AI and robots help Hawke's Bay apple exporter double processing capacity

A Hawke’s Bay apple exporter, Taylor Corp Apple, has doubled its processing capacity to 12,000–14,000 cartons daily—equivalent to 3000 apples per minute—by integrating AI and robotics into its packhouse. The family-owned business, exporting apples for over 100 years, upgraded its operations after Cyclone Gabrielle destroyed the original facility in 2023. Key upgrades include AI-powered blemish detection using the 'Spectrim' machine, which photographs each apple 500 times to identify flaws like splits or insect damage, ensuring compliance with export standards such as China’s restrictions on codling moth. The company employs around 400 workers, including 80 in the packhouse, with staff upskilled to operate robots rather than replaced. Lewis Worthing, head of digital operations, noted that internal system development allows faster, higher-quality packing and quicker adjustments for future seasons. Equipment like Aporo machines, designed in New Zealand, sorts apples by size and color for presentation, while robotic forklifts (AMRs) stack boxes autonomously, reducing health and safety risks. The packhouse now features $30 million worth of technology, with a five-year payback period. Taylor Corp’s fourth-generation grower, Cameron Taylor, emphasized the family’s long-standing embrace of innovation, tracing it back to early adoption of tractor hydraulics. The upgrades ensure apples are graded and packed efficiently, with AI-driven systems like Spectrim also managing storage duration based on minor flaws. Despite automation, the workforce remains stable, with robots handling heavy lifting and repetitive tasks. The packhouse exports around 10 40-foot shipping containers daily, supplying global markets with apples meeting strict quality standards. Taylor Corp’s investment in domestic technology underscores its commitment to efficiency and sustainability in New Zealand’s agricultural sector.