By Eamonn Ryan
Preserving freshness from farm to table.
The journey of fresh fruit from the orchard to our tables is a complex and carefully orchestrated process. As John Ackermann, founding chairman of SARDA explains, the post-harvest protocol is a critical stage, demanding precise techniques tailored to the unique characteristics of each fruit.
The overarching principles, however, remain consistent: the rapid removal of field heat immediately after harvest; as well as maintaining the moisture content – with the intent that the consumer enjoys the fruit quality as when it was hand-picked.
The stage of maturity at harvesting differs across the broad spectrum of fruits. Freshly harvested table grapes or golden delicious apples are crunchy to eat whereas those harvested when green, bananas or avocados, cannot be eaten until allowed to ripen. Certain fruits are allowed to ripen on the plant whereas others ripen after harvesting.
Post-harvest is not just about removing field heat but also the de-greening of citrus or sterilisation for the control of pests which is a requirement for various markets into which the fruit is being exported. Once harvested, fruits are typically transported to an on-farm facility for initial cooling. While some operations utilise rapid cooling tunnels for swift temperature reduction, the specific equipment and methods employed vary significantly depending on the fruit.
Some fruits undergo an initial heat removal before being placed in a holding area for further processing and cooling. It’s at this stage, prior to final packaging in boxes, cartons, trays or punnets, that the fruit’s core temperature begins its descent towards optimal storage conditions or for the start of a long logistics chain.
Ackermann notes that complexity arises in that the post-harvest process aims to bring the fruit to the required temperature before it enters the supply chain, but also taking into account its final destination. “Simultaneously, maintaining the correct moisture content is crucial to prevent dehydration and ensure a prolonged storage life, ultimately delivering quality produce to consumers, even those in distant markets.”
A fascinating aspect of post-harvest handling is the different controlled ripening of particular fruits, such as bananas. Unlike many other fruits transported at their peak ripeness under controlled temperature, bananas are typically harvested and shipped green to prevent spoilage during transit. The ripening process, occurring in specialised facilities near the point of sale, is a distinct yet integral part of ensuring consumer satisfaction.
For some fruits, it’s a fine line between the post-harvest and ripening processes, whereafter the consumer can eat it. “The ripening process of bananas is a different process,” Ackermann clarifies. “Bananas are generally transported green to the ripening room – you’ve got to trigger off the ripening process by using ethylene.” This involves placing the green bananas in a controlled, near-airtight ripening room with ventilation, and introducing a specific percentage of ethylene gas. This natural plant hormone initiates the ripening process, allowing the bananas to reach optimal ripeness for retail within a predictable timeframe, typically a few days. Notably, ripe bananas are not stored under refrigeration in supermarkets; they are displayed at room temperature.
The equipment and infrastructure required for effective post-harvest handling are directly dictated by the specific needs of each fruit. For instance, apples and pears destined for long-term storage often enter controlled atmosphere cold stores – because they may only ultimately go to the market in six months’ time. These airtight environments at low temperature and regulated carbon dioxide and oxygen levels, effectively putting the fruit into a dormant state for several months, at which point it will ‘come alive’ again. In contrast, banana ripening necessitates specialised ripening rooms where temperature control is less critical than the precise application of the ethylene. Table grapes require rapid cooling to around 0.5°C, while avocados benefit from storage at approximately 5°C to maximise their shelf life.
“Each one is different,” Ackermann stresses. “You’ve got to know the fruit and treat the fruit according to its characteristics.” This fundamental understanding of each fruit’s physiology is paramount to implementing successful post-harvest systems.
The art and science of post-harvest for fruit perfection
The critical role of infrastructure in maintaining fruit quality is paramount. Without sufficient facilities for cooling, controlled atmosphere storage and specialised ripening, fruits are highly susceptible to spoilage and degradation. As Ackermann illustrates, inadequate infrastructure leads to a decline in fruit quality, taste and nutritious value. He highlights the contrast between a dried, shriveled grape and a crisp, appealing one, or an undesirable soft banana versus the preferred firm texture, and the preference for a crisp apple over one with a mealy texture.
The sophisticated post-harvest systems in place ensure that consumers, even those thousands of kilometres away from the farm, can enjoy fresh, high-quality fruit. “The condition of the fruit upon arrival is a direct reflection of the care and precision applied immediately after harvesting, highlighting the critical role of rapid cooling and tailored handling techniques in the intricate journey from farm to table. In some regions, this even involves harvesting grapes during the cooler night or early morning hours to minimise initial field heat.”
For crops like table grapes, this rapid and careful handling is paramount. The gentle touch of human hands remains the predominant harvesting method, particularly in regions like the Cape, where a significant workforce relies on seasonal labour.
While mechanisation is being explored, the intricate process of selecting and snipping bunches often necessitates human precision. Workers navigate the vineyards with crates, their productivity sometimes monitored, ensuring a steady flow of harvested fruit. The goal is to minimise damage and maintain the integrity of each bunch, setting the stage for successful cooling and storage.
A significant focus within the industry is the continuous improvement of cooling techniques, striving for greater energy efficiency without compromising product quality. Ackermann notes the evolution of grape cooling, with processes that once took 22 hours now potentially achievable in 11 or 12 hours. This drive for efficiency is coupled with the ongoing development of new fruit varieties. Growers are constantly seeking apples and grapes with enhanced taste profiles, improved cooling characteristics and extended shelf life, often requiring tailored post-harvest protocols.
Identifying the right expertise and resources within the post-harvest sector is crucial for anyone seeking deeper understanding. Ackermann points to a network of key players, including engineers who design rapid cooling tunnels, such as Jeff Wedgewood (JWCE) and contractors who have in-house design capacity: ARE, GEA Africa and MRE. He says companies like the former SCM (now part of the
Beijer group) and Cubicool have also been instrumental in developing these critical cooling systems aimed at the post harvesting of fruit.
Beyond equipment providers, expert guidance on the specific temperature protocols and handling techniques for various fruits is essential. Ackermann recommends PPECB (Perishable Products
Export Control Board) as a valuable resource for this information. Additionally, the Fruit and Food Research Technology Institute (Infruitec) in Stellenbosch has historically been at the forefront of research into optimising post-harvest practices. He also suggests looking towards “old growth” knowledge, as the fundamental principles of preservation remain relevant.
South Africa has a wealth of expertise and know-how in the cultivation, harvesting and storage of sub-tropical, citrus, deciduous, pomme and berry fruits. Each sector has vibrant associations with unrestricted collaboration among members in developing new fruit handling techniques, packaging, skills development, pest control and the challenges in the face of global climate change. Ackermann recommends Hortgro, Citrus Growers Association, SATI,
Hortgro Pome and SAAGA to name but a few. In each of which there are iconic stalwarts, recognised internationally and who are passionate about fruit and take great pride in mentoring young entrants to the fruit industry.
Advanced mobile racking and shuttle automation in cold chain logistics
In agriculture’s post-harvest cold-chain, precision temperature control is essential to preserve product quality and extend shelf life. Across the global logistics sector, innovative mobile racking and shuttle systems are transforming how fruit, vegetables, and frozen goods are moved and stored. These solutions significantly speed up throughput compared to traditional structural-steel steri-tunnels, easing bottlenecks during the time-sensitive post-harvest window when freshness and marketability are most vulnerable.
Ensuring quality in perishable goods handlingThe Johannesburg Chamber of Commerce and Industry (JCCI) recently hosted a webinar on perishable goods handling, bringing together experts from across the shipping, freight, legal and insurance sectors. Hariesh Manaadiar – the founder of Shipping and Freight Resource, a digital media platform and industry hub for the global transport and trade ecosystem – highlighted the burgeoning significance of this sector. The global perishable goods market, valued at USD20.2-billion in 2024, is projected to grow to USD32- billion by 2033. This growth is driven by increasing demand for processed foods, the rising acceptance of natural and plant-based diets, and technological advancements that enhance supply chain monitoring. Manaadiar emphasised that perishable goods, by definition, encompass fresh produce, dairy, meat, seafood, pharmaceuticals (like vaccines), flowers, plants, frozen foods and even certain temperature-sensitive chemicals. The core challenge lies in their time and temperature sensitivity, making their journey a constant race against the clock to ensure they arrive in a usable and saleable condition. The transportation of these sensitive cargoes predominantly relies on reefer (refrigerated) containers. Global reefer container volumes saw a significant 6% growth in 2024 compared to 2023, reaching approximately 182 million TEUs (Twenty-foot Equivalent Units). The global reefer container fleet itself now exceeds 3.5 million TEU capacity. Manaadiar stressed that this isn’t merely about moving boxes; it’s about safeguarding high-value, high-sensitive cargo that feeds, heals and sustains global populations. Major trade corridors for these goods include South America to Europe, Africa to Europe (especially for flowers and fruit), and Asia, which leads in seafood and vegetable exports.
SA’s role in the perishable tradeSouth Africa holds a crucial position in the global perishable goods landscape. As a major agricultural exporter, perishable goods constitute a significant portion of the country’s exports, contributing approximately 2.5% directly to the national GDP. When considering its extensive value chain, including transportation, shipping, cold storage, packaging and retail, this impact expands to roughly 10% of GDP. Annually, agricultural exports exceed R200-billion, with fresh fruits alone accounting for over 35% of exports,generating almost R65-billion. The Citrus Growers Association reports that around 60% of South African citrus is exported overseas, alongside substantial volumes of table grapes, apples, pears, avocados and cut flowers. This underscores that perishable goods handling—including robust post-harvest practices such as pre-cooling, sorting, and protective packaging—is integral to export competitiveness and food security. The EU remains the largest market for South African perishables (around 38%), followed by the Middle East, UK, Asia, Russia and North America. Citrus, by far the largest commodity, shipped 2.8 million tons in 2023, with modest growth projected for 2024. South Africa is also a key regional cold chain hub for Southern Africa—further reinforcing the need for coordinated practices that begin at post-harvest and extend through to end delivery. The safe movement of perishable goods involves several critical steps: pre-cooling at the point of origin, temperature-controlled storage (insulated or refrigerated transport), monitoring and data logging of temperature and humidity, and seamless integration across multimodal transport methods (road, rail, sea). From harvest through post-harvest treatment, packaging and shipping, to final destination, careful handling is paramount. Some products require immediate cooling, while others are transported to cold stores or packed directly into containers. Packaging itself is crucial, demanding insulation, ventilation and compliance with export destination regulations. The dedicated focus on perishable goods handling is justified by their extreme vulnerability. The US Food Administration authority estimates that globally, approximately 40% of food produced is lost before reaching retail—much of it due to poor post-harvest handling, inadequate storage, or unsuitable containers. Perishables are uniquely unforgiving: even brief delays or temperature deviations can render shipments unsellable. |
From steri-tunnels to automated shuttle systems
Historically, refrigerated tunnels relied on manual forklift operations to place and remove pallets—a slow process that could chafe tight shipping schedules. Today,
mobile shuttle systems deliver pallets in under a few minutes, enabling rapid loading and unloading while maintaining cold-chain integrity. This evolution supports a faster,
more responsive post-harvest infrastructure, where temperature fluctuations and delays
must be avoided at all costs. This shift is
observable globally: companies like Mecalux offer automated pallet shuttles integrated with transfer cars to handle high-frequency pallet flows and optimise air handling in cold warehouses for energy reduction—crucial for reducing energy use and maintaining stable post-harvest storage conditions.
Key benefits of shuttle-based solutions:
- Speed and throughput: Shuttles rapidly retrieve pallets within deep racking during peak harvesting and shipping periods when throughput is critical
- Space utilisation: Automated shuttles allow ultra-dense racking configurations— for instance, Mecalux notes up to 40m high or 45m deep systems and Jungheinrich achieves up to ~90% fill rate, they claim —a clear advantage in land- constrained or volume-intensive post- harvest storage hubs
- Energy and cost efficiency: By reducing volume inside cooled storage, energy requirements drop; and fewer handling vehicles reduce labour and maintenance costs—vital in the context of sensitive post-harvest cargo that requires uninterrupted temperature control
- Automation and safety: Eliminating forklifts from aisles enhances workplace safety and minimises operator fatigue—an added benefit in sub-zero environments common to post-harvest cold storage
Many providers offer modular shuttle systems tailored post-harvest logistics include:
- Wi-fi enabled units supporting tablet or handheld control and full integration into warehouse management systems
- Freezer-rated shuttles with specialised mechanisms (eg. magnet-based retention) to ensure safe, reliable
- Cost-optimised base models focused purely on pallet movement efficiency—ideal for high-throughput yet simpler operations
Efficiency, footprint and ROI
Adopters typically see development cost savings of 25–50% through optimised racking layouts and reduced cold-space volume. Dense storage configurations not only cut land and refrigeration costs but also increase usable storage per square metre. In implementations like Coldo’s or Zikoo- enabled facilities, space and energy savings combine with fast ramp-up deployment to deliver strong ROI.
Automated shuttle systems are increasingly viewed as critical infrastructure for efficient post harvest operations. Major intralogistics providers—such as Dematic, Swisslog, Jungheinrich and Mecalux—now offer variants of pallet shuttle or channel- shuttle systems, often fully integrated with warehouse management software and tailored for environments ranging from ambient to deep. These technologies enable businesses worldwide to transition from labour-intensive, slow processes to automated, scalable, and space-optimised storage systems—supporting faster throughput, higher density, and reduced operational costs.
In short, across the global warehouse automation sector, mobile racking and shuttle-enabled cold storage systems deliver faster post-harvest cooling and pallet handling, greater storage density, cost-effective operations, and higher throughput than traditional manual methods—backed by modular design and seamless integration into modern WMS/WCS frameworks.
References:
1. Jungheinrich.co.za
2. Movu Robotics
3. zikooint.com
4. Mecalux
5. coldlinkafrica.co.za
6. LSE Group