The challenge
Apple packhouses rely on a consistent supply of fibre trays to keep packing lines running efficiently. Manually separating and loading tightly nested tray bundles can be labour-intensive, slow and prone to interruption, particularly during peak harvest periods.
A need was identified for a purpose-built solution that could reliably de-nest and load fibre trays onto conveyors at a consistent rate, while integrating seamlessly into existing packhouse control systems.
Our solution
Developed in collaboration between CR Automation, a technology provider and a local apple packer, the D-Nester was purpose-designed to reliably load fibre trays onto conveyors for produce packing lines.
The system can process up to 14 trays per side per minute and allows quick changeover between 50 x 30 cm and 60 x 40 cm tray formats, supporting operational flexibility across different product runs.
A unique two-stage picking mechanism is engineered to handle tightly nested bundles of fibre trays, ensuring consistent separation and placement onto the conveyor. Trays are loaded at an ergonomic working height, improving ease of operation.
Pattern control and fault reporting are managed via an integrated HMI or through the wider packhouse SCADA system, enabling clear visibility and streamlined line management.
Designed around low-force operation and 24-volt systems, the D-Nester removes the requirement for inhibitive guarding, supporting safe, accessible operation within the packhouse environment. This is a prime example of following “Safety by Design” principles to develop a safe machine.
The results
The D-Nester delivers consistent, automated tray loading that reduces manual handling and supports steady packing line throughput.
By combining ergonomic design, flexible format changeover and seamless control integration, the system strengthens reliability during peak production while maintaining a safe, efficient working environment.