26/10/17. Best Ginning Practices to Enhance Efficiency, Preserve Quality & Increase Cotton Fibre Output.

Transcription

1 26/10/17 Best Ginning Practices to Enhance Efficiency, Preserve Quality & Increase Cotton Fibre Output. By Dr. M. K. Sharma, Whole Time Director & CEO of Bajaj Steel Industries Ltd, Nagpur, Maharashtra, India At 8 th Open Session of 76 th Plenary Meeting of International Cotton Advisory Committee at Tashkent, Uzbekistan on 26 th Oct, INTRODUCTION Ø In the present year cotton is facing unrelenting competition from manmade fibre & consumption of cotton has witnessed over 20% drop in the last 25 years while the consumption of manmade fibres has increased over 25% during the same period. Ø This is mainly due to higher prices of cotton as man-made fibres continue to be less expensive than cotton. Ø When retailers and brands are looking to their margins, they tend to make more money when they substitute man-made fibres & cotton. Ø Cotton is a great product for a whole lot of reasons as it is the purest form of cellulose, its softness & breathability makes it the world s most comfortable fibre to wear. Ø Due to higher prices it has no longer remained a natural first choice of manufacturers & consumers. INTRODUCTION Ø The best textile mills in the world loose 3% to 8% of a bale of cotton when they paid for a full bale due to short fibres & other defects while every single fibre in a bale of man-made fibre is used with zero or negligible waste. Ø The Agricultural scientists are doing continuous research to reduce the cost of cultivation & harvesting as well as increasing the cotton yield per hectare and various discussions are being taken up at different forums in this regard. Ø However a significant value loss & undesirable cost additions occurs in the cotton due to various inappropriate post harvesting practices at Ginning & Pressing Factories level, which needs to be controlled. Ø This paper will restrict discussion for the best practices required to be exercised in Ginning Factories to reduce the cost of cotton per unit and to Enhance Efficiency, Preserve Quality & Increase Cotton Fibre Output from the available varieties of cotton in different part of the world. APPARENT SHORTCOMINGS IN CONTRIBUTING TO HIGHER COSTS OR LOWERING FIBRE The majority of Ginning Factories worldwide fall in the following categories : 1.Job working Ginning Factories in Private / Co-operative Sector : Ø These Ginners are inclined towards achieving higher volume of Ginning per hour so that they can earn higher job work charges for conversion of seed cotton into bales. Ø In this case, the seed cotton is owned by farmers or somebody else and the profit derived by selling of cotton lint/ fibre or cotton seed is not the concern of Ginner hence many of them are comparatively less sensitive about retention of cotton quality parameters or wastage of fibre. APPARENT SHORTCOMINGS IN CONTRIBUTING TO HIGHER COSTS OR LOWERING FIBRE 2. Ginning Factories in Government Sector : Ø Government of many of the countries have adopted monopolistic purchases of cotton & have set up the Ginning Factories in Government Sector where the capital funding of the Ginning Factories come either from Government funds or Term loans from International Financial Institutions or Government grants. Ø These Ginning Factories have advantage of monopolistic purchase of seed cotton from farmers at lower price as may be fixed by Government authorities. Ø In this case the Ginning Factories are run by Government employees or political appointees, many of whom are also not comparatively sensitive about preserving fibre quality or enhancing performance. 1

2 26/10/17 APPARENT SHORTCOMINGS IN CONTRIBUTING TO HIGHER COSTS OR LOWERING FIBRE 2. Ginning Factories in Government Sector: Ø Moreover, for selection of Ginning technologies they are either not having enough knowledge about suitability of particular Ginning technologies for Ginning of Cotton varieties available in the area where Ginning factory is being set up or these Ginning factories have to buy the Ginning machinery based on the considerations from the funding country without proper knowledge about availability of different Ginning technologies suitable for the cotton varieties grown in the region of Ginning factory establishment. APPARENT SHORTCOMINGS IN CONTRIBUTING TO HIGHER COSTS OR LOWERING FIBRE 3. Owner / Trader Ginner in Private Sector : Ø In this case, the Ginner purchases seed cotton from farmers or middle man & performs the Ginning for selling to traders or final users. Ø Normally, the Ginners tends to select proper Ginning technology suitable for fibre parameters of the cotton available in the area of Ginning factory installation but most of the time they are guided by the existing Ginning technology in use in the area mainly due to operational reasons or national standards / grades fixed for the cotton bale & trade practices prevalent in his area. Ø A country where seed cotton is clean and opened with below 2% trash when coming from the field but the standard fixed in that country for cotton bales specifies permissible trash percentage of 3% for highest grade i.e. grade 1 and spinning mills have to set buying parameters as per national standards, the ginner tend to increase the trash contents to 3% instead of removing any trash. APPARENT SHORTCOMINGS IN CONTRIBUTING TO HIGHER COSTS OR LOWERING FIBRE 3.Owner / Trader Ginner in Private Sector : Ø In the countries where in the normal trading practice trash of 8% is accepted by spinning mills for fixation of prices, the ginners tend to retain or take the trash to that level unless he has direct selling to spinning mills which is ready to pay premium for his clean cotton. Ø In many of the countries the cotton is sold through brokers, who are not in a position to take extra efforts for getting additional price for better quality clean cotton rather offer uniform price across the board for buying the cotton bales from an area. Ø Such practices prompt the ginners to retain the trash percentage at higher level, finally deteriorating the fibre parameters. 1. Fixation of National Standards for Cotton Trash : Ø Most of the countries do not have defined standard for trash percentage & the trade is being done based on practices where the trash percentages which were being obtained for different cottons in the earlier days when modernized & upgraded cleaning systems were not available. Ø The authorities drafting the National Standards in various countries for cotton trash and other fibre parameters normally get influenced by the standards prepared by other countries where the cotton parameters are different, such as in India, Bureau of Indian Standard may get influenced by the standards prevailing in USA, where the cotton is machine picked while in India it is handpicked. Ø In USA when we see the seed cotton coming from field, it is normally having around 15% or so trash while in India, the incoming trash is most of the time below 2% due to handpicking but the trash percentage mentioned in the standard for various grades of cotton may be same in USA as well as India, say 3% final trash in lint for grade 1 while for grade 6 it may be 12%. 1. Fixation of National Standards for Cotton Trash : Ø In the countries where in the normal trading practice trash of 8% is accepted by spinning mills for fixation of prices, the ginners tend to retain or take the trash to that level unless he has direct selling to spinning mills which is ready to pay premium for his clean cotton. Ø In many of the countries the cotton is sold through brokers, who are not ready to take extra efforts for getting additional price for better quality clean cotton rather offer uniform price across the board for buying the cotton bales from an area. Ø Such practices prompt the ginners to retain the trash percentage at higher level, finally deteriorating the fibre parameters. 1. Fixation of National Standards for Cotton Trash : Ø Though the standards so prepared are optional but the spinning mills have to follow these standards for arbitration and reference etc. Ø Hence if they allow 3% trash, the ginner has temptation to increase the trash to 3% from incoming below 2% instead of cleaning the cotton to bring it down than incoming 2% rather they have to adopt some means to increase the trash percentage to 3% so that they get additional benefit but due to this even the contamination does not get reduced as the cleaning equipments are not used also the moisture is not brought down. Ø An argument is being advanced that these standards are optional and not mandatory, hence the spinning mills should not take any reference for such standards but the reality is different as there has to be some standard documents for deciding the base and resolving the disputes. 2

3 26/10/17 1. Fixation of International / National Standards for Cotton Trash : Ø It is necessary that two separate standards should be prepared for each country one for machine picked cotton and one for handpicked clean cotton and all other aspects concerning fibre parameters must be properly understood and considered while preparing such standards. Ø These International / National Standards should be strictly made applicable for all similar cottons uniformly such as if in case of handpicked clean cotton trash percentage is fixed as 1% uniformly, the ginners may have to clean the cotton properly. 2.Trading Pattern of Cotton Bales : Ø The majority of cotton bales are sold worldwide either through the brokers or some parent sales organizations where it is very difficult for the broker or such organization to offer different prices for similar cotton parameters except trash. Ø The broker or parent sales organization offers one price for entire lot in an area where from they want to buy the requirement for their various clients, hence they offer uniform price based on particular standard say up to 3% trash but do not offer any premium if some ginner offers lower trash percentage say 2% or 1.5% or 1%. This compels the otherwise honest ginner to adopt malpractices to increase the trash percentage to 3%. Ø In many countries, permissible trash percentage is as high as 10% to 12% for certain varieties of cotton; hence there is every encouragement to keep the trash percentage higher. The higher trash percentage present in the seed cotton also damages the fibre properties while ginning. 2.Trading Pattern of Cotton Bales : Ø If the national standard or international standard for grade 1 cotton is fixed at 1% and the number of grades may be increased like grade 2 for 2% trash, grade 3 for 3% trash or so on then probably the prices in the market will also be fixed for such grades which at present start from 3% trash. If it is done spinning mills will have chance for getting the low trash cotton at better price even through the present system of sales through brokers or centralized sales organizations as the reference will be available for the lower trash cotton from such revised standards. Ø This feature is at present available only when the mills and ginners are dealing directly and both carry the trust for each other and special prices are fixed for same, which is happening in rare cases at present. 3. Sampling of Cotton Bales : Ø In majority of the countries the lint samples of each bale are not taken and only random sampling is done, which does not create level of trust and the price realization is on lower side. Ø The Ginners and Governments must learn from USA in this regard and sampling of each bale should be done and testing centres should be established by the government similar to USDA to enhance the reliability thereby improving the realization for cotton. 4. Unskilled Manpower for Operation of Ginneries : Ø The settings and maintenance of ginning machinery has significant effect on gin efficiency, energy consumptions and processing costs. It also affects to a great extent the quality of cotton produced from a ginnery. Ø The gin setting is an art that can be perfected through practice under supervision of skilled trainers. The skill of the operators decides the quality bales produced from a ginnery. Ø The availability of trained manpower in the ginneries is rare; hence, many ginneries operate with unskilled manpower that causes the deterioration of quality parameters and foreign matters present in bales. Ø Hence, it is extremely essential that the training facilities should be established for training of ginning operators and trained manpower should be employed to maintain the quality of bales produced from ginneries. & FIBRE The selection of a Ginning technology should depend upon factors like harvesting practices, trash contents, moisture contents, fibre length fuzziness, strength etc. rather than primarily on capital cost, funding institution etc. To understand better it is useful to discuss about the four ginning technologies used in the world : 1. Saw Ginning : Ø Two types of saw ginning are being used in the world (i) Brush Doffing type & (ii) Air Blast type. Ø Some saw gins use 16 gin saws while some use 12 gin saws which have different economics. Ø Saw ginning is more suitable for upland cotton, which adheres strongly to the seed and requires higher force to detach it from the seed and length of the same is below 29 mm. This Ginning technology is having around 50% share in the world cotton ginning. Ø The productivity per unit of electrical consumption is higher in case of brush type saw gins as compared to air blast type saw gins. 3

4 26/10/17 & FIBRE - SAW GINNING Pic 1 : Saw Gin Machine & FIBRE - SAW GINNING Pic 2 : Working Principle of Brush Type Saw Gin Pic 3 : Working Principle of Air Blast Type Saw Gin Machine & FIBRE SAW GINNING & FIBRE 2. Double Roller Ginning : Ø Several studies have demonstrated that saw ginned lint is shorter (0.5 to 1 mm), less uniform and contained more neps than roller ginned lint. Ø The saw ginning technology is most suitable for high strength, high maturity cotton varieties having length up to 29 mm, therefore this technology should be selected for ginning of suitable varieties only. Ø In case long fibre are ginned on saw ginning the residual fibre on seed is higher, hence need for compulsory delinting arises, which increases the cost of processing, also the fibre obtained is shorter in length therefore generates lower value. Ø This ginning technology is more suitable for clean cotton having above 29 mm length either for fuzzy long staple varieties or sea-island black / naked seeded varieties and preserves fibre parameters near to maximum. This technology is extensively used in India & Eastern Africa & having about 35% share in the world cotton ginning. Ø Double Roller Ginning technology is most suitable for clean and opened long and extra long (28 mm and above) cotton varieties with medium strength (micronaire in the range of 2.2 to 4.2) whether fuzzy seeded or sleek / black seeded having trash in size below 6 mm so that the same may pass through grid. Ø Since the seed coming out of Double Roller gin is having lower fuzz remaining on seed, the seed can be crushed for oil milling without delinting and oil to seed ratio is better. The neps generation is much lower in this ginning technology. & FIBRE DOUBLE ROLLER GINNING Pic 4 : Double Roller Gin with Auto Feeder Pic 5 : Working Principle of Double Roller Gin & FIBRE DOUBLE ROLLER GINNING Pic 6 : A view of Double Roller Gin Plant 4

5 26/10/17 & FIBRE & FIBRE ROTOBAR GINNING 3. Rotobar Rotary Knife Roller Ginning : Ø This technology is more suitable for sea-island or long staple cotton where the fibre does not strictly adhere to the seed and the lint can be pulled off, leaving the seed naked i.e. no fuzz on it due to which it comes out very easily and production rate of lint per hour is much higher i.e. 400 kgs. to 800 kgs. per hour, for such cotton as compared to other roller ginning machines where the production rate is between 50 kgs. to 150 kgs. lint per hour. Ø If fuzzy seeded cotton is used for Rotobar, the production rate comes down drastically i.e. almost half, moreover seed cut and un-ginned cotton getting mixed with ginned cotton seed is faced due to which this technology is not being widely preferred for fuzzy seeded cotton. Ø In case of fuzzy seeded cotton, the production rate per unit of power consumption also is adverse for rotary knife roller gin as it uses 15 HP electrical motor as against 5 HP electrical motor for double roller and single roller gin. Pic 7 : Bajaj Continental Phoenix Gin Pic 8 : Working Principle of Rotobar Rotobar Gin & FIBRE - ROTOBAR GINNING & FIBRE Pic 9 : A view of Rotobar Gin Plant 4. Single Roller McCarthy Ginning : Ø Single Roller Ginning technology is one of the earliest roller gin in which the separation of fibres and seed occurs by gentle pulling of fibres by using a roller. This technology has long been preferred method for ginning extra long staple, fine fibred sea island cotton, Egyptian cotton and Pima cottons (Bennett 1956) while it is possible to gin all types of cotton on single roller gin but it is more suitable for long and extra long cotton varieties and retains maximum natural fibre parameters of the cotton during the ginning, however major disadvantage of McCarthy single roller gin is its lower ginning capacity (about 25 kgs to 40 kgs. lint per hour) though only 5 HP electrical motor is required per single roller machine similar to double roller gin machine. Ø The Single Roller ginning technology can handle higher trash and also gin all kind of cotton whether fuzzy seeded or sleek / black seeded, however the production per unit of electricity consumption and per sq. meter area of space is costly as compared to other technologies, hence the cost of ginning and maintenance is higher as compared to other roller ginning technologies. & FIBRE - SINGLE ROLLER GINNING Pic 10 : Working Principal of Single Principle of Roller Gin Pic 11 : A typical Single Roller Gin & FIBRE - SINGLE ROLLER GINNING Pic 12 : A view of Single Roller Gin Plant 5

6 26/10/17 1. Capital Cost for Ginning & Pressing Factories : (a) Seed Cotton unloading and Storage section: There are different sections of ginning factories which contribute capital cost difference in the ginning and pressing factories. (a) Seed Cotton unloading and Storage section: There are alternative cost effective methods with a combination of less or more manpower depending upon availability of manpower in the area of ginning factory installation, such as telescope, tractor attachments, automated unloading by hydraulic movable base of cotton carrying vehicles and cost effective suitable selection of the method of seed cotton unloading may reduce the capital cost. Pic 13 : Unloading of seed cotton by Tractor Attachment Pic 14 : Unloading of seed cotton by Telescope (b) Seed Cotton Drying System : (b) Seed Cotton Drying System : Ø Many a time drying of cotton in ginneries is bypass even when incoming moisture percentage is higher than recommended, this reduces gin productivity and quality of fibre as cleaning and ginning machines operate optimally at 6 to 8% moisture contents. Ø There are different options of drying available such as hot air drying, blowing of hot air, open spreading of cotton in natural sun in storage area etc. Pic 15 : Vertical Flowr Dryer Pic 16 : Open spreading of cotton in storage area (c) Seed Cotton Conveying & Cleaning System : (c) Seed Cotton Conveying & Cleaning System : Ø The selection of seed cotton conveying and cleaning equipments should be based on actual requirements and not as per the practices which are used in the ginning factories where different parameters cotton is ginned. Ø It is found that in many cases additional cotton conveying and cleaning equipments are installed and used only because of ignorance about the actual requirement of the cotton varieties and parameters available in the area where the ginning factory is to be installed. Ø In the Western African countries though the cotton is handpicked clean but in many cases full set of cleaning and conveying machinery which is used for mechanically picked cotton has been installed, which is causing some extra damage to fibre and extra power consumption apart from incurring heavy capital cost. Pic 17 : Desired cleaning setup Pic 18 : Excess cleaning & conveying setup for Handpicked cotton in case of Handpicked seed cotton but required for machine picked seed cotton 6

7 26/10/17 (d) Uniform Seed Cotton Feeding Systems : (d) Uniform Seed Cotton Feeding Systems : Ø The manual feeding of seed cotton in ginneries increases foreign matters, manpower requirement and processing costs. In addition, manual feeding of seed cotton to belt conveyor/suction system results in non-uniform feeding to gin machines that results into about 20% less gin productivity leading to increase in cotton processing costs. Ø In order to address this issue, a cotton dispenser cum cotton feed control system has been recently introduced in ginneries to achieve uniform feeding of cotton. This feeding system reduces manpower requirement and saves about 25% power requirement and energy consumption in seed cotton conveying and also addresses the issue mixing of foreign matters by avoiding human intervention. Ø Hence, the cotton dispenser cum cotton feed control system should be employed in ginneries to reduce power requirement, energy consumption, manpower and capital investment and improving cotton grades. (d) Uniform Seed Cotton Feeding Systems : Pic 19 : Big J Seed Cotton Feed Control Pic 20 : Seed Cotton Dispenser with Stone removers (e) Seed Cotton Cleaning Systems : Ø Seed cotton cleaning is very important aspect in maintaining the quality of cotton processed in ginneries. There are a number of machines such as cylinder type cleaner, stick machine, impact cleaner, extractor cleaner, etc. available for cleaning of seed cotton. Ø The selection of cleaners for a ginnery is decided upon the amount of foreign matters present in seed cotton. Ø The handpicked cottons having 2-3% trash content can be optimally cleaned using a line of cylinder type cleaner having 4-6 spiked cylinders. Pic 21 : Seed Cotton Feeding through Pic 22 : Seed Cotton Feeding Central Distribution Conveyor through Trolley Systems. (e) Seed Cotton Cleaning Systems : Pic 23 : Pre-cleaner for Handpicked cotton Ø Suitable cleaning set up may be selected based on presence of foreign matters in seed cotton to reduce capital investment and improve fibre quality parameters. (e) Seed Cotton Cleaning Systems : Pic 24 : Impact Cleaner for Leaf Trash Pic 25 : Stick Machine for Cleaning Pic 26 : Stripper Cleaner for Cleaning Machine picked Seed Machine picked Seed Cotton Cotton 7

8 26/10/17 (f) Cleaning of Semi-closed boll cotton : (f) Cleaning of Semi-closed boll cotton : Ø There are some varieties of the cotton like V797, CJ73, Wagad, Kalagin etc. in India, where the cotton bolls are not fully opened hence the cotton cannot be picked in this case, it has to be removed from the plant alongwith cotton boll. This may be termed as hand stripping rather than hand picking. Ø Similar cottons are also produced in some other countries like Pakistan and Turkey Urfa region etc. and require special type of cleaning where the pod is first to be broken and then its pieces as well as the leafy trash has to be separated from the fibre and removed. The selection of cleaners for a ginnery is decided upon the amount of foreign matters present in seed cotton. Ø This requires a special cleaning machine which is normally manufactured in India. Pic 27 : Pod /Leafy Trash Cleaning Machine for close boll Seed Cotton Pic 28 : Pod/Leafy Trash Cleaning Machine for close boll Seed Cotton (g) Seed Cotton Ginning Machinery Section : Ø This is most critical area of machinery selection for cotton ginning factories as this can affect the fibre parameters and recovery significantly, such as if Single roller or Rotobar gin is selected for fuzzy seeded clean and open varieties, it may cause higher electrical power, lower production per unit, finally affecting the cost substantially. (g) Seed Cotton Ginning Machinery Section : Type of Roller Gins Ø Similarly, if the saw ginning is selected for long and extra long staple cotton, it may cause damage to fibre and reduction in the yield finally affecting the cost in substantial manner. Ø If the roller ginning is selected for seed cotton having fibre below 28 mm and extra strength, it may cause higher cost. Ø The proper selection of cotton ginning machinery suitable to cotton parameter is utmost necessary to obtain optimized fibre parameter to improve the pricing of cotton lint and seed as well as further processing costs of cotton fibre and cotton seed. (g) Seed Cotton Ginning Machinery Section : Type of Saw Gins Pic 29 : Saw Gin Pic 30 : Phoenix Rotobar Gin Pic 31 : Double Roller Gin (h) Cotton Lint/ Fibre Conveying from Gin to Lint cleaning Section : There are alternative methods of cotton lint / fibre conveying from each gin to lint cleaner such as Continuous Individual Gin Lint Suction System, Intermittent Lint Suction System, Belt Conveyors, etc. Proper selection of the system can save lot of power and fibre parameters consequently the cost. Pic 32 : Brush Type Saw Gin Pic 33 : Air-blast Type Saw Gin Pic 34 : Individual Gin suction sys belt Pic 35 : Intermittent Lint Pic 36 : Lint Conveying suction sys (ILSS) from each gin through 8

9 26/10/17 (i) Cotton Lint/ Fibre Cleaning Section : There are alternative methods of lint cleaning such as spiked cylinder lint cleaner, saw type lint cleaner, air jet lint cleaner, moreover, the degree of cleaning differs in case of different cotton varieties depending upon trash and moisture contents. Pic 37: Spiked cylinder Pic 38 : Saw type Lint cleaner Pic 39 : Centrifugal Lint cleaner for machine picked cotton (Air-jet type) handpicked cotton Lint cleaner (j) Cotton Lint Fibre moisturizing / conditioning Section : Ø There is requirement of 8-9% moisture content in lint for formation of bales in proper shape and size of bales with optimum energy consumption. Ø Pressing of cotton with less than 8% moisture content increases energy consumption and reduces the weight of pressed bales that increases the bales transportation cost. Ø The natural wax layer present over cotton fibres does not allow cold water to penetrate into fibres resulting into accumulation of water over surface of cotton leading to formation of fibre lumps in bales, yellowing of fibres, degradation of fibres, etc. Ø The best practice for moisturization of cotton is the induction of hot humid air over lint that reduces the surface tension of fibres resulting into entering of moisture into inner surface of cotton as air passes through the fibres. The hot air humidification system improves the moisture, strength and cotton grade so ginner realises higher price for better quality lint. Hence, the hot air humidification system should be installed in ginneries to reduce energy consumptions at bale press. (j) Cotton Lint Fibre moisturizing / conditioning Section : Pic 40 : Hot air humidification system practised for restoration of lint moisture (k) Cotton Lint / Fibre Baling Section : Ø Modern up-packing/down-packing oil hydraulic, door less, double box, single stage presses are used in ginneries for bale formations. Ø Now-a-days, modern baling presses are employed along with online bale handling, weighing and bagging system that reduces the manpower requirement in ginneries. Hence, the modern ginneries shall employ modern baling presses along with bales handling, weighing and bagging system to reduce their manpower requirement. Ø Various countries are having different sizes and different weight of cotton bales, whereas the uniform standard bales as per ISO 8115 should be used worldwide which will save packing cost as well as uniform bale opening machinery in all countries. Ø The bales in size 42 x 21 (which also complies with the principle that length and width should be in proportion to 2:1 for best space utilization) proper compression i.e. about 500 kgs/m3 and uniform weight 227 kgs. (500 pound) will save shipping cost. The production of uniform baling presses worldwide will reduce the capital cost of baling presses also. (k) Cotton Lint / Fibre Baling Section : (l) Manual Loading of Cotton Bales & Non-standard sizes of Bales : Ø In the many of the ginning factories the cotton bales are made of different weights considering the strength of manpower to load it on vehicles and large number of manpower is required for this operation. Ø The alternative mechanical methods such as use of forklift or tractor attachments, have now been introduced where substantial manpower can be saved. Pic 41 : Down Packing Baling Press Pic 42 : Up Packing Baling Press Ø Further, if worldwide single standard size and weight of cotton bales is adopted, it will be easy to develop cost effective handling devices, which will save substantial costs. 9

10 26/10/17 (l) Manual Loading of Cotton Bales & Non-standard sizes of Bales : Pic 43 : Manual Packing Baling Press Pic 44 : Bale Press with Bale bagging arrangement (l) Manual Loading of Cotton Bales & Non-standard sizes of Bales : Pic 45 : Bales loading by Forklift (m) Cotton seed conveying from Gins to Storage / Packing Sections : Ø There are alternate seed conveying and packing methods such as bucket elevator and screw conveyor, roots blower blowing of seeds, bagging on multiple points manually and manual weight adjustment, online weighing and bagging etc. Pic 47 : Cotton seed conveying Pic 46 : Bales loading by Tractor attachment (m) Cotton seed conveying from Gins to Storage / Packing Sections : Pic 48 : Cotton seed Bagging Pic 49 : Cotton seed conveying Root Blower Pic 50 : Cotton seed Bagger (n) Fire Detection & Diversion System : Ø Ginneries are prone to catch fires that results in significant financial losses to ginneries. The risk of fire hazard is further aggravated due to increased automation and use of large volume of air for material handling systems. Ø Recently, the sensor based fire detection and diversion systems have been introduced that effectively control the risk of fire hazards in ginneries & reduces the manpower required for dousing of fire and to cleaning of premises after fire accident. GINNING FACTORIES 2. Electricity Consumption per unit of Production ØHigher electricity consumption per unit of production in the ginning factories is also the major contributor in the higher cost of cotton. ØIn the recent time various alternative methods have been adopted, which have resulted in substantial saving in the electricity consumption. Fox example, a normal 15 bales/hr. handpicked cotton Double Roller gin plant used to have connected load of about 600 HP till 2012, which has now come down to about 400 HP for same capacity. Some of the developments which have taken place in the recent past are mentioned below: (a)seed Cotton Suction System replaced with Seed Cotton Dispenser system with Tractor attachments : Pic 51 : Fire Detection & Diversion system for Ginneries ØThis has resulted in reduction of electrical motor power from over 50 HP to about 20 HP for entire system for about 15 bales/hr. plant. 10

11 26/10/17 2. Electricity Consumption per unit of Production (a) Seed Cotton Suction System replaced with Seed Cotton Dispenser system with Tractor attachments : Pic 52 : Seed Cotton Suction System 2. Electricity Consumption per unit of Production Electricity Consumption per unit of Production (a) Seed Cotton Suction System replaced with Seed Cotton Dispenser system with Tractor attachments : Pic 54 : Cotton Seed feeding by Tractor Attachment Pic 53 : Cotton Seed Dispenser cum Stone Removing Electricity Consumption per unit of Production (b) Conveying of Seed Cotton by suction replaced with Belt Conveyors System : (c) Individual DR Gin Feeding Distribution Conveyor replaced with Central Distribution Conveyor System : Ø This has resulted in lowering of about 50 HP electrical power for a normal 15 BHP Ginning Factory. Ø This has resulted in substantial saving (about 20 HP) in installed electrical power for the system. Pic 55 : Seed Cotton Suction Sys Pic 56 : Seed Cotton conveying by belt 2. Electricity Consumption per unit of Production (d) Lint Suction System replaced with Intermittent Lint Suction System : Ø This has resulted in lowering of installed electrical power to 10 HP as compared to earlier 30 HP for this system for a 15 BPH plant. Pic 57 : Ind. lane Distribution Screw Conveyor Pic 58 : Central Screw Conveyor Seed Cotton feeding sys 2. Electricity Consumption per unit of Production (e) Conveying of Lint by suction replaced by Belt Conveyors System : Ø The electricity cost for conveying the lint from one point to other by suction system is normally much higher as it requires high air volume such as for a 15 bales/hr. plant conveying of lint may require above 100 HP for two suction systems while by belts the same conveying may be done by 6 HP, hence there is vast difference. This has also resulted in substantial electrical power saving such as from 30 HP suction fan belt requires only 3 HP electrical power. Ø This has also resulted in substantial electrical power saving such as from 30 HP suction fan belt requires only 3 HP electrical power. Pic 59 : Conventional Cotton Lint Suction Sys Pic 60 : Intermittent Lint Suction Sys Pic 61 : Lint Suction Sys Pic 62 : Lint Conveying by belt 11

12 26/10/17 GINNING FACTORIES 3.Manpower Cost per unit of Production The manpower cost is also one of the major contributor in the final cost of cotton. In the conventional ginning factory of about 15 Bales/hr. sometime over 100 people are required however, in the recent times, various developments have taken place in the machinery used in the ginning factories, which has resulted in substantial reduction of manpower, such as for same ginning factory now about 15 people are required. (b) Online bagging & weighing of Cotton Bales instead of manual weighing: Ø Four (4) peoples were required to handle manual bagging and weighing of each bale, now only one person can handle this operation. (c) Online bagging & weighing of Cotton seeds instead of manual bagging & weighing : Ø A large number of people are required to fill the bags and weighment for cotton seed, however online bagging arrangements are available, which can substantially reduced the manpower requirement in this field. (a)seed Cotton Suction System has been replaced with tractor mounted buckets feeding through dispenser units: Ø Earlier about 10 people were required to handle each suction system to feed an average 15 BPH ginning factory due to introduction of dispenser system, now it requires only 2 people. Pic 63 : Manual Seed Bagging Pic 64 : Online Seed Bagger GINNING FACTORIES 4. Wastage of Fibre & damage to Fibre Parameters : Ø A lot of fibre is wasted where excessive conveying and cleaning machinery and saw ginning technology is used inappropriately for handpicked long staple clean cotton. In all these cases appropriate roller ginning technology should be used. Ø Use of excessive conveying and cleaning machinery and saw ginning technology for handpicked clean cotton results in damage to the fibre parameters such as excessive neps formation, length cut, brittleness due to higher speed etc. which also affects the spinning parameters as fibre rapture at blow room goes up, blow room waste goes up, CSP goes down and the average speed of ring frame has to be kept low. Ø It is necessary that the cotton conveying, cleaning, ginning and pressing machinery is selected carefully considering all the parameters so that optimized results are obtained. GINNING FACTORIES 5. Over Capacity Installation for Ginning & Pressing Plant : Ø Most of the ginners try to install excess capacity equipments such as if they have immediate requirement of 10 bales/hr. capacity, they tend to install the baling press of 20 bales/hr. and also keep half space in the ginning area unutilized for future expansion, this in many cases result in higher capital cost and higher recurring charges as the idle power utilization for many system is on higher side which incurs higher costs. Ø In many cases future expansions do not take place, and ginning and pressing factory continue to pay extra electricity charges and interest on extra capital cost spent on excess capacity provisions. Ø Therefore in normal course the planning of ginning and pressing factories should be exactly done as per current needs and for future expansion fresh plant should be considered so that the current operation is always lean and thin and excess capital cost and extra cost of on account of electricity etc. is not incurred. GINNING FACTORIES 6. Ginning of different varieties on same technology even when not suitable: Ø In the areas where short staple and long staple varieties are grown and the picking methods are also machine picked as well as handpicked, a careful consideration should be given to select the proper ginning technology for each variety and each type of cotton, so that extra wastage or extra processing of any fibre is avoided. Ø Separate technology plant for each type of cotton may be suitable even if somewhat lower volume of each variety is available as the effect of price of cotton lost may be much more higher than the cost of separate ginning facility over a period. 7. Improper Utilization of Co-products / By-products : Ø Majority of ginning factories do not optimize the use of co-products / byproducts which are generated in the ginning factory such as cotton seed, linters etc. If the use of these products is optimized extra revenue can be generated and the competitiveness may be improved. RECOMMENDATIONS (A) Best Practices to be considered by Ginning & Pressing Factories 1. Purchase of Correct Machinery : The cotton loading-unloading, conveying, drying, cleaning, ginning, humidification, baling and handling machinery should be selected considering practical capacity requirement, level of drying and cleaning required, suitability of ginning technology to fibre parameters for cotton to be ginned, lowest electrical power consumption per unit of production, lowest capital cost and lowest manpower requirement. 2. Future Expansion Provision : Provision for future expansions in the same plant should be avoided until immediate future requirement is clear and confirm in short term. 3. Adoption of New Technologies : The latest alternative methods / equipments of handling, conveying, drying, cleaning, and fibre friendliness should be selected. 12

13 26/10/17 RECOMMENDATIONS (A) Best Practices to be considered by Ginning & Pressing Factories 4. Skilled Manpower : The skilled manpower for operation of ginning and pressing machineries should be appointed or the training which may be available from machinery manufacturers or various institutions available for training of ginning technicians like Ginning Training Centre in India, should be used for training to operators etc. 5. Upgradation of Existing Machinery : The existing ginneries should replace their old and high cost less efficient cotton handling, drying, conveying, cleaning, ginning, humidification, etc. machinery with the alternative advanced cost effective fibre friendly machinery developed in the recent times. 6. Increased Communication with Spinning Mills & Buyers : The ginners, cotton association throughout the world should make it a point to regularly interact with spinning mills and other buyers to better understand their requirements and consider the same while processing the cotton, which will certainly bridge the gap and the spinning mills will be in a position to offer better prices for their exact requirement, which in-turn will enhance their efficiency. RECOMMENDATIONS (A) Best Practices to be considered by Ginning & Pressing Factories 7. Optimized Utilization of By-products / Co-products : All ginners should also concentrate on better utilization of by-products / coproducts such as cotton seed, and linters etc. which will reduce the burden on prices of cotton and make it competitive. (B) Best Practices by Government Authorities & Market at Large 1. The Preparation of Trash Standards : Ø The trash standards of baled cotton grades should be prepared where they are not made or revised so that the lowest trash should be specified for grade 1 cotton as at least 1% and consecutive grades for 2% and 3% and so on up to a maximum permissible trash percentage so that options are available for clean cotton. Ø At present Indian Standard for bales BIS specifies permissible trash as 3% for extra long staple (32.5 mm and above), for long and medium staple 5%, for medium and short staple 6% while for closed boll cottons it is 10% trash content, therefore no encouragement is derived for cleaner cotton which have less than 3% trash. If the grades are increased and start from 1% trash it may help to the ginners which wish to produce cleaner cotton. RECOMMENDATIONS (B)Best Practices by Government Authorities & Market at Large 2.Standardization of Cotton Bale Sizes & Weight : Ø There should be an international consensus between all the cotton producing countries to adopt uniform bale sizes and bale weight over a period of about 10 years and a best suitable size and weight should be selected say bale size of 42 x 21 and bale weight 227 kgs. (500 Pound). Ø The government of each country should make regulations for adoption of uniform bale size by ginners and all cotton associations worldwide should promote this. 3.Sampling of each Bale : Ø The government should establish necessary testing centers in each reasonable catchment area for cotton ginning and make it mandatory that sample each bale should be taken and tested at centralized laboratory like being done in USA. Ø The trade cotton bales should take place based on test reports from these testing centers, which will be an independent report, hence trustworthy and the price realization based on same is bound to improve. CONCLUSION Ø It may be seen that if various considerations and best practices are adopted to reduce the capital cost, electrical power cost, manpower cost, measures are taken to preserve the fibre parameters, best utilization of by-products / co-products, standardization of bale weight, proper standards for trash percentage are made individual bale sample and testing is done, it will help to improve competitiveness of the cotton to a large extent. Ø It will help to improve competitiveness of the cotton to a large extent and the consumption percentage of the cotton as compared to manmade fibre may go up and the cotton can regain its market share, which in long turn will benefit the cotton sector to regain its glorious past, at the same time new uses needs to be found for increasing the consumption of the cotton so that the sustainability of increased cotton production and profitability of the cotton sector is achieved. REFERENCES 1. Anthony, W.S Overview of the ginning process. In Cotton ginners handbook, Agricultural handbook number 503, Anthony W.S., and W.D. Mayfield, eds. Washington, D.C.: USDA, ARS. 2. Anthony, W.S., and W.D. Mayfield Cotton ginners handbook, Agricultural handbook number 503. USDA, ARS, Washington, D.C. 3. Arude, V.G., S.K. Shukla, D.N. Makawan, T.S. Manojkumar, and J.M. Nath Modernization of Indian roller gins and the effect on cotton fibre quality. Journal of Agricultural Mechanization in Asia, Africa and Latin America (AMA). 41(2): Arude, V.G., S.K. Shukla, and T.S. Manojkumar Cotton ginning : technology, trouble shooting and maintenance. ICAR-CIRCOT, Mumbai, India. 5. Estur, G., and N. Gergely The economics of roller ginning technology and implications for African cotton sector. Africa Region Working Paper Series No. 129 (a). USA. 6. Faulkner, W.B Comparison of picker and stripper harvesters on irrigated cotton on the high plains of Texas. Texas A&M University, Biological and Agricultural Engineering. REFERENCES 7. Faulkner, W.B., J.D. Wanjura, B.W. Shaw, and E.F. Hequet Effects of harvesting methods on foreign matter content, fiber quality, and yarn quality from irrigated cotton on the high plains. ASABE. 8. Harmancioglu, M., and N.E. Maustafa Influence of cotton ginning techniques on the open end spinning processes and on properties of openend yarns. Melliand Textilberichte (English Edition). 2: Hughs, S.E., W.F. Lalor, and F.T. Wahba Relationship of ginning and fiber properties to dyeing imperfections. Textile Research Journal. 58: Hughs, S.E., and C.G. Leonard Roller versus saw ginning of longstaple upland cotton. The Cotton Gin and Oil Mill Press. 87: Iles, G Leading American inventors. Hony Holt and Company, New York. 12. Le, S Lint cleaning with two air-jet cleaners in series. The Journal of Cotton Science. 12: Mangialardi, G.J Effect of roller ginning on market and spinning value of Mid South grown cottons. The Cotton Gin and Oil Mill Press. 96:

14 26/10/17 REFERENCES 14. Mangialardi, J., G. J., and W.S. Anthony Cotton saw gin stand developments. USA: Educational N.C.C. 15. Mayfield, W.D., and W.S. Anthony Development of the cotton gin. In Cotton Ginners Handbook. Agricultural Handbook Number 503. Anthony W.S., and W.D. Mayfield, eds. Washington, DC,: USDA, ARS. 16. Indian Standard for Cotton Bales Specification IS Thanks! Call us for More Details: Dr. M.K.Sharma Mobile : mks@bajajngp.com Web : 14