68 | Whitehall Fruitpackers Steep learning curve all worth it Richard Loader The installation of automation and robotics included the In-feed systems, camera grading of the fruit, carton handling systems which are all self-fed and self-regulated, automated tray filling, automatic stacking and labelling, and robotic pallet assembly and pallet strapping. HORTICULTURE “For all your Fruit Case Handling & Palletising needs” 100% Designed & Manufactured in NZ 09 828 3304 | www.jmp.co.nz Commissioned just in time for this season’s kiwifruit harvest, the installation of automation and robotics into Whitehall Fruitpackers packhouse on the banks of Lake Karapiro proved to be a steep learning curve, explains CEO and Co-founder Mark Gardiner. “Installation started last October and it got right down to the wire because of Covid and container hold-ups. It was meant to be nicely commissioned by Christmas, with all the testing completed well before March this year, but we were still finishing it while we started to pack fruit. “To be honest, the first few days were a nightmare with things not talking to each other and equipment not functioning as it should. It took us longer than we ever anticipated to get the system operating the way we thought it should be.” In addition to supply chain issues, Covid also impacted on human resource, with staff and supplier technicians either away sick or isolating. “It was quite a giant leap forward and a very steep learning curve but we’re now seeing the benefits of the project. We decided to go down this path because the technology had reached an acceptable level of maturity and it enabled many of the repetitive labour intensive packhouse jobs to be done mechanically. “We tried to pick the eyes out of all the developments in automation, and put it all together to form, as much as you can, a reliable system that requires very few people to operate it,” says Mark. Automation included the In-feed systems, camera grading of the fruit, carton handling systems which are all self-fed and self-regulated, automated tray filling, automatic stacking and labelling, and robotic pallet assembly and pallet strapping. Whitehall Fruitpackers’ roots go back almost five decades. Raised on a sheep and beef farm Mark went farming as a young man, but became disillusioned with the earnings from that sector. “I figured there were better returns from a more intensified land use and planted my first Kiwifruit vines in 1975 on lease land and started growing, establishing a packhouse in 1984. “My wife Robyn and I went through the highs and lows of the industry, came out the other side and continued to grow by taking up opportunities when they presented themselves. “We purchased a 60-hectare block of land in 1999 when the Kiwifruit Marketing Board “We tried to pick the eyes out of all the developments in automation, and put it all together to form, as much as you can, a reliable system that requires very few people to operate it.” rebranded as Zespri and were promoting the new gold variety of kiwifruit. So we took up that opportunity and developed a lot of gold hectares and a new post-harvest facility.” The Gardiner family’s kiwifruit plantings now encompass 250 hectares throughout the Waikato, with clusters of orchards in certain parts of the region, even stretching up to Waihi. While not a main centre for kiwifruit, Mark says there are pockets of well drained, elevated and north facing land very suitable for growing kiwifruit in the Waikato. “Waikato is looked upon as a riskier place to grow kiwifruit because it’s a colder more frost prone climate, but we have set up either wind or water systems to combat frosts where that’s a danger.” Employing a permanent staff of 70, along with 10 contract orchard gangs providing year-round labour, Whitehall Fruitpackers has capacity to produce 2.5 million trays rising to 4 million trays of fruit each year. Very much a family business, Mark and Robyn feel privileged that their children have chosen to be part of the business and occupy key positions. “Our daughter Kristin is the HR, Shipping and Inventory Manager. Ben is the Operations Manager. “Paul is in Finance and Business Analysis and our son-in-law James runs our honey operation and health and safety.” Proud to be producing quality food, Mark says there is world demand for kiwifruit and New Zealand grows great food in a great environment with great natural resources.
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