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Modern apple growing faces a big challenge: how to reduce production costs when there are fewer workers available?

The solution is simple — move from labor-intensive dessert orchards to super-intensive industrial apple orchards, fully adapted for mechanical harvest.

Let’s visit the model experimental orchard at the Lubelski Ośrodek Doradztwa Rolniczego w Końskowoli (LODR). This orchard was designed for mechanical harvest using the FELIX Z apple harvester.

We were guided by Sebastian Balant, orchard specialist at LODR, who explained the main goals and technical solutions used in this project.

Variety Selection: Genetic Resistance Instead of 20 Sprays

The foundation of a modern industrial apple orchard is reducing chemical protection.

At LODR Końskowola, they planted apple varieties with genetic resistance to apple scab, such as:

• Galiwa – sweet, suitable for dessert and processing

• Chopin – acidic, ideal for processing

Thanks to genetic resistance, growers can reduce plant protection treatments by 60–70%.

Key Benefit

In a traditional orchard, growers perform around 20 scab sprays per season.
In a modern orchard with resistant varieties, these treatments are almost eliminated.

This means:

• Lower fuel costs

• Less time spent spraying

• Lower chemical costs

• More environmentally friendly production

Building a Fruit Wall – The Super-Intensive System

To allow efficient work of the FELIX Z apple harvester, the orchard must be designed as a fruiting wall system.

Tree Spacing

• Trees are planted every 0.7 meters in the row.

• This high density helps quickly fill the space.

Canopy Width

• The tree canopy should not exceed 30 cm from the trunk axis.

• Narrow trees allow smooth harvester operation.

Support Structure

• Concrete posts

• Wires

• Bamboo sticks

This creates a stable structure fully compatible with the FELIX Z harvester.

The First Year: Invest in Tree Structure

In a mechanical harvest apple orchard, the first year is about building strong trees.

Although fruit appeared in the experimental orchard (planted in November 2024), most fruitlets were removed.

Only 2–3 apples per tree were left.

Why?

Because the goal is to:

• Strengthen the trunk

• Build a strong canopy

• Prepare trees for full production in year three

Strong trees can better handle heavy fruit load and mechanical harvesting.

Full Mechanization – From Pruning to Harvest

The orchard was designed with complete mechanization in mind.

Mechanical Pruning

• Cutting bars are used for pruning.

• Only minimal manual correction is needed.

Mechanical Harvest

• Trees are guided along bamboo sticks.

• The narrow canopy allows efficient fruit shaking.

• The FELIX Z harvester ensures clean and fast harvest.

Is a Super-Intensive Apple Orchard Profitable?

Switching to an industrial orchard model is not only about saving labor costs.

It also gives:

• Predictable production

• Less dependence on seasonal workers

• Only 3–4 workers needed (including tractor and harvester operators)

• Better reaction to changing market conditions

Traditional vs Modern Industrial Orchard

fewer and fewer people willing to harvest, higher rates

Main Advantages of the Super-Intensive System

• Up to 70% lower protection costs

• Fully mechanized pruning and harvest

• Faster return on investment

• Lower long-term harvest costs

• Reduced labor dependency

Want to Prepare Your Orchard for Mechanical Harvest?

Are you planning to design a super-intensive apple orchard for the FELIX Z harvester?

Contact our technical advisors to learn how to:

• Choose the right varieties

• Plan tree spacing

• Build the support system

• Prepare for full mechanization

Start building a modern apple orchard today and reduce your production costs tomorrow.