From the depths of a grain bin, a robot is doing the dangerous work once performed by farmers. As it scurries across the grain, the Grain Weevil breaks up hardened surface crust and ridges, leveling out the grain and improving airflow. From outside the bin, the farmer can now remotely control the robot as it completes a once-perilous task.
“Cleaning out grain bins and leveling grain is by far the most dangerous thing we do, so to be able to stay physically out of the grain as much as we can, that’s a huge improvement in safety,” says Zach Hunnicutt, a farmer from Giltner, Nebraska.
The History – From Duct Tape to Deployment
The Grain Weevil’s story begins in 2020 when Chad Johnson and his son, Ben Johnson, started working on a project to teach kids workforce skills through innovation – specifically, building robots. When a local farmer saw what the duo had created, he asked a simple but profound question: Could they build a robot that would keep him out of the grain bin?
From there, the father-son duo made a 3D-printed robot, complete with duct tape, and showed it to a group of farmers gathered to watch the movie Silo. The Johnsons took that feedback home, and in 2021, they officially started working on their Grain Weevil business.
| Year | Milestone |
|---|---|
| 2020 | Father-son robotics project begins |
| 2020 | Farmer asks for grain bin robot |
| 2021 | Grain Weevil business officially launched |
| 2025-2026 | Over 100 robots deployed |
Chad Johnson reflects on the journey:
“We knew that’s when we were going to be able to turn this little project into a startup, and now into a company that has over 100 robots deployed.”
How the Grain Weevil Works
The Grain Weevil robot is designed to address two of the most dangerous tasks in grain storage:
| Task | Danger |
|---|---|
| Leveling grain | Farmers must walk across unstable grain surfaces |
| Breaking up crust | Hardened surface crust can collapse unexpectedly |
Design and Operation
- Appearance: Looks like a bug with augers instead of wheels
- Function: Scurries across grain, breaking up crust and ridges
- Control: Remotely operated from outside the bin
- Benefits: Improves airflow, levels grain, reduces spoilage risk
The robot allows farmers to complete these tasks without physically entering the grain bin – eliminating the risk of entrapment, suffocation, or injury.
The Danger – Grain Bin Entrapment Statistics
According to Purdue University, there were 22 fatalities in confined spaces such as grain bins in recent reporting periods. Grain bin entrapment is one of the most persistent and deadly hazards in agriculture.
Common Causes of Grain Bin Accidents
| Cause | Description |
|---|---|
| Flowing grain | Acts like quicksand, pulling a person under in seconds |
| Bridging | A crust forms on top; when it breaks, the person falls into the grain |
| Crust collapse | Walking on hardened surface that suddenly gives way |
| Atmospheric hazards | Toxic gases or oxygen deficiency |
Hunnicutt emphasizes: “Cleaning out grain bins and leveling grain is by far the most dangerous thing we do.”
Engaging the Next Generation
The Grain Weevil is not just about safety – it is also about involving young people in farming operations without exposing them to unnecessary risks.
Hunnicutt, a fifth-generation farmer growing corn, popcorn, and soybeans, says it is a challenge to include young children when working with grain because of the risks. However, with the Grain Weevil, the robot is controlled from outside the grain bin, away from the danger.
“Without having to physically enter the grain is a pretty neat thing to be able to do, still keeping them working, but not putting them in danger,” Hunnicutt says.
Video Game-Like Controls
Hunnicutt draws comparisons between operating the Grain Weevil and playing video games:
“They have a lot of similarities to video game controls, so I think it’s pretty instinctive to someone who’s played any kind of video game.”
This design choice has multiple benefits:
- Lower training time for younger operators
- Intuitive interface reduces user error
- Appeals to Gen Z farmers who grew up with gaming
For the Johnson family, the project has also been a personal success. Chad Johnson says:
“It’s great, we get along very well … you couldn’t ask for any better situation than to be able to build robots with your kid.”
Support and Market Adoption
After five years in business, the Johnsons have sold more than 100 Grain Weevil robots – each with the goal of making it safer for farmers when working with grain in storage.
Along the way, they have had the support of Ag Launch for marketing, testing, and getting the product to market.
“We built this robot to help keep farmers and workers out of the grain when there’s a situation where they could get hurt, entrapped or any of the dangers that go along with it,” Chad explains.
Current Deployment
| Metric | Number |
|---|---|
| Robots deployed | 100+ |
| Years in business | 5 |
| Fatalities prevented (potential) | Countless |
The Broader Context – AgTech and Labor
The Grain Weevil is part of a larger trend in agricultural technology: using automation to address dangerous or labor-intensive tasks.
Related Innovations
- Agtonomy – Tapping into the gaming generation to solve the ag labor crisis, offering screen-based expertise as an alternative to traditional manual labor
- Autonomous tractors – Reducing operator fatigue and injury risk
- Drone spraying – Eliminating chemical exposure for ground crews
As the agricultural workforce ages and labor shortages persist, robots like the Grain Weevil offer a way to maintain productivity while improving safety.
The Johnsons’ Vision for the Future
The Grain Weevil is already saving lives, but the Johnsons see even greater potential. Their vision includes:
- Expanded deployment – Getting robots into more bins across more farms
- Enhanced capabilities – Additional sensors and automation features
- Data collection – Using robot-generated data to optimize grain storage conditions
Chad Johnson sums up their mission simply:
“We built this robot to help keep farmers and workers out of the grain when there’s a situation where they could get hurt, entrapped or any of the dangers that go along with it.”
A Small Robot with a Big Impact
Farming is full of dangers, but few are as unforgiving as grain bin entrapment. A person can be pulled under flowing grain in seconds – often before anyone can react. The Grain Weevil robot, born from a father-son project with duct tape and a 3D printer, is now a commercial product that is keeping farmers safe.
With over 100 robots deployed, the Johnsons have turned a simple idea into a lifesaving innovation. And for farmers like Zach Hunnicutt, the ability to level grain and break up crust without stepping inside the bin is nothing short of transformative.
As Chad Johnson said: “You couldn’t ask for any better situation than to be able to build robots with your kid.” And for the farmers using those robots, you couldn’t ask for a better way to come home safe at the end of the day.
