efficient irrigation plans.

Managing water distribution: By monitoring soil moisture and plant water stress, drones help farmers optimize irrigation schedules, ensuring that water is used efficiently and only where needed. This technique wastes less water and promotes sustainable farming.

Managing pests: Drones enable early detection of pest infestations by capturing detailed images of the crops. Early intervention can prevent the spread of pests and limit crop damage. With precise location data, drones can help apply pesticides only in affected areas, reducing the overall use of chemicals and limiting environmental impact. Advanced drones can spray crops with more precision than a conventional tractor, thus shielding farm workers from pesticide exposure. Cost effectiveness and speed add to their advantages. [DV]

These drones are especially handy when attending to plants in mountainous areas such as Brazil. Steep terrains make it difficult for humans to apply pesticides. Even crewed aircraft, such as small planes, face dangers on these terrains because pest application is hazardous. Today, farmers rely on drones to improve yield in an environmentally friendly way. [DV]

Drones are transforming Brazilian coffee farming by providing valuable insights into crop health, best using resources, and enhancing pest management. This technology helps farmers increase efficiency, reduce costs, and adopt more sustainable practices.

Using mechanized harvesters, terracing, and deploying drones and sensors collectively benefit coffee production in Brazil. They help the country become more efficient and sustainable while addressing challenges such as labor shortages and the physical limits of traditional farming methods. Still, widespread adoption may be several years away. Technical challenges, costs, and the need for further testing and refinement are among the factors that could slow the pace of adoption.

The United States uses automated harvesting wherever labor costs are high

In U.S. coffee-growing regions with high labor costs, such as Hawaii and California, farmers have become more interested in applying automated harvesting technology as a way to reduce labor expenses and increase productivity. In addition to techniques described for Brazil above, research institutions and agricultural technology companies in the U.S. have been working on developing robotic harvesters that could be tailored to the needs of coffee farmers in these regions. Here are some of the notable ones:

Abundant Robotics: This company, based in California, has developed a robotic apple harvester that uses vacuum technology to gently pick fruit without causing damage. Though mainly focused on apples, the technology is adaptable for other delicate fruits, including coffee cherries. Their system uses computer vision to identify ripe fruits and could be customized for coffee harvesting. [CT]

Agrobot: This company has developed a 24-arm robotic harvester designed for strawberries, using machine learning to identify and measure ripeness. The adaptability of their technology means it could be modified for use in coffee harvesting, for which selecting only ripe cherries is crucial. [CT]

Harvest CROO Robotics: Known for their work in automating strawberry harvesting, Harvest CROO Robotics uses advanced imaging and mechanical systems to pick ripe fruit efficiently. They focus mainly on strawberries, but the principles of their technology can apply to coffee harvesting, in which picking is also labor-intensive. [SG] [FTN]

Naio Technologies: Based in France, Naio Technologies has developed several agricultural robots for tasks such as weeding, hoeing, and harvesting. They focus on various crops, but their autonomous robots, equipped with precision tools and AI, can adapt for coffee harvesting, ensuring efficient and gentle handling of coffee cherries. [FTN].

The exception to automating coffee production in the U.S. is cozy Kona farming, which has resisted automation in harvesting. As Kona Earth staff say at Medium.com, most Kona coffee farms are smaller, family-owned ventures. During harvest season, workers pick ripe red cherries by hand. Though labor and cost intensive, this hand-picking process ensures they harvest only the ripest fruit, leaving the rest on the tree for subsequent rounds of picking throughout the season. [KE]

Producers of 100% Kona coffee also don’t use AI automation. Granted, farmers use machinery to automate some farm management tasks, such as mowing and fertilizing. Machines such as pulpers and dryers are also used to process the coffee. The closest thing to AI in Kona coffee production is the use of optical sorters that use near-infrared (NIR) technology and cameras to determine bean size and quality.

Kona farmers decide how to employ these tools and continue to oversee every step in the process. Humans still load pulper hoppers and rake seeds drying on the deck. They also monitor moisture content and bag coffee for storage. Like any artisanal product, Kona coffee is made by human hands.

This “Kona exception” may offer some solace to those of us who sometimes believe technology is moving too quickly into many areas of our lives. But automated harvesting, terracing and other methods of managing terrain for more effective production, as well as using advanced drones and sensors, are likely to win the day overall.

References

Croptracker, “Blog: Robotic Technologies In Agriculture,” https://bit.ly/45VacjW, 2024.  [CT]

DroneVideos.com, “Are Drones the Future of Coffee Farming?,” https://bit.ly/3RWReUk, March 30, 2023.  [DV]

Vasileia Fanarioti, “Exploring the Potential of Drones in Coffee Production,” https://bit.ly/3RX8QPL, Barista Magazine Online, February 23, 2023.  [VF]

FutureTEKNow, “21 Robotics Companies Revolutionizing Modern Agriculture,” https://bit.ly/3zuSMhY 2024.  [FTN]

Stephen Gossett and Brennan Whitfield, “15 Agricultural Robots and Farm Robots You Should Know,” https://bit.ly/3RTiLpJ, May 1, 2024. [SG]

Helena Coffee Vietnam, “Drones in Coffee Farming: Helena Coffee’s Innovative Technology,” https://bit.ly/3RYfIfI, 2023.  [HCV]

Kona Earth, “Kona Coffee Farming: Embracing the Human Touch,” https://bit.ly/3VVm7cV, Jul 28, 2023.  [KE]

Tavares TdO, de Oliveira BR, Silva VdA, Pereira da Silva R, dos Santos AF, Okida ES. “The times, movements and operational efficiency of mechanized coffee harvesting in sloped areas.” https://bit.ly/3zuSV50, 2019.  [TEA]