SBIR-STTR Award

Trellis installation is a major expense for establishing a new commercial blackberry or raspberry (bramble) planting. There has been significant research by the USDA and universities on developing novel trellis designs and methods of manipulating bramble canes for cutting cost of labor for cane pruning and training, to increase hand-harvest efficiency, to improve quality and yield, mechanically harvest fresh market fruit, and to reduce winter injury. A system like the Rotatable Cross Arm (RCA) Trellis improves hand harvest efficiency, can be combined with a winter protection technique, and is amenable to harvesting fresh market quality fruit with an over-the-row mechanical harvester. But, the high cost of trellis posts and hardware has limited the expansion of this system into the commercial sector. The objective of this proposal is to develop a universal trellis post and hardware system for bramble production that will reduce trellis component and installation costs by more than 50%. We will use the latest in manufacturing technology to design fiber reinforced components and innovative methods to manufacture low cost components. These components needs to be easily configured to create the various designs needed for commercial bramble production, installed in the ground, and, if needed, quickly disassembled. This research will be conducted with scientists at USDA in Kearneysville, WV and Cornell University in Ithaca, NY. We will focus on the RCA Trellis System for blackberries at USDA and on trellis systems for high tunnel production of red raspberries at Cornell University. The research will include collaboration on trellis design and trellis requirements for blackberry and raspberry production, fabricating prototypes, laboratory testing of trellises for load and stress limitations, evaluating the adaptability of new trellis designs for blackberry and raspberry production, data collection and analysis, and preparation of a final report. The long term goal of this project is to develop a trellis system that can be economically produced, easily distributed to growers throughout the bramble industry, installed in the ground, and versatile in design for different applications in production of raspberries and blackberries. The new trellis design will be economical and lasting and will enable bramble growers to improve their profitability by using novel growing methods developed in collaboration with USDA and Cornell University. OBJECTIVES: The primary objective of this research and development effort is to develop and evaluate a novel modular trellis post and hardware system that will facilitate crop positioning, winter protection, and cane manipulation in blackberries and raspberries and costs 50% less than the existing technology. The work involving the design and field testing will be conducted at three different locations. TGS LLC, Fort Wayne, IN, USDA, Kearneysville, WV, and Cornell University, Ithaca, NY. Our goals are A) develop a post profile and hardware with sufficient structural integrity to carry the heavy crop and wind loads, B) define trellis features which add value to canopy management of different brambles, C) develop best methods for attaching and managing winter protection cover, D) deveop the ideal and universal hinge mechanism for the RCA trellis system, E) develop appropriate ground anchor systems for the different trellis applications, and F) define wire tension standards for different loads and trellis applications with both monofilament and hi-tensile steel wire. The expected output from this project is significant knowledge of trellis requirements over a broad range of applications. This knowledge will enable us to define product design requirements and move forward with commercialization. APPROACH: The work involving the design and field testing will be conducted at three different locations. TGS LLC, Fort Wayne, IN, USDA, Kearneysville, WV, and Cornell University, Ithaca, NY. TGS LLC, Fort Wayne, IN This project will 1) determine the required capacity of end post tension, 2) design and field test rotatable tension wire mechanism for end posts, 3) provide prototype components and materials for structural and field testing, 4) analyze material costs, 5) analyze manufacturing costs, 6) comparative analysis of assembly and installation costs, 7) measure and quantify the value of features such as adjustable trellis wires and adjustable branches, 8) design in ground receptacle for removing/reinstalling trellis posts, 9) coordinate the collaboration and develop final reports. USDA, Kearneysville, WV This project will 1) determine the capacity of assembled trellis to vertical, lateral, and horizontal strain, 2) determine out-and-down force balance for an assembled trellis supporting mature blackberry plants with a heavy crop load, and 3) evaluate functionality of the modular trellis assembly for rotation of the plant canopy to position canes close to the ground in winter and to upright/diagonal orientation for first harvesting in late spring. Cornell University, Ithaca, NY The objective of this research is to evaluate a novel modular trellis post and hardware system to facilitate cane positioning, cane management, and harvesting in red raspberry, black raspberry and blackberry. Current technology used by growers involves wood and metal. These materials are cumbersome to install and difficult to modify as the crop canopy changes. This project will 1) convert existing raspberry and blackberry trellis systems consisting of wood and metal to the novel system, 2) evaluate the ability of the novel trellis system to be modified as the canopy changes in order to support the canes and crop, and 3) compare the cost and effort of installing and maintaining the conventional system with the novel system. In addition, the ability of the novel system and canopy cover to protect blackberry canes from winter injury will be evaluated. Over the course of our project, there wil be several visits to both the USDA and Cornell University and collectively review project findings. A final report will be prepared inclusive of the three field testing locations

Trellis installation is a major expense for establishing new commercial blackberry or raspberry (bramble) plantings. Research by the USDA and universities clearly demonstrates that by developing novel trellis designs and methods of manipulating bramble canes, costs of labor for cane pruning and training and winter injury can be reduced and hand-and mechanically-harvested efficiency, fruit quality and yield can all be improved. A system like the Rotatable Cross Arm (RCA) improves hand harvest efficiency, can be combined with a winter protection technique and is amenable to harvesting fresh market quality fruit with an over-the-row mechanical harvester. But, the high cost of trellis posts and hardware has limited the expansion of this system into the commercial sector. In Phase I of this SBIR project, Trellis Growing Systems (TGS), LLC proved the feasibility of an improved modular trellis concept. Based on the RCA design, TGS, in partnership with USDA and Cornell University, developed the AV trellis system. Phase I included successful demonstration of laboratory load testing on fiber reinforced trellis post, cross arm components and aluminum brackets and hardware. Phase I also included successful field trials of the RCA and AV trellis systems at TGS (Fort Wayne, IN), Cornell University (Ithaca, NY) and USDA-ARS (Kearneysville, WV). Phase I efforts also focused on reducing the estimated production cost of the RCA trellis design by 50 percent. At the end of Phase I, TGS reduced costs by 46 percent; Phase II will focus on surpassing the 50 percent cost reduction goal. Phase II will also focus on researching innovative manufacturing technology to design fiber reinforced low-cost components. These components must offer easy in-ground installation, the ability to be configured to create a range of designs needed for commercial bramble production and offer easy disassembly. Phase II will continue the successful partnerships offered in Phase I with the USDA (Kearneysville, WV) and Cornell University (Ithaca, NY). Efforts will focus on RCA Trellis System for blackberries at USDA and on AV trellis systems for high tunnel production of red raspberries and black raspberries at Cornell University. Phase II objectives are: (1) design and prototype rotatable cross arm (RCA) and adjustable V (AV) trellis systems; (2) lab test trellis system components; (3) field test prototype systems for structural integrity and functionality; (4) beta test prototype systems with growers and research institutions; (5) analyze costs (material, manufacturing, packaging and shipping); (6) measure and quantify the value of product features; and, (7) develop final reports. Successful completion of Phase II objectives will lead to the commercialization of the AV trellis system. Potential markets include both commercial producers as well as home gardeners. Based on a technology niche assessment conducted by Foresight Science and Technology, a new light-weight, easy to install and affordable trellis system offers extensive promise in today's marketplace. OBJECTIVES: The overall goal of this SBIR project is to develop and evaluate a novel modular trellis post and hardware system that will facilitate crop positioning, winter protection, sun protection and cane manipulation in blackberries and raspberries for less cost than the existing technology. Phase II efforts will focus specifically on refining trellis component design and beta test trellis systems in different growing environments. The specific technical objectives for Phase II are as follows: 1) Design and prototype rotatable cross-arm (RCA) and adjustable V trellis (AV) systems 2) Lab test trellis system components 3) Field test prototype systems for structural integrity and functionality 4) Analyze costs (material, manufacturing, packaging and shipping) 5) Measure and quantify the value of features such as adjustable trellis wire and attachment of winter and sun fabrics 8) Develop post stabilizer brackets 9) Develop final reports All Phase I subcontractors will continue their involvement in Phase II. The work involving the design and field testing will be conducted at three different locations: Trellis Growing Systems, LLC (Fort Wayne, IN), USDA (Kearneysville, WV), and Cornell University (Ithaca, NY). The expected outputs of the research will be a modular trellis system design which can be economically produced, distributed to the growers, easy to install, and long lasting. Our beta testing results will identify trellis system performance and specific requirements in different growing locations and conditions. Addressing these requirements and incorporating into final trellis design will create value to a broader group of growers. APPROACH: TGS team, at the direction of Barnes, will complete design for next version of prototypes and build and supply to Cornell University and the USDA by April of 2009. Based upon observations and analysis of Phase I prototypes, these new versions will include new cross-arm length dimensions, improved wire stay, improved post stabilizer, and improved end post anchors. Prototypes will be evaluated in laboratory at USDA (Kearneysvlle, WV) for structural integrity and submit report to TGS. Evaluation will include analysis of assembled trellis to vertical, lateral and horizontal force. Upon performance approval by TGS, first versions of Phase II prototypes will be installed replacing older versions of the RCA and AV systems at all three field trial locations: USDA (Kearneysville, WV); Cornell University (Ithaca, N)Y; and, TGS (Fort Wayne, IN), by May 2009. Performance of latest prototypes will be reviewed over the growing season from May through September 2009. Any changes required for product improvement will be implemented and incorporated into the next version of prototypes. TGS will select 10 sites for beta testing latest versions of RCA and AV trellis systems which will include both commercial growers and research stations. These growers will represent a diverse variety of growing conditions which will expose the trellis systems to a range of growing conditions. Installations will begin in September and will be completed by the end of November 2009. This will allow two full growing seasons for all varieties, with the exception of primocane fruiting raspberries which will be one full season an a partial second season. TGS will use the Normative Comparison method in gathering and analyzing the data provided to the team by beta tester sites. Each grower will replace a section of their existing trellis (the control) with an equal amount (in row feet) of either the RCA or AV trellis. The plants in both the RCA or AV trellis and the control trellis trials will be managed exactly the same. The only variable will be the trellising methods. TGS will provide each grower with defined criteria and log forms for recording findings. Each grower will have the exact same forms. These forms will include specific grower information as outlined above. Growers will gather data on both the newly installed RCA or AV systems and the control for comparison. Methods of manufacturing technology and different materials will be researched with comparative cost analysis and recorded. At the directions of J. Branstrator, a comprehensive cost analysis of product materials, methods of manufacturing, packaging and shipping costs will be conducted throughout the research period of this grant. By analyzing the data from the beta test sites and observations by TGS and subcontractors, the cost/performance value of product features such as ease of installation, end post anchor system, post stabilizer bracket, adjustable wire stays, attachment of winter cover fabric and attachment of shade protection fabric will be determined. TGS will use beta testing results to measure the differences between the growers' previous trellising methods (control) and the TGS system