Coffee Picker

This was part of a project for my Product design studio class. I was tasked with identifying a problem and developing a solution to help tackle the problem.

This included identifying the problem, conducting user interviews, field research, identifying key stakeholders, opportunity gaps, ideating, and prototyping.

The entire process took place over 4 phases.

Tools - Adobe Creative Suite, Rhino, Keyshot, 3D Printing

Areas - Industrial Design, User Research, User Experience, Prototyping, 3D Printing

Problem

India holds the sixth position among the world's leading coffee producers, contributing 3% to the global coffee production. A significant majority of this coffee, over 70%, is cultivated in the state of Karnataka. Nonetheless, the distinctive geological and topographical features in India create challenges for the practical use of large-scale machinery in the coffee harvesting process, and the scarcity of labor adds to the overall cost of coffee cultivation.

PHASE 1 - Research

To help understand the problem faced by Coffee farms in India better, I began by conducting Domain Research that helped me understand the coffee industry better.

Following this, I interviewed coffee farmers in India and swiftly discerned that the farm's size had a substantial impact on the time required for harvesting, the type of harvesting, and the associated labor costs. In India, a significant proportion of farms encounter constraints when it comes to implementing machinery akin to those utilized in countries like Brazil, primarily due to the distinctive topographical attributes of Indian coffee cultivation regions, which render such mechanization unfeasible. Additionally, it's noteworthy that in India, 65% of the expenses linked to coffee harvesting are attributed to labor costs, a stark contrast to the 20% observed in a country like Brazil.

For my field research, I chose to visit several farms in India during the coffee harvest season, providing me with a firsthand opportunity to observe the coffee-picking process.

Coffee Picking Methord

Farmers select one of the two methods for picking coffee cherries based on the labor availability and labor cost.

Selective picking

In the selective harvesting method, only the fully ripe red beans are gathered. This process unfolds over multiple rounds, with workers hand-picking the beans at their optimal ripeness. While this approach ensures high-quality beans, it is time-consuming and incurs higher costs due to the extended harvesting period.

Strip picking

Involves the complete removal of all coffee cherries from the entire branch. This method is employed when the majority of the cherries on the branch have ripened to a red color, even if some green ones remain. Both the red and green beans are harvested during strip picking. One advantage of strip picking is its efficiency, often accomplished in a single round, which reduces labor costs. However, there is a downside to this approach: it can occasionally damage future coffee beans, as the buds of the following year are susceptible to harm. Another challenge with strip picking is the potential presence of red ants, which sometimes build their nests on these branches, leading to instances of farm workers getting bitten. Additionally, strip picking may result in coffee beans being accidentally thrown onto the farm floor, potentially causing crop losses.

Work cycle for the Coffee Picking Process

To understand the pain points of workers, I shadowed them and identified their pain points in their picking process.

To commence the harvesting process, workers typically start by spreading a tarp on the ground or securing it to several branches of the coffee tree.
In the next step, the workers proceed to strip the coffee branch in one fluid motion, dislodging leaves, debris, and the cherries. If the selective picking method is being used, they carefully select and pick only the ripe berries while leaving behind the unripe ones.
After the lower branches have been harvested, there are times when workers may need to ascend the tree to access the higher branches, or alternatively, they may employ an improvised hook to bring the out-of-reach branches within their grasp.
Prior to harvesting any coffee cherries, it is crucial for workers to inspect the branches for the presence of red ants. If they find red ants on the branches, they must use a specialized ant powder to eliminate the ants. This step helps ensure a safe and efficient harvesting process.
After harvesting the coffee cherries using the strip method, the next step involves transferring the cherries from the tarp to sacks for transportation. To accomplish this, the workers gather the corners of the tarp and flip it to pour the cherries into the sacks. Unfortunately, at times, some cherries have a tendency to roll off and fall onto the ground, resulting in a loss of crops.

PHASE 2 - IDEATION

Once I had pinpointed the issue, I went on to brainstorm and create initial sketches of possible solutions to address the challenges related to coffee harvesting. I came up with two refined concepts.

Concept 1

Concept one presents a practical handheld device designed to improve the selective picking process during coffee harvesting. This device utilizes vibration technology to achieve several advantages:

1. Selective Picking Enhancement: The device helps speed up the selective picking process. When it comes into contact with the coffee branches, it applies gentle vibrations, which cause only the ripe (red) cherries to detach and fall onto the collecting surface. This ensures that only the desired cherries are harvested, enhancing the overall quality of the beans.

2. Reduced Ant Risk: Since the device eliminates the need for direct hand contact with the coffee branches, it reduces the risk of workers getting bitten by ants or other pests, improving safety during the harvesting process.

3. Accessibility for High Branches: The device features an extendable extension or arm, making it easier for workers to reach and pick coffee cherries on higher branches without the need to climb the tree. This ergonomic design increases efficiency and minimizes the physical strain on the workers.

Concept one represents a practical and user-friendly solution for coffee harvesters, addressing both the efficiency and safety aspects of the selective picking process.

Concept 2

Concept two introduces a more futuristic approach to coffee harvesting, aiming to not only streamline the process but also assist farmers in estimating their crop yield. This concept involves the use of mini robots equipped with computer vision technology. Each robot is assigned its own section of the coffee farm, with designated trees.

The robots utilize computer vision to identify and distinguish between ripe (red) and unripe (green) coffee berries. They are equipped with a specialized vibrating mechanism located beneath them, which can vibrate at the precise frequency required to ensure that only the ripe red berries fall onto the tarp. This selective harvesting approach is designed to leave the green berries on the branches, as well as protect the buds for next year's crop.

Moreover, these robots, as they move through their designated spaces, continuously capture visual data of the coffee plants. This data can be used to provide estimates of coffee yield in various regions of the farm. This information is valuable for farmers, as it not only offers an overall estimate of the yield but also pinpoints areas that may need special attention during the next crop cycle.

One of the significant advantages of this concept is the potential reduction in the labor force required for harvesting, as the robots can work autonomously. This innovative approach combines automation, data collection, and precision harvesting to enhance efficiency and provide valuable insights for coffee farmers.

Phase 3 - Prototyping

Considering the limited timeframe of the project (3 months) and the cost-effectiveness of manufacturing concept 1, it was determined to be the more feasible and practical option to develop. Additionally, the immediate benefits it offers to coffee farmers, such as enhanced picking efficiency and reduced ant-related risks, made it a compelling choice. Therefore, the decision was made to proceed with the development of concept 1, which could have a more immediate and direct positive impact on the coffee harvesting process.

One of the distinctive features of the Coffee Picker, setting it apart from similar products on the market, is its advanced vibration control capability. This unique functionality enables more precise and swifter selective picking, ensuring that only ripe cherries are harvested. This precision has several key advantages for coffee farmers:

1. Improved Crop Quality: By allowing farmers to selectively pick only the ripe cherries, the Coffee Picker elevates the overall quality of the crop. Ripe cherries fetch better prices in the market, enhancing the economic returns for farmers.

2. Labor Efficiency: The Coffee Picker's ability to increase picking speed reduces the time required for harvesting. This, in turn, leads to a decrease in labor costs, making coffee harvesting more cost-effective. Farmers can potentially accomplish more in less time.

3. Cost Reduction: The reduction in labor hours translates to cost savings for the farmers. By decreasing the time and workforce required for harvesting, the Coffee Picker contributes to a more efficient and cost-efficient coffee production process.

The Coffee Picker's emphasis on precision, speed, and cost savings makes it a valuable tool for coffee farmers looking to optimize their harvesting operations and enhance the quality of the coffee they produce, ultimately benefiting their bottom line.