Less labor and optimal space utilization at the new Gebr. Valstar location through full automation of the delivery process.
Recently, we visited the new location of Gebr. Valstar in Bleiswijk to see our installation in action. WPS provided the complete automation of the delivery process in this nursery. By automating almost the entire process, Valstar makes optimal use of the available space and requires less labor compared to a manual process. The decision to invest in automation was a logical step, considering the experiences Gebr. Valstar has gained at other locations. Raimond Hagedoorn from Gebr. Valstar enthusiastically guided us through the entire process.
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 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 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. As shown in the photo, Valstar cultivates a wide variety of green plants, requiring 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 operator enters the order into the Order Control System (OCS). The system 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, after which the employee goes to the indicated buffer(s), scans the tray, and releases it to begin its journey to the packing station.
The packing stations are among the few places requiring manual labor, apart from plant cleaning. This step is challenging to automate due to the volume of labels Valstar processes. Nevertheless, 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 for maintaining 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.
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 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.
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, we remain committed to collaborating with our partners to innovate and deliver solutions that advance the horticulture and plant research sectors.