Case study: Platforms and automation delivering the goods

Opportunity

Over the past decade, Plunkett's expanded their business and looked for opportunities to boost efficiency, productivity and workplace safety. The farm had transitioned from traditional ladder and picking bag systems to cherry pickers and bottom pickers but recognised that platforms offered the best solution.

'For the best quality fruit – and to keep costs down – everyone needs to be happy and safe.' - Danny, Orchard Supervisor

Technology

Innovation at Plunkett’s is about rethinking work - from the orchard to the packing shed. The team has introduced major technology upgrades and redesigned orchards to save time, boost production and ensure consistent fruit quality, while creating a safer work environment for everyone.

Orchard operations

• Introduced in 2018; 12 self-propelled platforms with automated steering.
• Each platform carries six workers across three levels, led by a team leader.
• Automated bin trailers halve ganging costs and improve transport efficiency. The trailers have also lowered the risk of vehicle accidents (reduced reliance on tractors and forklifts for bin movement).

Packing facility

• Advanced pre-sizing: Each fruit is photographed up to 40 times to create a precise 3D image for accurate grading.
• Versatile combi-sort line: Handles multiple crops including apples, pears, peaches, kiwifruit, and pomegranates.
• Reduction in manual handling: Automated box filling, overhead conveyors, and a palletiser (added mid-2024) significantly reduce manual handling.
• Integrated digital systems:
  • Safe Food Pro – manages training records
  • Tie Up Farming – ensures full traceability
  • SWAG – streamlines worker clock-in/out.

Orchard design

• Transitioned to a quad stem design.
• 2D fruiting walls enable platform picking and mechanical hedging.
• Pruning simplified: one branch removed manually, tractor-mounted hedger shapes canopy.

Technology adoption journey

Outcome

Plunkett’s are pleased with the transformation. The adoption of platforms, automated bin trailers, high-density orchards, and packing shed automation has made operations more efficient, improved fruit quality, and created a safer workplace.

Improved efficiency and productivity

'Now we can put 6 people on here, and every single person on that platform will get 6 bins in 8 hours. Which is $45 a bin. It’s a big difference.' – Danny, Orchard Manager

Automated bin trailers help move harvest bins around the orchard (and to the packing facility) while reducing manual labour and the need for tractors. This has cut the cost of organising and transporting bins by about half and makes the whole process more efficient and safer.

In hiring people for picking work, Plunkett’s have found that a willingness to learn often matters more than picking experience.

'With clear instructions, even those new to the role or with limited English can succeed and do an excellent job.' – Jess, People and Culture Manager

'The most common injuries in packing are twists and strains from manual handling. In my two years here, we haven’t had any.'
– Brenton, Packing Operations Manager

Farm safety benefits

Safety is central to Plunkett’s operations.

Jess leads safety programs, weekly wellbeing check-ins, and manages accommodation options, including alcohol-free housing. New employees complete induction videos (available in English, Mandarin, and Hindi), are guided through operating procedures, and receive hands-on training before operating equipment. Team leaders provide ongoing supervision, and workers have clear, easy ways to raise safety concerns at any time.

Ladder-related injuries were once the biggest concern, but since adopting platforms, incidents have been rare – even with around 150 seasonal workers each year.

Automation in the packing shed has further reduced injuries. Old lines created trip hazards and involved heavy lifting. New overhead systems deliver a one-directional workflow, eliminating twisting and manual handling.

Last Word

Innovation and technology has boosted productivity across the orchard and packing shed and also strengthened workplace safety.

'Adaptability and willingness to learn matters more than old methods. Our systems, technology and processes have completely changed. Any picker that has worked on another orchard without platforms and then comes here thinks they’re in heaven.' – Danny, Orchard Manager

'Safety is integral to everything we do, it’s important and we take it seriously.' – Jess, People and Culture Manager