Progress 09/01/22 to 12/31/24
Outputs
Target Audience:The goal of this Phase II effort was to commercialize a mid-capacity, electric greens spinner through three objectives: 1) create a beta I prototype for testing and on-farm trials, 2) complete a life cycle analysis, and 3) create a beta II prototype for regulatory certification in preparation for commercialization. This projecthas a strong connection to the USDA program priority Agriculturally-Related Manufacturing Technology. As a part of this project, Johnny's Selected Seeds (Johnny's) will build on its successful Phase I effort to develop a mid-capacity, electric greens spinner and prepare a manufacturing strategy capable of meeting expected product demand. This work will advance Johnny's plans for production and commercialization of new farm equipment, which will benefit the fabricators and suppliers involved in manufacturing the final product. This project directly supports the intent and purpose of USDA SBIR Topic Area 8.12: Small to Mid-Size Farms. In this Phase II effort, Johnny's modifiedthe alpha prototype 10-gallon, electric greens spinner into an improved beta prototype. This mid-capacity spinner is targeted toward small and mid-size farms (small farms) growing leafy greens with the goal of improving the drying efficiency of their products. The Phase I prototype followed a hygienic design to help improve food safety and vastly increases a farm's efficiency in handling leafy greens, which, without an electric spinner, relies on manual labor inputs to harvest, wash, dry, and package greens in small-scale settings. This new product greatly reduces labor time and costs associated with postharvest handling, thereby enabling farmers to achieve greater profit margins and improve the profitability and sustainability of their operations. Changes/Problems:There were some required changes to the scope of work but none that resulted in a significant change to any technical objectives or tasks. What opportunities for training and professional development has the project provided?? How have the results been disseminated to communities of interest?
Nothing Reported
What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
Task 1.1 - Alpha Prototype Evaluations The proposed research aimed to confirm all directives and standards required for product evaluations and testing. Upon establishing the evaluation criteria,we discussed the specific certifications that would be important to the product and how certain design choices may affect certification requirements. PSC advised us on six points of compliance that would best reduce any certification rejection which gave us targets to achieve with our bill of materials (BOM) and operability. Task 1.2 - Beta I Prototype Concept Design and Development This task expanded on the research completed in Task 1.1 by refining the prototype concept design and development. The goal of this task was to host meetings with Eleven (lead subcontractor) to share the results of Phase I project and Task 1.1 and to impart details that would inform the concept design and development.This served as an introduction to the project as we demonstrated the existing alpha prototype builds created by Johnny's team in Phase I. We discussed testing protocol and any existing design issues that were most pressing to address in commercialization. Based on background and benchmarking research provided by Johnny's, we discussed key players in the greens spinner market to consider and evaluate the competition as outlined in our commercialization plan.After careful consideration, we down selected to a single concept. We completed this task in January 2023. Task 1.3 - Beta I Engineering Development The goal of Task 1.3 was to expand beyond the 2D renderings of the greens spinner designed by the technical team, with the first step of preparing a mechanical engineering layout adjustment for all components and a detail part design. We worked with our engineering consultant, Duncan Wood to design and build optimal control electronics and user interfaces. As part of our quality control effort, these systems were also reviewed by Eleven. Successful completion of this task resulted in a SolidWorks 3D database and bill of materials required to produce a functional beta I prototype in Task 1.4. This work began with CAD development, translating design concepts into CAD parts. We originally planned to rely on RIM modeling, but costs were too high for the tooling and per part price. This pivot resulted in a CAD revised for a combination of rotationally molded and pressure formed parts. Removing RIM operations led to the addition of a steel frame support which Eleven designed with our product development team.Benchmarking tests were necessary to validate the motor, and we built a revised prototype to test alongside the primary competing products, a retrofitted washing machine and the Electrolux model (see Task 1.5). Additionally, the prototype has a mechanical braking system that brings the basket to a stop with a revolution. The Electrolux uses an enginebrake which still requires much longer (15-20 seconds) spin down than the JSS prototype. One solid take-away is that the JSS prototype gets greens driest in the shortest cycle time out of the three--a key operational efficiency we hypothesized and validated. Task 1.4 - Beta I Prototype Development During this task, Johnny's, Eleven, and Duncan Wood, worked collaboratively to fabricate the Beta I prototype. Johnny's also worked with a second fabricator, not funded as part of this effort, to build an identical prototype. The two prototypes were then assembled and tested for functionality at Johnny's product design shop in Georgia and on the research farm in Maine.The Beta 1 prototype was built earlier than scheduled in the work plan timeline in order to test certain key performance indicators (KPIs). It was important to validate our motor since sizing and mounting style could greatly impact production pieces. We wanted to test the braking system and a revised drive mechanism that was reconsidered after Task 1.3 was completed. This proved valuable in our benchmark testing. The beta 1 prototype gave us the function and performance we desired, with the exception of accurately reviewing sanitation friendly features. Instead, in this task we focused on determining production strategy and connecting with production vendors to generate a pre-production sample (needed for Task 2.1 and 2.2). We identified a couple vendors that are now in conversation with our team and will be explored further in year 2 and prior to commercialization. We have also determined pricing for all plastic components but are still looking for a reliable motor source as well as our electronics source for a custom board / electronic component. Task 1.5 - Prototype Testing Simultaneous to Tasks 1.3 and 1.4, the prototype testing (tasks 1.5a) was conducted from May 1, 2023, to July 31, 2023. This task resulted in preliminary testing of our functional beta I prototype at Johnny's, as described in Tasks 1.3 and 1.4.We also postponed testing with offsite farmers (Task 1.5b) until we can secure pre-production samples and ensure sanitary design requirements are met, as all off-site farm testing includes actual products to be sold by testers. All testing with our current prototype will help to validate certain KPIs but will not give us the accurate picture of how the product will fit with various growers' operation. For our own benchmarking, we compiled a testing protocol that will be shared with offsite farms to guide their testing. We concluded our early-stage greens spinning trials comparing our prototype to an Electrolux model and the retrofitted washing machine. Results seem to be fairly consistent, with our JSS prototype model fairing quite well. Task 2.1 - Component and Product Packaging Design This task was completed concurrently with Task 1, using the logistics and value-chain assessment from Phase I. Johnny's researched the optimal packaging design and commercial collaborators. This included the design of the packaging into which the unit will be shipped/transported. The product is anticipated to be light enough to use a heavy-duty carton to hold the entire device. A single carton strategy provides an adequate shipping vessel while minimizing cost implications of shipping larger products. We also explored levels of disassembly for packing, but the way the unit is designed this does not lend much value to our shopping nor does it reduce costs. Thus, Mr. Bowe and Mr. Cook worked with our packaging vendor to develop a carton to house the entire assembled product. The packaging vendor developed the dieline and recommended the cardboard stock size for which they felt would best handle the product and ensure its safety in transit. Task 2.2 - Warehousing and Distribution Analysis Johnny's reviewed customer survey data from Phase I and informally surveyed distributors to craft a warehouse and distribution plan for launch.Although the greens spinner was designed and developed in the U.S., once the decision to purchase these components from China had been made, we concluded that the complete machine should be assembled in China. We will review our decision to source materials internationally annually, as changes to pricing may fluctuate. We would prefer to purchase materials from U.S. suppliers and manufacturers when the economies of scale make sense for the unit. Task 2.3 - TABA Using TABA funds, Johnny's hired Atlantic Corporation (Atlantic). Atlantic completed custom market research for business development.The work in this task confirmed the expected customer profiles and segments and answered critical questions about our pricing strategy. . Task 3.1/3.2- Beta II Prototype and Certification Johnny's worked with Mr. Wood and Eleven on this task. The team used the beta I prototype to validate and refine several aspects of the final unit with plans for certification and commercial development in Task 3.2. This task included commercial certification testing of Beta II by Product Safety Consulting, Inc (PSC).
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Progress 09/01/22 to 08/31/23
Outputs
Target Audience:Tarrget audiences: include two customer segments identified by the company: 1) Current customers who are green's growers in the U.S. and Canada; and 2) Greens growers in the U.S., Canada, and other foreign countries, who are not current customers. Efforts: Year 1 efforts included surveying our target audience (61,1156 greens growers we currently work with)for attitudes and preferences regarding the optimal greens spinner design (see full technical report submitted to the awards management division). Efforts will be conducted in year 2 of the project once the prototype is shared with our sample of test farms paid to trial the prototype. Efforts will continue in Phase III as the new commercial greens spinner is sold direct-to-consumer through additional marketingand advertising campaigns. Changes/Problems:There were some required changes to the scope of work but none that resulted in a significant change to any technical objectives or tasks. Scope of work changes included: 1) postponing field testing with trial farms to year 2 (Task 1.5b); 2) completing component and product packaging design (Task 2.1) in 2023 Q4; and 3) finalizing a warehousing and distribution analysis 2024 Q1 and Q2. The project is still on-time, as scheuled, with an antiicpated project end date of August 31, 2024 and commercial launch in January 2025. What opportunities for training and professional development has the project provided?
Nothing Reported
How have the results been disseminated to communities of interest?This information will be dissemintated to communites of interest (U.S. and Canadian greens growers), upon commercialization in the second period of performance. What do you plan to do during the next reporting period to accomplish the goals?Tasks expected to be completed during the next period of performance (September 1, 2023to August 31, 2024) include the following: Task 1.5b - Field testing with trial farms (October 2023 to December 2024) Task 2.1 - Component and product packaging design (January 2024 to June 2024) Task 2.2 - Warehousing and distribution analysis (January 2024 to June 2024) Task 3.1 - Optimization of beta II development (January 2024 to June 2024) Task 3.2 - Commercial certification (June 2024 to August 2024)
Impacts
What was accomplished under these goals?
This interim period of performance consisted of the following tasks, as proposed in the SBIR application, and described in detail in the 15-page report submitted to the Awards Management Division and National Program Leader. Technical Objective 1, task 1.1, "Alpha prototype evaluations" Technical Objective 1, task 1.2, "Beta I prototype concept design and development" Technical Objective 1, task 1.3, "Beta I prototype engineering development" Technical Objective 1, task 1.4, "Beta I prototype development" Technical Objective 1, task 1.5, "Prototype testing" Technical Objective 2, task 2.3, "Technical and business assistance"
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