MANUAL WORKING STATION

Products & Solutions

for forest nurseries

Manual operations are often required in

containerized forest nurseries. These
operations include preparation of cutting
material, setting of cuttings, manual planting of
large sized seed, transplanting small seedlings
into larger tray cells, quality control and packing
of seedlings for dispatch.
BCC MANUAL WORKING STATION
BCC has designed and developed a wide range of
Manual Work Stations for different manual operations and
conditions. These MWS are customized according to
requirement and modularized. This means that MWS can
be extended as production in the nursery increases.

The MWS concept allows the nursery manager to

centralize production operations, which ensures improved
monitoring and quality control over the processes. Further,
it provides a better work environment to the operators
through integration of ergonomics in the design of the
stations, which in turn improves productivities and quality.
The BCC MWS’s are completely integrated into the rest of
the production line, which further improves productivities
and reduces labor requirement. MWS can also operate as
stand-alone units, depending on requirement e.g.
preparation of cutting material and packing stations.

THE PROCESS
Various solutions are available for MWS’s and can be
fully customized according to requirement. Some of the
standardized concepts developed for different projects
around the world include:

Two-level MWS with fixed operator tables

Two-level MWS are more flexible and more suitable for larger operations and could also fulfill multi-functional operations
e.g. setting of cuttings and packing of plants. These MWS’s consist of two levels, one for in feed and one for out feed.
Conveyor belts are generally used for both in feed and out feed. Depending on the type of operation in feed can be on the
upper or lower level. When setting cuttings, the lower level is normally used for in feed while the filled trays are fed out on
the upper level. This minimizes the distance between the upper and the lower levels, reducing the distance the tray needs to
be lifted by the worker. In situations where the MWS is very long (>12meters) or connected in series with the filling line, in
feed driven roller conveyors with accumulation function are used. These conveyors are driven by chain with rollers mounted
to the chain, which ensures that trays accumulate without wearing out the conveyor. Operator tables are fixed to the MWS
on either side. The operator tables can be continuous or separated into individual units.

Two-level MWS with tilt control operator tables

Trays are fed into the MWS via an upper roller conveyor with tray accumulating function. Persons are seated at individual
operator tables, which are fitted with a pneumatic cylinder with a tilt control function. After trays are filled with cuttings/
seed, the cylinder is activated to tilt the platform down and slide the tray onto the lower out feed belt conveyor.

Three-level MWS

Three-level MWS are commonly used for plant packing lines. Trays with plants are fed into the MWS on the middle level.
Persons are seated at individual operator tables, which are fitted with a pneumatic cylinder with a tilt control function. After
removing the plants from the tray and packing them into boxes or bags on the integrated operator tables (one platform for
the tray and one platform for the packing box/bag), the empty tray is placed on the upper level. The cylinder is activated to
tilt the platform down and slide the box/bag onto the lower out feed belt conveyor to be transported to the end of the line
for further dispatch.

BCC MANUAL WORKING STATION

Closed-loop MWS

Closed-loop MWS are used where a large number of persons are required in a relatively small area. The closed-loop
station functions similar to a carousel, where the complete station is placed adjacent to the production line and connected
by a transfer area. Trays are transferred into and out of the closed-loop by pushers and tray stoppers, which are controlled
by queue-detecting sensors.
At the start of production a set number of trays are allowed to enter the closed-loop MWS. The number of trays
entering the line is determined by manually turning a selection switch. This pre-determined number of trays will remain in the
closed-loop line for the entire operation. The same number of trays transferred out of the line will be fed into the line.

After filling, trays accumulate on a driven roller conveyor with accumulation function, ready to be transferred into the
closed-loop MWS. When a queue builds up, a photocell sends a signal to stop further filling and feeding. A planted tray is
detected through a photocell and automatically transferred out of the line, while a pusher feeds a new tray into the line.
Persons are seated on either side of the MWS along operator tables. A walkover bridge allows access to the center of the
closed-loop MWS.

OPERATIONAL BENEFITS & KEY FEATURES

• Fully customized according to nursery’s requirements in terms of physical and budget limitations.
• Modular concept for easy extension.
• Centralized production for improved monitoring and control of operations.
• Full integration into plant production lines through the use of accumulating roller conveyors, photocells,
pushers and stoppers.
• Continuous feed and availability of filled trays to avoid production stoppages.
• Stainless steel operator tables.
• Better work environment through ergonomic design to optimize productivities, maximize quality and
reduce physical fatigue.

ACCESSORIES AND EXTRA FEATURES

Degree of integration

MWS’s are either free-standing or integrated into the plant production line. Free-standing
MWS are operated independently from the rest of the plant production line. These MWS are
generally used for operations such as:

• Cutting material preparation - tables which incorporate a bench and working surface on
either side of a central waste trough accommodates four persons.

• Plant packing – MWS’s for plant quality checking and packing for dispatch normally ope-
rate as stand-alone units. A deplugger can be added to the front of the line to ensure easier
extraction of the plants from the trays during the packing operation.

MWS’s integrated in the plant production line are controlled through the use of PCL’s (where
required), photocells, queue detecting sensors, pushers and stoppers to activate in feed of trays
from the tray filler and out feed to subsequent processes after the MWS (e.g. watering tunnel

Products & Solutions for forest nurseries

 and accumulation for loading). These MWS are used for operations such as:Setting of cuttings
– trays filled with growing substrate are fed to operators located along the MWS for setting of
cuttings.

• Manual planting of large sized seed – in cases where seed size or irregular seed shape
prohibit automated seeding, seed is sown by hand. The process is similar to setting of
cuttings.

• Transplanting of small seedlings – forest nurseries that have limited greenhouse area, ger-
minate seedlings in trays with higher density and smaller cells. After the germination phase
when roots consolidate sufficiently, the seedlings are transplanted into larger tray cells.
MWS’s are commonly used for this purpose, by adding a transplanting dibbler at the start
of the line. Trays with larger cells are filled and dibbled, while plants are removed from
the smaller cells for manual transplanting. Since subsequent root development is critical
to plant quality, this operation is normally done by hand in containerized forest nurseries.

Degree of automation

Depending on budget constraints and physical limitations, functions of the MWS’s could be
automated to a more or lesser degree. Some of these automations include:

• Cutting material preparation tables could be fitted with integrated waste feeding belts in
the center trough, which allows for automated removal of waste into collection containers
at the end of the table.
• Individual work platform with pneumatic tilt control – trays fed into a MWS on the
upper conveyor is placed on individual operator’s platforms for setting of cuttings. These
individual platforms are fitted with a pneumatic cylinder, which allows the operator to tilt
the platform down for transferring a tray or box onto the lower out feed conveyor.

BCC AB, Profilgatan 15, 261 35, Landskrona, Sweden, www.bccab.com, bcc@bccab.com
Tel: +46 418 449920 Fax: +46 418 449922