Roller Ginning Research Articles

Technological Evolution and Current Practices in the Indian Ginning Industry

The Indian ginning industry occupies second position in the world. In India, there are about four thousand ginning factories located across the cotton belt mostly equipped with double roller ginning machines except factories which adopted saw gin technologies in Punjab, Haryana, and Rajasthan. Ginning is a systematic process of removing fibre, debris, and cottonseed from kapas. The kapas which heaped in the form of a large conical pile in the open yard of the ginning factory catches moisture and contamination. This results into material loss and cost escalation due to additional technical process required to get quality output. Now, a modest attempt made in this paper to study the ginning practices and technological adoption in changing scenario of the Indian industry. The traditional DR gin machines now improved with versatile highest capacity model gin machines which are economical, productive, and consume less power.

Relative cost of ginning cotton using saw, conventional roller, and high‐speed roller gins in the United States

AbstractThe primary objective of this study was to investigate whether the cost of processing cotton using high‐speed roller gins is comparable to saw gins. The results from a “true” random effect model estimated using proprietary data voluntarily shared by cotton gins operating in Arizona and California showed that the average cost inefficiency for the sample gins analyzed in this study was 13.5%. Moreover, the cost of ginning using conventional roller gins and high‐speed roller gins was 24.42% and 14.18% higher than saw gins, respectively, and roller ginning costs were 10% lower for high‐speed roller gins than conventional roller gins. [EconLit Citations: D24; O14; Q16].

Evaluation of Alternative-Design Cotton Gin Lint Cleaning Machines on Fiber Length Uniformity Index

Developing cotton ginning methods that improve fiber length uniformity index to levels that are compatible with newer and more efficient spinning technologies would expand market share and increase the demand for cotton products and give U.S. cotton a competitive edge to synthetic fibers. Older studies on lint cleaning machines showed that the most widely used feed mechanism that places fiber on the cleaning cylinder damages the fiber and reduces uniformity. The present study evaluates how conventional and experimental feed mechanisms affect uniformity. The lint cleaners were used with both saw and roller gin stands. Four diverse cotton cultivars from the Far West, Southwest, and Mid-South were used in the test. Statistical analysis used a random effects modeling approach which included constructing a 95% confidence interval for each ginning treatment around the predicted mean for the fiber property of interest, and then examining which treatments overlap (for comparison). Results show that the micro-saw gin with the direct-feed lint cleaner had the best uniformity at 85.8%. Prior research has shown that roller ginning is consistently higher in uniformity than any type of saw ginning. In this study, the roller ginning treatments had uniformities of 85.3 and 85.6%, so it is encouraging that the saw gin stand with the direct-feed lint cleaner had very high uniformity. This suggests that it may be beneficial to place fiber directly onto the lint cleaning saw without changing direction. Additionally, the saw gin-coupled lint cleaner had a uniformity of 84.3% which is also a respectable level of uniformity. These results indicate that the direct-feed lint cleaner and coupled lint cleaner warrant further testing under better controlled conditions.

Modeling and Optimization of High-Capacity Experimental Reclaimers to Minimize the Seed and Lint Loss during Roller Ginning of Upland and Pima Cotton

In the present study, two high-capacity experimental roller gin reclaimers, (a) a modified 3-saw cylinder stick machine (three-saw) and (b) a modified 2-saw cylinder gin stand feeder (700), were optimized with respect to reclaimer saw cylinder speed and carryover/seed ratio to minimize the seed and lint loss for both Pima and Upland cotton varieties and were compared to a conventional roller gin reclaimer operated by the ginning industry under standard conditions. Developed regression models adequately described the seed and lint loss phenomena during the reclaiming process. Surface plots indicated that the reclaimer saw cylinder speed and carryover/seed ratio impacted the seed and lint loss for both the 3-saw and 700 reclaimers. Under optimized conditions, the 700 reclaimer resulted in lower lint and seed loss compared to the 3-saw reclaimer when using Upland cotton. In the case of Pima cotton, under optimized conditions, the 3-saw reclaimer had 38% lower lint loss and 24% higher seed loss compared to the 700 reclaimer. The regression equations of both 3-saw and 700 reclaimers were further used to optimize the reclaimers in parallel arrangement to minimize the seed and lint loss. With Upland cotton, the economic loss was about 2.5 times greater with the conventional reclaimer compared to the 3-saw and 700 reclaimers ($15.97/bale loss for the conventional, $8.63 for the 3-saw, and $6.44 for the 700 reclaimers). With Pima cotton, the conventional reclaimer resulted in a lower economic loss ($3.44/bale) compared to the 700 reclaimer which had a loss of about $3.59/bale.

Seed Hull Fracture Resistance of Upland and Pima Cotton Cultivars

Seed durability is a current issue of cotton ginners, who have noted smaller and weaker seed, lower seed grades, and increased seed coat fragments within ginned cotton fiber. To better understand the differences in the seed hull properties of Upland (Gossypium hirsutum L.) and Pima (G. barbadense L) seed, compression testing was conducted to determine the seed hull fracture resistance of both species. Plants were grown in Five Points, CA, U.S., for two years. After roller ginning, seed were conditioned to standard environmental conditions and were compressed until rupture on a material strength tester. Seed of the Pima cultivars generally required greater maximum compressive force and energy to rupture than did the seed of the Upland cultivars. However, when the seed were compressed in a vertical orientation, a few individual Upland cultivars did have compression properties within the range of values observed for the Pima cultivars. Hence, it is possible to find Upland seed with compression properties comparable to or slightly greater than those of some Pima seed. Differences in the data for the two years showed that growing environment affects seed hull strength properties. The results should help clarify some conflicting literature regarding the relative strength attributes of Gossypium species seed.

Study on the analysis of cotton ginning machine transmission system

India is the second ranked large cotton producing country of world. Separation of fibre and seed is initial process desired for converting cotton crop to any finished product. Mostly ginning machines are developed as per need and volume of work to be processed. Ginning machine is main processing tool between cotton producers and textile industries. Commonly machines using double roller are utilized in India. As per the need from time to time Indian farmers adopted tools and techniques to provide high-quality cotton to local and overseas textile mills, ginning machines are upgraded step by step to cope up the demands. Twin roller ginning machine needs to be further developed and enhanced so as to improve performance of textile industries. In this paper, the analysis is conducted for betterment of current design. Double roller gin is focused here using analytical analysis for force acting on gears while transmission of torque, as well as balancing of components and thrust force acting on the bearing that creates vibration in the complete ginning machine assembly. Innovative design aspects considered in this work are found to be very effective for improve of double rolling gin machine performance.

Determining forces arising during the passage of cotton fiber between the fixed knife and working drum of the roller gin

The object of this study is a roller gin. Roller gins are installed in the gin shops of cotton factories and their purpose is to mechanically separate cotton fiber from seeds in fine-fiber varieties of cotton. The criteria for the technological evaluation of roller gin are the sum of defects and fiber contamination after ginning, the cleansing effect of gin on weeds, damage to seeds, and fiber tow effects. Existing methods do not fully reveal all the reserves of increasing the productivity of the machine, improving the design of the main working bodies of the roller gin, ensuring the effective operation of the machine, and preserving the natural qualities of fiber and seeds. The determination of the force on the surface of the drum during the ginning process is of great practical interest for designing main working bodies of roller gins. The efficiency and quality of the processed product depend on the interaction of the working drum and knife with the breaking organ in the process of fiber separation. The design of the drum and knife, their kinematic parameters, the stability of technological wiring largely determine both the performance of the gin and the quality of the fiber and seeds. Theoretical studies have been conducted to determine the factors that affect the performance of roller gin. Based on the results obtained, it is recommended to change the most important structural parameters of the machine. The obtained analytical expressions for the specific pressure and specific friction forces applied from the side of the drum surface to the processed mass of raw materials make it possible to conclude that when the load from the breaking body increases during the lower rebound, the process of grasping, dragging, and holding the fibers between the working drum and the fixed knife worsens

Total Quality Management (Tqm) As a Prerequisite For Improving The Competitiveness In Waste Management And Waste Reprocessing Micro, Small And Medium Enterprises To Achieve Business Excellence

Total Quality Management (Tqm) As a Prerequisite For Improving The Competitiveness In Waste Management And Waste Reprocessing Micro, Small And Medium Enterprises To Achieve Business Excellence

Theoretical substantiation of the conditions for capture of fiber by the working drum by the knife in roller gins

Roller ginning provides 2–3 times less mechanical damage to cotton fiber than saw ginning. In recent years, these positive moments have predetermined attempts to gin medium-fiber cotton on roller gins. However, the low productivity of roller gins compared to saw gins does not yet allow for a complete transition to this process. To design high-efficiency roller gins, it is necessary to deeply study the mechanics of the basic processes of interaction of raw cotton with the working organs of the gin. It is necessary to determine the reserves for improving the efficiency of the process of capturing and tightening the fiber behind the knife, to investigate the mechanics of the process of rebounding seeds, and to find new solutions to reduce their damage. As a result of the research reported here, a mathematical model of the roller ginning process has been built, which makes it possible to determine the impact of technological and structural parameters of the roller gin on the efficiency of the process. This allows for the reasonable application of a variable periodic friction field between the knife and working drum. When studying the kinematics of the interaction of the surface of the working drum with the knife, dependences were established to accelerate the points of the surface of the working drum before it enters behind the knife, making it possible to determine the forces acting on the fiber when it is captured by the micro-irregularities of the drum. In the study of the process of tightening the fiber with a pair of working drum-fixed knife, the conditions for ginning the flyer fibers and the dependence of productivity on the average pressure in the contact of the knife with the drum were determined. The study of the influence of the rigid characteristics of the working drum-knife system on the ginning capacity of a roller gin has made it possible to reveal new reserves for improving the efficiency of roller ginning

Investigation of Ethiopian Cotton Fiber Stickiness. Part 1 – Northern Part

ABSTRACT Cotton is the most important natural textile fiber in the world used to produce apparel, home furnishings and industrial products. However, in the last decades cotton stickiness has become a very serious problem caused by excess sugars on the lint, either from the plant itself or from insects and it is a challenge for cotton growers, ginners, and spinners. It affects the processing efficiency as well as the quality of the product. Ethiopian textile industries are facing this problem every season and not solved it yet. In this article, the Ethiopian northern region cotton stickiness properties have been characterized and their spinning risk probability identified. The stickiness was measured for hand and roller ginned cotton fiber using sticky cotton thermo-detector (SCT), high-speed stickiness detector (CONTEST-S), high volume instrument method (CONTEST-F) and colorimetric method according to ES ISO 12027:2013 and UNI EN 14278–3 standard methods. The statistical analysis of test results showed that the studied locations’ cotton fiber stickiness properties significantly change in SCT, CONTES-S and CONTEST-F methods at P-values of 0.0423, 0.003 and 0.008, respectively. The cotton stickiness has slightly reduced after the roller ginning process compared to hand ginning. Metema and Humera’s cotton fiber have a better stickiness property than other northern areas. Generally, nine northern parts of Ethiopian cotton fiber stickiness resulted in a ‘No Risk’ class ‘Low Risk’ spinning risk probability grade.

Environmental impacts on the design and arts environment for industry 3.0 cotton roller ginning process

The past five decades have been characterised by passage of the environmental impact assessment (EIA) legislation dealing with the environment, including legislation on the control of land, air and water pollution, solid and hazardous waste management, resource conservation and recovery, and soil and ground water and surface water remediation. The aim of this research is to investigate and discuss coronavirus and byssinosis disease impact assessment. Sustainable development is the artistic idea that science and humanities must live and meet their needs without compromising the efficacy and efficiency of future generations to meet their own needs. Prediction and assessment of environmental impacts (effects) on the design and arts environment for industry 3.0 cotton roller ginning process is provided. Sustainable design and arts are discussed in this research work. EIA of conventional design and arts is also investigated. Sustainable design and arts environment for cotton ginning process is presented. The case study and check of strengthening of agricultural extension through sustainable entrepreneurship is discussed in this article.
 
 Keywords: Agriculture, arts, cotton, design, environment, entrepreneurship, ginning, sustainability.

ВАЛИКЛИ ЖИНЛАРНИНГ РЕГЕНЕРАЦИЯ БЎЛИМИНИ ТАКОМИЛЛАШТИРИШ

Methods for improving the area of regeneration of roller gin in the process of processing long-staple cotton have been studied. At present, in the process of processing long-staple cotton of the selection variety Surkhan-9 in the regeneration section of the DV-1M roller machine, the choice of cell sizes for removing exfoliated seeds from the fiber is being studied and substantiated by experimental methods.Keywords: long fiber, roll gin, regeneration, variety, pile drum, mesh, fixed blade, forging drum, grill

Effect of Roller Ginning on Fiber and Yarn Properties of Some Egyptian cotton Varieties

Effect of Roller Ginning on Fiber and Yarn Properties of Some Egyptian cotton Varieties

INVESTIGATION OF THE INTERACTION OF THE ROLLER AND THE STATIONARY KNIFE OF THE ROLLER GIN WITH COTTON FIBER

The work is devoted to one of the topical issues of the cotton ginning industry. The article discusses the dynamic and mathematical models of the process in the interaction of the working drum-stationary knife system with the fiber of the ginned fly and solutions are given that allow you to determine the necessary part of the surface of the working drum and knife, taking into account the dynamics of the system. This method of solving problems is relevant because leads to the intensification of the roller ginning process.

Environmental health impact assessment of chrome composite leather-clad rollers used by Indian cotton roller ginning industries and design and development of Eco-friendly alternatives

This research article realises the hazards of chromium contamination and pollution caused by using chrome composite leather-clad (CCLC) rollers that are commonly used in the cotton roller ginning industries and attempts to eliminate the chromium contamination and pollution during the cotton ginning process. The chromium traces found contain hexavalent chromium being adsorbed from chromium-contaminated lint, yarn, fabrics, seeds, by-products and textile effluent. Chromium acts in three ways on humans, viz. (i) local action explained as dermatitis or absorption through skin, (ii) direct inhalation and (iii) ingestion or absorption into the stomach. Toxic effects are produced by prolonged contact with airborne or solid or liquid chromium compounds even in small quantities because of their properties, viz. carcinogenicity, mutagenicity and corrosiveness. Traces of Cr (VI) are found even in analar grade trivalent compounds, and complications do arise due to reduction in the nature of these traces that affect the organic tissues of the body. These regenerating effects occur rapidly and are dependent on the dose. This research article realises the hazards of chromium contamination and pollution caused by the use of dust-producing grinding of CCLC rollers that are commonly used in the cotton roller ginning industries and attempts to nullify this problem during cotton ginning. This research has been carried out with the following objectives: to identify and study the environmental health effects existing with the present CCLC rollers being used in the Indian cotton roller ginning industries; to conduct an environmental health impact assessment in Indian cotton roller ginning factories during the research years of 1998–2018; to design and develop an eco-friendly chrome-free roller and evaluate its performance with reference to environmental health effects and techno-commercial aspects in the ginning industries. With the author’s research background and practical experience in cotton ginning and textile industries, this study is attempted to eliminate the environmental health impacts to a great extent at the source itself, through a suitable design and development of an eco-friendly, pollution-free, chromeless roller for cotton roller gins. An eco-friendly roller ginning process has been designed and developed for replacing the conventional CCLC roller ginning process, to eliminate the chromium contamination and pollution from cotton roller ginning industries and to meet the requirements of World Health Organisation standards, while maintaining high-quality spun yarns and woven fabrics which meet the international standards.
 
 Keywords: Assessment, chromium, ginning, health, impact.

COTTON GINNERS HANDBOOK: Development of the Cotton Gin

Cotton fiber was first used in 6000 B.C. The two New World cotton species that are most of today’s production include G. hirsutum (Upland) and G. barbadense (Extra Long Staple [ELS]). The first cotton gin existed by the 5th century A.D (single-roller gin). The next development was the churka gin (double-roller gin) which ginned cotton five times faster than the single-roller gin. The churka gin was widely used in North America by 1750 and ginned both Upland and Sea Island (ELS) cotton. The spike-tooth cotton gin was developed by Eli Whitney in 1794. Hodgen Holmes developed a continuous flow gin with toothed saw blades in 1796. These were a different concept than the double-roller gins. Holmes’ saw gin dominated the industry for Upland cotton (and still does), whereas double-roller gin use continued for Sea Island cotton. In 1840, Fones McCarthy developed a reciprocating-knife roller gin. The saw gin had a significantly higher ginning capacity than the McCarthy gin, so it was used with Upland cotton and the McCarthy roller gin was used with Sea Island cotton to preserve the long-staple cotton’s quality. Sea Island production ceased in 1923 because of the boll weevil, but Pima (ELS) cotton had developed by this time in the Southwest, so roller gin use continued. In 1963, a rotary-knife roller gin was developed that ginned at five times the rate of a reciprocating-knife gin. A high-speed roller gin was developed in 2005 with a ginning capacity, on a per-width basis, comparable to modern-day saw gins.

Evaluating Alternative Seed-Cotton Reclaimers for High-Speed Roller Ginning

HighlightsExperimental high-capacity seed-cotton reclaimers were evaluated for the growing high-speed roller-ginning industry.The experimental reclaimers minimized the amount of seed-cotton loss compared to the conventional reclaimer, but had more seed loss than a conventional reclaimer.The conventional reclaimer had the lowest combined seed and lint loss when processing Pima cotton.An experimental reclaimer based on a current cotton gin machine had seed and lint losses nearly $10 per cotton bale less than the conventional reclaimer when processing Upland cotton.Abstract. In a roller ginnery, a reclaimer machine removes partially-ginned or unginned seed cotton (carryover) from the mixture of carryover and ginned cottonseed that is expelled from the roller-gin stand during operation and returns the carryover to the gin stand for re-ginning. Conventional seed-cotton reclaimers are marginally adequate in their capacity to handle the increased carryover that high-speed roller ginning produces. Overloading a reclaimer often leads to choke-ups and downtime for the ginnery. The objective of this study was to develop and test high-capacity reclaimers. A modified 3-saw cylinder stick machine and a modified 2-saw cylinder gin-stand feeder were tested and compared to a conventional reclaimer. The saw-cylinders in the modified machines were operated at standard full speed, 1/2 of full speed, and 3/4 of full speed. Both Pima and Upland cotton were included in this study because there is a sizable amount of roller-ginned Upland cotton. Results showed that the experimental reclaimers reclaimed more carryover than the conventional reclaimer. An effective reclaimer will 1) reclaim carryover without also capturing residual seed that will likely be removed with cotton trash when returned to the gin stand feeder (seed loss) and 2) allow seed to pass through to the seed storage while minimizing the amount of residual carryover that escapes with the seed (carryover loss). The experimental reclaimers minimized the amount of residual carryover loss, but they had more residual seed loss than the conventional reclaimer. Increasing the saw-cylinder speeds of the experimental reclaimers decreased the residual seed loss but increased the residual carryover loss. Estimates of the value of the lost seed and of the lint on the lost carryover revealed that the conventional reclaimer had the lowest combined loss of $3.56 per bale when processing Pima cotton and the experimental 2-saw feeder with saw-cylinders operating at full speed had the lowest combined loss of $6.89 per bale when processing Upland cotton. The results suggest that losses of lint and seed may be further reduced by using a combination in series of different types of reclaimers to take advantage of each of their respective best features. Keywords: Cotton ginning, Roller ginning, Seed-cotton reclaimer.

Effects of harvesting and ginning practices on Southern High Plains cotton: textile quality

The impact of the harvesting method, as well as the ginning method (saw or high-speed roller ginning), on textile quality was studied over three years of cotton production in the Southern High Plains. The Southern High Plains region is the largest cotton production area of the USA. The Southern High Plains and the Texas Gulf Coast are the only areas of the USA where brush-roll stripper harvesting is common, alongside traditional spindle picker machine harvesting. Different harvesting methods lead to differences in micronaire, maturity, length distribution, color and non-lint content within the bale. Ginning differences were primarily found to be length and length distribution related. Lint was processed into rotor-spun, carded ring-spun and combed ring-spun medium count yarns to determine the impacts of harvesting and ginning methods on textile product quality. Rotor spinning produced comparable quality yarns regardless of harvest or ginning method, while carded ring-spun yarns showed statistical differences in quality, with spindle-picked cottons having greater uniformity and higher tenacity. Combing was able to eliminate any functional differences in quality due to the pre-mill handling of the cottons at the expense of increased noil levels for stripper-harvested cottons. There were no differences in ends-down during ring spinning, regardless of harvest and ginning method, although cottons produced with high-speed roller ginning were able to be spun at higher spindle speeds, which equates to higher production speeds.

Effects of harvesting and ginning practices on Southern High Plains cotton: fiber quality

The lint yield and fiber quality of cotton produced in the Southern High Plains of the USA have improved over the last decade, renewing interest in finding harvest and ginning practices that better preserve fiber quality. Previous research showed that picker harvesting and roller ginning may better preserve fiber quality, but conventional roller ginning was too slow to be adopted as the primary ginning system used for Upland cotton. Advancements in roller ginning technology have increased the ginning rate per unit width of rotary-knife roller gins to approximately equal that of saw gins. Research has shown that improvements in nep content and fiber length characteristics afforded by conventional roller ginning compared to saw ginning are maintained by the new high-speed roller gins (HSRGs). The objective of this work was to compare the fiber quality, seed quality, ginning rate, and lint turnout of Upland cotton produced in the Southern High Plains, harvested using a picker or a stripper, and ginned using saw or HSRG systems. The findings of this work indicate that the HSRG substantially improved the length characteristics of the Upland cultivars tested regardless of harvest method. Turnout was higher for the HSRG and for picker harvested cotton. Nep content was reduced for picker harvested cotton and the HSRG. The fiber length distribution and nep content improvements from the HSRG system make this fiber more attractive to ring spinning mills that produce high-count yarns for high-value products.

Ginning Efficiency and Fiber Quality Properties of Cotton as Affected by Roller Gin Stand Feeding Methods and Seed Cotton Grade

Aims: Attaining the highest ginning efficiency process and fiber quality properties of Egyptian cotton cultivar ̔ Giza 88᾿during feeding methods of roller gin stand is the ultimate objective of the community of cotton field industry for local uses, but the productivity of the three feeding methods of conventional roller gin stand used in ginning process still limited.
 Therefore, the aim of this investigation is to overcome this obstacle.
 Study Design: This investigation was conducted in a completely randomized design with three replicates and analyzed as a factorial experiment.
 Place and Duration of Study: Plant Production Department, the Faculty of Agriculture (Saba Basha), Alexandria University, Egypt during 2017.
 Methods: Four seed cotton grades; namely, Good to Fully Good (G/FG), Good + ¼ (G + ¼), Good (G) and Good -¼ (G - ¼) belonging to ̔ Giza 88᾿ cotton cultivar were used in this work. The extra-long staple Egyptian cotton variety with the pedigree and origin of cotton Giza 88 (Giza 77 x Giza 45 B) was used. This work was carried out in 2017. About half cantar (1 cantar = 157.5 kg) of each seed cotton grade as a bulk sample was thoroughly mixed and checked and reclassified by a committee of three expert classers belong to the Cotton Arbitration for Testing General Organization (CATGO), in the gin plan.
 Results: The obtained results indicated that the gin stand's hand feeding method (control treatment); results in significant increases the highest mean values of the gin stand capacity (0.97 kg lint/inch/h), Lint % (36.59%) and lint grade code (27.33) and the lowest mean value of the ginning time (1.42 h/cantar). Meanwhile, the Belt (2 row) as a mechanical feeding method; gave rise to the lowest mean value of gin stand capacity (0.89 kg lint/inch/h). The differences in fiber length parameters (Upper half mean length and short fiber index), fiber elongation %, micronaire reading, yellowness degree (+b) were not significantly affected. The highest seed cotton grade (Good / Fully Good) gave the better lint cotton grade and the best fiber properties tested by HVI instrument of ̔ Giza 88᾿ cotton cultivar.
 Conclusion: The hand feeding method of seed cotton to the gin stand surpassed all studied feeding methods in gin stand productivity, lint percentage and the most HVI fiber properties are better classer grade. Though, this method is recommended to be used specially with the high levels of the extra-long cottons.
 Cylinder feeding method ranked first in order among studied mechanical method and it could be recommended for ginning medium and low seed cotton level.
 Belt (2 rows) is the preferred feeding method regardless of gin stand productivity.