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Abstract. The U.S. apple industry, which generated more than $2.7 billion in revenue at the farm gate in 2013, is facing critical challenges with decreased availability of labor and increased labor and production costs. To address these challenges, a self-propelled apple harvest and in-field sorting machine is being developed in our laboratory. This article reports on the economic evaluation of this prototype machine by considering machine cost (annual ownership and operating costs), harvest productivity increase (including that due to decreased occupational injuries), and cost savings in postharvest storage and packing resulting from in-field sorting of fresh market quality apples from processing apples for both fresh apple growers and processing apple growers. The economic evaluation was conducted based on the assumptions that the machine increases harvest productivity by 43% to 63% and operates for 360 h during the harvest season. For fresh apple orchards with processing apple incidences of 5% to 15%, the net annual benefits that would accrue from owning one machine range from $13,500 to $78,400 when the machine price is between $100,000 and $160,000. For processing apple orchards with processing apple incidences of 80% to 90% and the same machine price range, the net annual benefits that would accrue from owning one machine range from $23,900 to $81,700. Overall, the benefits gained from in-field sorting outweigh those from the harvest productivity increase, and integration of the harvest-assist and in-field sorting functions is more beneficial to apple growers. This technology will help the U.S. apple industry improve labor productivity and reduce production costs, and thus it looks promising for commercialization. Keywords: Apples, Economic evaluation, Harvest-assist, In-field sorting, Machinery system, Occupational injuries.

Abstract. The bin filler, which is used for filling the fruit container or bin with apples coming from the sorting system, plays a critical role in the self-propelled apple harvest and in-field sorting (HIS) machine that is being developed in our laboratory. Two major technical challenges in developing the bin filler are limited space in the HIS machine and high throughput. A literature review showed that despite many different types of bin fillers currently available for in-field use, none of them is suitable for the HIS machine because of their large size, use of the bin rotating design concept, and high unit cost. Effort has thus been made on the development of new bin filling technology for use with the HIS machine. The new bin filler mainly consists of a mechanical system with a pinwheel design and an automatic control system. A key innovation in the mechanical system is the use of two foam rollers to catch freely falling apples, which has greatly simplified the bin filler design and also made the system compact and lower in cost. The control system is mainly composed of an onboard Arduino microcontroller and three sensors (one infrared sensor and two Hall effect sensors) to monitor and measure the status of apples filling the bin as well as the rotational speed of the pinwheel. A program was developed for the Arduino microcontroller to record and process the data from the sensors in real-time to achieve automatic control of the bin filling. Laboratory tests with ‘Gala’ apples demonstrated that 97% of apples that had been handled by the new bin filler were rated Extra Fancy grade, and its performance exceeded the industry’s requirement for bruising damage to apples. Keywords: Apples, Automatic control, Bin filling, Bruising, Harvest, Sensors, Sorting and grading.

Bin fillers play a critical role in transporting and distributing fruit evenly and without bruising into individual bins or containers from harvest platforms infield or sorting lines in the packinghouse. Over the years, a large variety of bin fillers have been developed for infield use and postharvest handling. This article reviews different bin filling technologies in terms of major design features, performance, and throughput, as well as automatic control and safety features. For infield use, bin filler designs have evolved from the early use of conveyors and reciprocating plates to recent adoption of soft pads and foam rollers, to reduce bruising and improve fruit distributions. For postharvest use, tilted bins and conveyors commonly used with early bin fillers have been replaced with hinged trays and vacuum suction cups for fruit transport and cylinder brushes and swingable dividers for bruise prevention. While many types of bin fillers have been developed, few are suitable for infield use because it imposes more constraints than postharvest use. Despite the use of automatic sensing and control in most bin fillers, human assistance is still needed during their operation. There are still major issues with the current bin fillers, such as large size, complexity in design, uneven fruit distributions, and low throughput. Further effort should, therefore, be directed towards the development of high throughput, simple yet reliable, compact and fully automated, or even intelligent bin fillers for infield and postharvest use.