Food Movers: Robots as Farmhands

Food Movers: Robots as Farmhands

Every day there’s a new story about robot bartenders on Carnival Cruise Lines or Domino’s Pizza delivery pods trolling the streets in Europe. For now these are mainly stunt-bots, more public relations than practical. Yet there are already many kinds of robots at work in our existing food supply, albeit models slightly more mundane.

Whether robots (and their engineers) will totally replace regular workers is still up for grabs, but in truth bots will soon be everywhere in the supply chain: Packing and warehousing, farming, food processing and, yes, even hamburger flipping and order taking.

This is the first in a series on food bots, starting with a deeper dive into three cases where bots have taken over some of the dreariest jobs in mass production — repetitive, physically stressful, low-paying, dead-end, sometimes dangerous — that many humans would rather not do.

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BOT

a device or piece of software that can execute commands or perform routine tasks either automatically or with minimal human intervention.

THE FEED BOT

A Dutch dairy technology company called Lely makes Vector, a battery-powered feed bot that looks like a slow-moving escapee from the teacup ride at a state fair. Its speed belies its benefit to a working dairy barn: Consider that a cow can eat for six hours per day, and dairies feed hundreds of cows. Vector uses lasers, ultrasound sensors and metal guides to keep on track as it slowly scoots around, distributing feed, and then plugs into a docking station to recharge during downtime. Vector re-ups with silage — aka the mix of grasses, corn, sorghum and other grains dairy cows need for good-tasting milk — using a laser-assisted claw that serves up the proper proportions. (Watch the Vector do its job.)

Inside the robot’s 600-kilogram basin is a mixer arm, which automatically starts to blend different types of food together as soon as they hit the bowl. The system can prepare different formulas based on which groups of cows Vector needs to feed.

The constant spinning of the robot’s “skirt” brushes feed up along the open gates of a cattle barn, where the cows can easily get to it. The robot glides around until its laser finds a spot low or empty of feed; a sliding door rises up and feed settles out.

THE PICK AND PLACE BOT

One of the more common robotic technologies used in the food industry is “pick and place,” which is exactly what it sounds like. These robots move things from one place to another with lightning-fast speed. They’re also making basic decisions, thanks to digital cameras and other tools that let the robots “see.” As things come down a conveyor belt, for example, robots rotate and place items into the proper packages, or — with the addition of special tools — score bread loaves, decorate cakes and swish sauce across pizzas (watch it sauce pizza). Many work something like ABB Robotics’ IRB 360 FlexPicker, which hangs from above and look like a giant daddy longlegs. Skinny metal arms triangulate to pack cookies, beers, cherry tomatoes, beef jerky, pancakes or — with some heavy-duty models — even boxes or pallets.

The bot “sees” using mounted cameras connected through network software, which means it can find objects when they’re overlapping and in random positions. The “hands” can be suction pads, “fingers” or special tools for slicing or spreading.

Pick-and-place robots handle more than 15 pounds and can relocate things up to five feet, making their moves in less than a second.

THE SEE AND THEN DO BOT

More advanced robots work by combining the sensor technology used above — cameras, 3-D mapping and digital “vision” — to execute more complex actions. A handful of companies make robot systems that can process meat, for example, using 3-D scanners or X-rays to map the bone placement of pork sides or lamb carcasses. The robot arms — its fingers would be the knives — react within seconds to make the right cuts. More mobile versions of these systems are also applied to farming: In California, Blue River Technology’s LettuceBot uses computer vision to see fields as it crawls them, perfectly thinning lettuce starts in vast fields (watch it work). Other farmbots include Hortibot, which can see weeds and treat them, a RowBot made for dense cornfields and an Agrobot that travels down a raised bed of strawberries scanning each plant and harvesting only the ripe, red fruits.

The LettuceBot attaches to an ordinary tractor, then uses camera systems to see plants in 3-D as they roll by. It picks out which to thin and which to keep in less than a second. Blue River Technology uses the term “see and spray,” as in the bot sees the plants in a field and precisely sprays only the lettuce plants to be thinned. The LettuceBot processes thousands of plants per minute with an accuracy of a quarter of an inch, says the company. Most people rent them by the acre for the vast lettuce farms of California and Arizona.

Your Food: Up for Grabs?

Your Food: Up for Grabs?

Don’t panic, but your food is about to appear on your plate in surprising and unexpected ways.

More than ever, food delivery is becoming faster, fresher and more personal. Our food supply chain looks transitory as it shifts to accommodate changes in where our food comes from and where it’s going. The traditional food movers — large logistics, distribution and transportation companies — are now in the company of small, scrappy, food delivery services.

These changes are the result of the aggregation of big data and consumers who are willing to forego the shopping experience for the shipping experience. Both the data and the consumers who create that data have come together to transform our food supply chain. For the better, we think. Just about everything is up for grabs. Farmers look more like engineers, food is fresher and those who deliver our food are coming from unexpected directions.

This issue, our third, takes a close look at some of the shifts from imagination to reality. Food waste is a top concern now as consumers are either being shamed by the amount of food left on their plates or rallied to find new ways to use food waste. If we accept the fact that we can’t eliminate the waste in our supply chain, we can turn our attention to ways we can put it to use, either as a source of energy or repurposed as new food or non-food products. Ari LeVaux takes us to the land of biodigesters and ugly fruit jam. Jen Wong offers surprising ways in which food waste reappears in new shapes and forms, such as coconut shell tiles.

When two Norwegian shipping firms, Yarrao and Kongsberg Gruppe, announced their electric, driverless ships, the prospect of a global food supply chain that doesn’t require bunker fuel (the lowest grade of fossil fuel) suggests we may soon see more sustainable ways to ship food around the world. Providing context for this new model for shipping food is our story about canals and barges, the original slow movers of food along inland waterways. David Leftwich shares his story of barges that travel up and down the Mississippi in this moment of battery-powered cargo. And Jeannette Vaught’s history of cattle logistics reminds us that the tracks of our food have been visible on our landscape for centuries.

The Norwegian vessels also promise robot loading and unloading of cargo, one of the many human displacements occurring within our food supply chain. Rachel Wharton’s story about robots and Melanie Haupt’s images of vending machines that serve us our food suggest that the experience of eating may lose its deeply human connection.

To give us some perspective of how we got here, Laurie Zapalac explains how a mundane container of food was invented because of a challenge prize offered by Napoleon in the late 19th century. Cans today are smarter, carrying much more than food. They carry the history of their contents, and some contain sensors for tracking and tracing a can throughout the supply chain. Zapalac sheds light on how we’re getting a better view of a more transparent food supply chain.

Jane Black’s story about urban agriculture tells us more about the complexities and questions that accompany this new way to feed cities. And if you thought urban agriculture was the way to create Smart Cities, read Gergely Baics’ story about a 19th-century smart city. Cory Leahy’s deconstruction of wartime cookbooks on ration use brings new meaning to ways we might attack the food waste problem.

We do our part to help change how we feed our cities through our annual Food+City Challenge Prize. Each year we see more and more startups that are finding ways to improve food logistics. See our description of what these startups are doing to get food faster and fresher to our cities. And finally, check out our recommendations for cool books and nerdy websites.

Food for Thought: Smart City Tools, Then and Now

Food for Thought: Smart City Tools, Then and Now

Food technology — gizmos such as blockchain, sensors, taste algorithms, genomic tracking — is a hot topic these days, generously funded by venture capitalists. But food technology has been around for decades. Can openers, anyone?

 

No one would dispute that a GPS tracker is sexier than a simple can opener. But those early inventors deserve credit for laying the foundation for today’s innovations. After all, it took almost 50 years after the can was invented before someone made an opener for it. Our everyday can opener — the rotating serrated-wheel device — first appeared in 1870, and it’s still in everyone’s kitchen drawer, nearly 150 years later.

Food storage technology developed from clay amphorae and wooden barrels to polyethylene drums with lever-lock rings for transporting food commodities such as cooking oil. Today, wooden barrels appeal to artisan fermenters and brewers who embrace the flavor-enhancing properties of wood. Sacks and bags continue to transport our food from the grocery store to our house or from the coffee plantation in Kenya to our roaster in Brooklyn. Some are still made of cloth, paper and hemp, while others are big, woven-plastic buffle sacks that optimize space in container ships.

Weights and measures are the quants of food markets. Beginning as bowls and rocks in the Indus River Valley, weighing scales used balance mechanisms, such as this early 19th century balance scale, until the digital age arrived in the early 1980s. Not quite the graceful scales of the past, these digital scales are more sensitive and adapt to multiple units of measure.

Maintaining its utility throughout the ages is the meat hook, the hand tool for butchers and meat processors. The only difference between this 19th century hook and today’s version is the handle: one is wood and the other plastic. Some technology endures the test of time.

Urban Agriculture: Can it Feed Our Cities?

Urban Agriculture: Can it Feed Our Cities?

From rooftop gardens and indoor vertical farms to community plots and edible landscapes, urban agriculture is on the rise. As more of the world’s population resides in cities, city farming is touted as a sustainable solution. But are there enough rooftops to make it work?

New Jersey has been known since the late 19th century as the Garden State. But today its 12th largest city, Camden, is anything but lush and green. It is the country’s poorest city — an astonishing 42 percent of the population lives below the poverty line — and one of the country’s most dangerous. A recent Rolling Stone profile of the city began: “The first thing you notice about Camden, New Jersey, is that pretty much everyone you talk to has just gotten his or her ass kicked.”

And yet.

A small food economy is blossoming in Camden. AeroFarms, an indoor agriculture firm, plans to break ground as early as this year on a 78,000-square-foot vertical farm that would grow 12 stories of red-leaf lettuce, kale, bok choy and more.

Meanwhile, more than 100 of the city’s thousands of vacant lots have been transformed into community gardens. In 2009, at the dawn of enthusiasm for urban farming and during the last available year data were collected, gardeners at 44 sites harvested almost 31,000 pounds of vegetables. Had it not been an unusually wet and cold summer, it might have been more.

It’s all very inspiring: Whizz-bang technology that offers healthier food and much-needed jobs. Communities taking charge of their food destiny in a place that the almighty market has neglected. (Camden, population 77,000, has just one supermarket within its city limits.) But it’s not only struggling cities that see the promise of urban farming.

Urban agriculture — which by definition includes indoor farms, rooftop and backyard gardens, community plots and edible landscapes — is often hailed as a solution to daunting global challenges. It addresses climate change by allowing food to be grown close to home, rather than hauled thousands of miles. It could affect obesity and chronic disease by making healthy options more available. And urban farming could help feed a quickly growing world population, because many of the predicted 9 billion people on the planet (by 2050) are increasingly headed to cities.

SUSTAINABLE SOLUTION?

But can urban farming sustainably feed cities? A close look under the agri-hood suggests that it’s a lot more complicated than advertised.

For starters, let’s examine the history. The Industrial Revolution quickly and dramatically severed ties between consumers and the farmers who grew their food. Efficient train networks transported food more rapidly, from farther away, and more people moved away from rural areas to cities for work in factories. Since then, there have been regular waves of enthusiasm for urban gardening in the West, motivated by social reformers, who made a moral connection between the land and healthy living, or by the innate human desire for self-sufficiency.

To wit: One of the Salvation Army’s first initiatives in late 19th-century London was “farm colonies” designed to help city folks feed themselves. Beginning in the 20th century, Israel’s early Zionists created thousands of small urban farms. But the only examples of urban farming feeding substantial numbers of people occur when there is little other choice.

In Israel, urban farms soon gave way to rural kibbutzim (collectives based around agriculture). The United States saw Americans plant more than 5 million household plots during World War I and 20 million in World War II. Those 1940s victory gardens produced 9 million pounds of produce each year — what amounted to 44 percent of the U.S. harvest. (Read more about how people cope with food shortages during wartime in our story about rations.) But when the war ended, citizens largely abandoned their gardens and returned to the convenience of shopping at the supermarket.

World War II: Glass balls for forcing early cabbages are placed in position at a Salvation Army farming colony in Hadleigh, Essex, 1940. (Photo by Popperfoto/Getty Images)

HIGH-TECH FARMING

Proponents of urban farming say this time could be different. Besides the global challenges of climate change and population, there is wide consumer demand for locally grown food. Moreover, technology that makes urban farming more productive and more sustainable could tip the balance. The technologies include lightweight beds that can be stacked, efficient LED lights and hydroponics and aeroponics, by which plants grow without soil and fed a calculated diet of nutrients by water circulating beneath them.

“By some estimates, we will need 50 percent more food by 2050,” says David Rosenberg, CEO of AeroFarms. “We need transformational changes. Vertical farming does more with less.”

A decade ago, not even one of these so-called vertical farms existed. Today, there are dozens of them — one in Singapore, one in a former bomb shelter in London and one in Japan, built by researchers to provide safe food after the devastating Fukushima earthquake in 2011. That farm, formerly a semiconductor factory, now produces 10,000 heads of lettuce per day.

AeroFarms operates nine vertical farms. Its largest, in Newark, 90 miles northeast of Camden, produces 2 million pounds of leafy greens each year. The 70,000-square-foot complex is a poster child for futuristic farming. Inside, so-called grow tables are stacked 12 levels high and enveloped by a glow of pink LED light. (Plants, it turns out, require little from the yellow part of the light spectrum, which requires greater amounts of power to produce.)

Rosenberg sees AeroFarms less as an agricultural producer than as a data-science company, delving into the intersection of plant biology and engineering with the goal of controlling every aspect of growing and maximizing efficiency.

“We take data on plants and understand what makes them grow,” he explains. “You can’t do it this way in the field. There are too many unknowns.”

AeroFarms’ vertical gardens grow under energy-efficient LED lights and use up to 70 percent less water, compared with more traditional soil-based or horizontal farming. Its largest facility, in Newark, New Jersey, produces 2 million pounds of leafy greens each year, which don’t have to travel far to reach urban markets. Despite these efficiencies, critics of vertical farming say using electricity rather than renewable sunlight doesn’t add up for high-volume production. Photo courtesy Aerofarms.

RESOURCE CONSERVATION: PROS AND CONS

The biggest boon of vertical growing may be water conservation. Drive through California’s Salinas Valley, where the vast majority of America’s salad greens are grown, and you’ll see hundreds of sprinklers shooting great arcs of water across the fields. Some of that is used by the plants, but much is lost to evaporation and runoff.

In contrast, hydroponic and aeroponic systems give the plants only the water they need, and it is recirculated through the system. On average, indoor farms and greenhouses use at least 70 percent less water than traditionally farmed lettuce in California.

There are other benefits, too. The produce doesn’t have to travel — unlike the lettuces that journey as far as 2,800 miles if they are shipped from coast to coast. This all but eliminates the greenhouse-gas emissions associated with transport, though those are only a fraction of the total associated with producing food. (Read more about greenhouse gases tied to food waste in our feature on page 18.) And because they are fresher, the greens last longer in consumers’ refrigerators, which means less lettuce thrown away because it’s gone bad before it could be eaten.

No wonder vertical farms are catnip to technology investors looking for the next big disruptor. According to AgFunder, in 2016 funders poured $126 million into indoor agriculture- related startups (including things like lighting and software). But critics say that the environmental benefits of indoor farms don’t add up.

For one, to grow even a fraction of the fruits and vegetables needed to feed cities would take vast amounts of space. According to one analysis, it would require a 150-foot-by-150-foot, 37-story building to provide the vegetables for a city of just 15,000. This would cost $250 million to build and $7 million in electricity to run annually.

Indoor farms also fail to take advantage of a free and renewable source of energy: the sun. “If you’re not taking advantage of the sunlight, then the process will inherently involve excess energy consumption and carbon emissions,” says Stan Cox, a researcher at the Land Institute in Salinas, Kansas.

Substituting electricity for sunlight is costly. Using current technology, the equation just about works out for leafy greens, which are 90 to 95 percent water and don’t require as much light to grow. But do the math on denser fruits and vegetables or other crops — carrots, potatoes or wheat — and the amount of power required to grow them soars. According to Cox, it takes about 1,200 kilowatt-hours of electricity for each kilogram of edible matter (excluding the water stored inside). Or to put it another way: You need the same amount of electricity to grow one kilogram of tomatoes as you do to run your home refrigerator for an entire year.

“The claim of indoor farming is that we can spare the land by getting rid of industrial farming,” Cox says. “But of course, this vision uses more industrial inputs than anything done on the landscape.”

AeroFarms’ Rosenberg counters that lighting technology is getting ever more efficient. And though he concedes that indoor farming may look industrial, it addresses major challenges including the depletion of arable land, water pollution and conservation: “We don’t use soil. We don’t use pesticides. We use a fraction of the water that field farms do. We have a much softer footprint.”

In sunlit greenhouses on the outskirts of urban areas where land is more plentiful, BrightFarms raises greens and tomatoes using hydroponics — a system in which plants grow directly atop pools of fortified water. These and other crops like strawberries, cucumbers and peppers benefit from growing near where they’ll be consumed, a selling point for cities that have an urban-adjacent BrightFarms facility nearby. But hydroponic agriculture isn’t the right fit for all crops; apples, for instance, store well and travel more easily than delicate tomatoes, making traditional orchards a better option, for now. Photo by Chelsea Clough.

GREENHOUSE GROWING

An even softer footprint comes from other types of commercial urban and peri-urban farms that use greenhouses. Take BrightFarms, which operates three commercial greenhouses and sells directly to grocery stores in seven states and the District of Columbia.

BrightFarms uses hydroponics, which means that trays of greens grow atop vast ponds. But rather than place its farms in cities, where land is generally more limited (and much more expensive), it locates its greenhouses just outside of urban areas. With more space, it is not necessary to stack plants to turn a profit. The use of hydroponics also means that the farms can be, well, horizontal — and take advantage of (free) sunlight.

Today, the crops that make commercial sense for hydroponic farming are greens and tomatoes, says BrightFarms CEO Paul Lightfoot. Both crops travel long distances, unless you live on the West Coast. Both too are highly perishable and sell for a premium price. And, as anyone who has eaten a winter tomato knows, these crops benefit from being grown closer to home.

One day, Lightfoot hopes that BrightFarms will expand to other crops that meet the same criteria: strawberries, peppers and cucumbers. But there are limits to what he can produce. BrightFarms, he says, will never be able to compete on a crop like apples, which grow in many geographic areas, store well and travels easily. They will always be cheaper and more sustainably grown in the field.

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Hydroponics

A method of growing plants without soil, using mineral nutrient solutions in a water solvent. Nutrients may be delivered a variety of ways, including fish waste, duck manure or a fertilizer containing key macronutrients.

In a hydroponic set-up, plants get the nutrients they need through irrigation water. The process eliminates soil and increases yield. For this process to be successful, ventilation and temperature modulation are key. Solar panels provide renewable energy to power irrigation pumps and ventilation systems, and rainwater is captured in roof tanks for use as irrigation in dry periods. Water is constantly recirculated in a hydroponic system, wasting none. Illustration by Ellaphant in the Room.

CLOSING THE GAP

Commercial farms, of course, do not have to produce everything. Could community, rooftop and backyard gardens make up the difference? According to a 2016 report from the Johns Hopkins Center for a Livable Future, the answer is no. While a significant proportion of fresh produce needs could theoretically be met in some places, it would only work in those locations if urban farms are widely implemented and focus on intensive forms of production such as rooftop gardens.

To feed Cleveland, for example, 80 percent of every vacant lot (of which there are many), 62 percent of industrial and commercial rooftops, and 9 percent of every occupied residential lot would have to be put into food production. Those are daunting numbers before you even consider practical constraints such as property values, infrastructure limitations and zoning regulations.

Urban agriculture’s limits do not make it a failure. Community, rooftop and backyard gardens make significant impacts in the lives of the people who tend them, and give poor communities like Camden access to fresh, free food.

Dominic Vitiello, a professor of city planning and urban studies at the University of Pennsylvania who has studied urban farming in cities including Camden, concludes that in the United States, perhaps urban farming’s greatest potential is to effect “inside-out” community revitalization. Urban farming offers opportunities for social enterprise and supplemental income for low-income families. It also helps to build and sustain vital social networks that go unmeasured by traditional economic-development research.

In other words, urban farming may not feed a city like Camden. But its gardens can help rejuvenate the city and make it a worthy representative of the Garden State.

Really, Really Smart Cities

Really, Really Smart Cities

At Food+City, we think a lot about the relationship between food and our cities. Now, through the artistry of Josh Cochran, we can look at how food might fit into future urban landscapes and what urban designers now call Smart Cities. We contacted three really, really smart people for their visions of what our food-wise city might look like in the future.

JOHN JUDGE

The president of the Appalachian Mountain Club brought his view of how plants, agriculture and the natural environment could mingle in a city. He envisioned new uses for telephone pole infrastructure as aeroponic poles, vertical gardens to be found every few feet. And he sees car-oriented technology reapplied to food, including parking lot–based planters powered by hydrogen fuel cell vehicles that plug in during working hours; and a just-in-time composting “uber” with sensors that indicate when the bin is full and trigger a self-driving composting barge to come pick it up.

SONIA MASSARI

As director of the GustoLab Food Studies Program in Rome, Massari sees an end to restaurants as we know them but no lack of socializing over food. People will prepare food and eat on the go in their driverless cars; and solar-powered food trucks will grow their own ingredients in mobile gardens. City squares and green spaces — some on rooftops — will become open-air gyms and community gardens. And neighborhoods will be equipped with digital vending machines that sell fruit, vegetables, milk and other fresh products. In Massari’s future, every flower bed and traffic barrier will become agricultural land. Through an app, all citizens will be able to water plants and take care of these areas. Urban gardens and agricultural areas will be monitored using Information Communication Technologies (ICT) and digital devices. And perhaps most notably, food waste will disappear: All leftover food from supermarkets, kitchens, industries or urban agriculture will be gathered by food collection apps (which will direct food to people who need it) or it will be sold in supermarkets featuring soon-to-expire foods sold at a discount.

LAURIE ZAPALAC

An urban planner who works with cities as centers of innovation and food distribution, Zapalac sees kitchens as hubs of information that feed individual food supply chains. The details of our kitchen inventories will be available on our smart devices, so we avoid buying duplicate bottles of mustard — but also so that grocery delivery services can be truly automated. Along the way, recycling and compostable waste collection will be complementary services to grocery delivery: Containers will be reused rather than recycled (think the return of the milkman), and our food scraps will become the compost feeding the produce that will eventually become our next great meal. Thinking more broadly, in neighborhoods once recognized as food deserts, an expanding network of community foodscapes will combine concepts from the edible education movement with innovative forms of job training — building capacity by strengthening the soil and enhancing the beauty of once depleted communities. These places will also function as stages and urban “dining rooms,” providing venues where local culture and local identity can be shared and celebrated.