USTER INTELLIGIN-M APPLICATION REPORT Monitoring of the ginning process THE GIN PROCESS CONTROL SYSTEM S. Dönmez Kretzschmar, A. Ellison April 2010 SE 639
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Contents 1 Introduction... 5 2 The total quality control of the ginning process... 5 2.1 What is the function of a cotton gin?... 5 2.2 Why we should monitor the ginning process?... 7 2.3 Benefits and the opportunities of the USTER INTELLIGIN... 8 3 System Features... 10 3.1 The USTER INTELLIGIN M organization... 11 3.2 The USTER INTELLIGIN-M Reports... 14 4 Field Test... 16 5 Conclusion... 19 6 Literature... 19 USTER PRODUCTS 3 (20)
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1 Introduction After the harvest, a producer wants the optimum yield possible and the spinner wants the highest quality fiber available. The ginner is asked to make both happen. Cotton ginning is an important step in the cotton production sequence. The purpose of the ginning operation is separating the cotton seed from the lint and removing sticks and coarse trash from the input material. Input materials coming from a variety of growing areas are processed together and the process acts as a first blending of massive quantities of fibers [1]. The true art of ginning is knowing when and how to use a technical advantage. Because not all cottons are the same, the ginning process requires constant monitoring based on incoming harvest qualities, fiber characteristics, picking methods and growing conditions. The USTER INTELLIGIN-M monitors and/or controls the ginning process through a system of online sampling stations located throughout the gin from the module feeder to the bale press. Information on fiber moisture, trash and color are fed into a main console where software analyzes fiber value for optimum dryer temperature and lint cleaning practices. Optional bypass valves automatically reroute cotton only through necessary equipment preserving fiber quality and reducing processing costs. From an easyto-use console, the ginner has a complete picture of all variables and can manually adjust the process or set perimeters to allow the process to run automatically. The USTER INTELLIGIN-M provides total quality control of the ginning process. 2 The total quality control of the ginning process 2.1 What is the function of a cotton gin? The principal function of the cotton gin is to separate lint from seed. The gin must also be equipped to remove foreign matter, moisture, and other contaminants that significantly reduce the value of the ginned lint. Gins (Fig. 1) must produce a quality of lint that brings the owner of the cotton maximum value while meeting the demands of the spinner and consumer. Cotton seed is an important by-product of cotton manufacture and most of the seed is crushed for oil or used for animal feed. According to the yarn producer, cotton seed represents hazard and excessive seed-coat fragments make the spinning process more difficult. USTER PRODUCTS 5 (20)
Fig. 1 Gin On the other hand, the economics of ginning are affected by the sale of byproducts, and thus they have some effect on the cost of the cotton mill. The cost of the cotton in the mill represents roughly half of the yarn cost. Not only the cost but also the quality of the product depends the total quality control of the ginning process Therefore the yarn producer must have a strong interest in the basic fiber production [1]. Fig. 2 Cotton lint and cotton seed Cotton Ginning Transportation to warehouse Warehousing / Storage Transportation to mill Preparation in Mill Fig. 3 Fiber Flow Field to Sliver 6 (20) USTER PRODUCTS
2.2 Why we should monitor the ginning process? We should monitor the ginning process because the cotton is a huge variable with different: Cotton Varieties Fiber Characteristics Picking Methods (Spindle stripper hand ) Growing Conditions Harvest Conditions Market Changing Requirements Domestic Export Because not all cottons are the same, the ginning process requires constant monitoring based on incoming harvest qualities, fiber characteristics, picking methods and growing conditions. The USTER INTELLIGIN-M monitors and/or controls the ginning process through a system of online sampling stations located throughout the gin from the module feeder to the bale press. Information on fiber moisture, trash and color are fed into a main console where software analyzes fiber value for optimum dryer temperature and lint cleaning practices. The USTER INTELLIGIN provides total quality control of the ginning process (Fig. 4). Thus the ginner has a complete picture of all variables and can manually adjust the process or set perimeters to allow the process to run automatically. High Moisture Max Drying Intelligin Zone Maximum Advantage High Trash Domestic Export Low Trash Intelligin Minimum Advantage Low Moisture Min Drying Fig. 4 Process Control Decisions USTER PRODUCTS 7 (20)
2.3 Benefits and the opportunities of the USTER INTELLIGIN In Table 1 and in the following figures (Fig. 5 to Fig. 9) we can see the measurement and control opportunities and benefits of the USTER IN- TELLIGIN-M during the ginning process. Ginning Process Sections of Gin Measurement Opportunities Control Opportunites Benefits Figure Seed Cotton Entry Into Gin 1. Module Feeder 2. Suction Telescopes 3. Big-J Feed Control - Incoming Moisture - Incoming Trash - Feed Rate Seed Cotton - Gin Performance - Trash Levels Cleaning % Efficiency Fig. 5 Seed Cotton Cleaning & Drying 4. Vertical Flow Drier 5. Incline Cleaner 6. Stripper Cleaner 7. Stick Machine 8. Tower Drier 9. Incline Cleaner 10. Impact Cleaner - Temperature for Drying - Quantity of Pre- Cleaning Stages - Maximized Yield - Gin Performance - Fiber Quality (Length, Neps, Trash, Strength - Energy Costs Fig. 6 Ginning Separation of Seed and 11. Conveyor Distributor 12. Feeder 13. Gin Stand - Moisture - Temperature for Drying - Optimized Moisture for Ginning - Fiber Quality Fig. 7 Trash Removal From Lint 14. Centrifugal Cleaner 15. 24-D Tandem Lint Cleaners - Trash Level in Lint - Color - Moisture - Quantity of Lint Cleaners - Quantity Grid Bars (Louver Control) - Maximized Yield - Fiber Quantity No Unnecessary Cleaning - Fiber Quality - Maximized Value Based on Market Criteria Fig. 8 Baling Final Package 16. Battery Condenser 17. Covered Lint Slide 17. Moisture Addition 18. Belt Feeder 19. Bale Press 20. Bale Tying 21. Bale Bagging and Conveying - Trash Final - Color Final - Moisture in Lint After Cleaning - Moisture in Bale - Feedback to Prior Measurements - Moisture Restoration - Maximized Yield - Immediate Knowledge Grades for Merchandizing - Final Color & Trash Grades for Allocation & Storage - Final Moisture Optimized - Warehousing Efficiencies Fig. 9 Table 1 The measurement and control opportunities and benefits of the USTER INTELLIGIN -M 8 (20) USTER PRODUCTS
Fig. 5 Seed Cotton Entry Into Gin Fig. 6 Seed Cotton Cleaning & Drying Fig. 7 Ginning - Separation of Seed and Lint Fig. 8 Trash Removal From Lint Fig. 9 Baling - Final Package USTER PRODUCTS 9 (20)
3 System Features The basic USTER INTELLIGIN-M system is for monitoring, information, and database collection purposes only. The system includes one measurement station at lint flue. The USTER INTELLIGIN-M system provides leaf grade, % trash, color grade, extraneous matter identification, and lint moisture measurement at lint flue. Reports on machine use, moisture, leaf and color as well as gas & electricity use on a per bale basis if outputs are provided. There are also some additional available options or measurements: Louvered Grid Bar Control Incoming module moisture Final Bale moisture Energy Monitoring Machine Efficiency Monitoring The Monitor system gives gins with hands on management the necessary tools for processing quality cotton. This system will monitor the gin process from manual changes and adjustments. Ginners can use realtime information to make decisions for setting dryer temperatures and determining leaf grades. The Control system constantly controls the gin to set specifications without constant manual changes, leaving the ginner to focus on labor and maintenance issues. Monitor or Control system Real-time measurement of fiber color, trash and moisture Patented color and trash sensor technology to HVI modules Reporting software for an up-to-the-minute data analysis Control system only Patented decision making software algorithms Main console with touch screen controls that integrates into current gin control database Automatic control of dryer temperature for optimum fiber moisture Automatic control of seed cotton and lint cleaner bypass valves 10 (20) USTER PRODUCTS
3.1 The USTER INTELLIGIN M organization The following diagrams shows us the USTER INTELLIGIN-M organization and the system layout of the sampling station and the USTER INTELLIGIN host console in the gin (Fig. 10 and Fig. 11). Gin Office Gin Internet Real Time Display Real Time Display Remote Service and Support Process Measurements Reports Remote Monitoring by Gin Mgmt USDA Information Input for Calibration Gin Console Sampling Station Fig. 10 The USTER INTELLIGIN M organization IntelliGin host console Sampling Station Fig. 11 System layout in the gin The system has a sampling station and a host console. Positioned just past the lint cleaners, this station gives a final reading of fiber moisture, trash and color to ensure the accuracy of the decisions made before cotton enters the bale press. This information is used to give feedback to ginners so that they might make adjustments to the ginning process to optimize fiber qualities, yield and moisture content (Fig. 12 and Fig. 13) USTER PRODUCTS 11 (20)
Fig. 12 Lint Flue Sampling Station Fig. 13 Lint Flue Sampling Station In Fig. 14, we can see the sampling station and all sensors such as paddle sampler, moisture measuring sensor and the USTER HVI color head. Paddle Sampler Moisture Measuring Sensor HVI Color Head Fig. 14 Sampling Station Open, showing all sensors 12 (20) USTER PRODUCTS
The main console gives the ginner a complete summary of the ginning process. It provides information that is necessary for the ginner to make informed decisions to improve fiber moisture levels, and preserve fiber properties (Fig. 15). Fig. 15 Gin Host Console By using this system, the user can make reliable cotton value decisions by using real time information which is obtained by the USTER INTELLIGIN M. Classer s Trash Leaf Grade Measurement (% area) 1 <= 0.08 2 <= 0.12 3 <= 0.18 4 <= 0.34 5 <= 0.55 Too little cleaning may allow higher grade creating discount Lint Bale Cleaners Weight 0 516 1 498 2 490 Too much cleaning costs yield, as much as 8# for second LC The ginner will learn that in some cases better leaf grade is not possible. Then the best strategy is to maximize yield by accepting the discount. Length 32nds nds HVI Length (Inches) 32 0.99-1.01 33 1.02-1.04 34 1.05-1.07 35 1.08-1.10 36 1.11-1.13 37 1.14-1.17 Too much cleaning will shorten fiber. Fig. 16 the USTER INTELLIGIN M Organization In Fig. 17 we can see the special model of the USTER INTELLIGIN-M which is primarily for Texas developed. The benefits are given in Table 2. Fig. 17 shows the indication of bark and grass in the cotton. USTER PRODUCTS 13 (20)
Specification Measurement Opportunities Control Opportunites Benefits Indication of bark and grass Automatic Bark & Grass Detection Quick feedback to producer Optimized ginning decisions Reduced discounts if ginning procedures will reduce contamination Table 2 The measurement and control opportunities and benefits of the USTER INTELLIGIN-M Texas Fig. 17 Indication of Bark and Grass 3.2 The USTER INTELLIGIN-M Reports The USTER INTELLIGIN-M gives the user easy-to-read graphical reports and provide summaries and in-depth analysis of bale characteristics for producers (Fig. 18). Fig. 18 Report 14 (20) USTER PRODUCTS
The trends for process improvement are also available for gin administration (Fig. 19). Fig. 19 Display of the USTER IN- TELLIGIN The reporting package delivers analytical reports that detail every level of the ginning process. Reports such as color grade, leaf grade and moisture provide value to producers, while production and shift reports are essential to improving gin profitability.the monitoring of the final bale moisture enables the ginner to see the realtime results of the ginning process as it affects the moisture of cotton (Fig. 20). Fig. 20 Graphs of the bales USTER PRODUCTS 15 (20)
Moisture of cotton is critical when decisions are being made to optimize the dryer settings. The final bale moisture sensor also allows the ginners to see the results of any supplemental moisture restoration system. Research shows that optimum moisture level in a bale is 7.5%, matching USDA conditions for classing cotton. Achieving this balance depends on accurate measurements throughout the ginning process (Fig. 21). Fig. 21 Actual dryer temperatures 4 Field Test During a field test, we have taken cotton from the same cotton field. The yield has been made under the same conditions and the same amount of raw material has been processes first time by using (active) the USTER INTELLIGIN and the second time without using (passive) the USTER IN- TELLIGIN. These cotton bales are tested by using the USTER HVI. When we look at the percentage of the total measured bales which are ginned with the USTER INTELLIGIN, the fibers shorter than 34 mm are only 1%. The bales which have fiber lengths of 37 mm or more have a percentage of 70%. On the contrary, the bales which are ginned without the USTER IN- TELLIGIN have generally lower mean length values (Fig. 22). 16 (20) USTER PRODUCTS
80 70 60 Without Intelligin 58 With Intelligin 70 50 40 30 20 24 29 18 10 0 1 < 34 35-36 > 37 Fig. 22 USTER HVI length values When we look at the percentage of the total measured bales which are ginned with the USTER INTELLIGIN, the fibers with a strength value of 28 or less are only 24%. The bales which have fiber strength of 30 [cn/tex] or more have a percentage of 52%. On the contrary, the bales which are ginned without the USTER INTELLIGIN have generally lower mean strength values (Fig. 23). 60 50 40 41 Without Intelligin With Intelligin 34 52 30 24 25 24 20 10 0 < 28 29 > 30 Fig. 23 USTER HVI strength values In Fig. 24, we can see that the bales which are ginned with the USTER INTELLIGIN have generally better uniformity values. USTER PRODUCTS 17 (20)
90 80 70 60 50 40 30 20 10 0 Without Intelligin With Intelligin 77 55 44 14 9 1 77-79 80-82 83-85 Fig. 24 USTER HVI uniformity values In Fig. 25, we can see the quality characteristics of the cotton fibers. The mean values of neps, the upper quartile length (w) and short fiber content are given. According to the USTER AFIS values, we can easily see the positive effect of the USTER INTELLIGIN on the fiber quality (Fig. 25). 350 300 310 Without Intelligin With Intelligin 250 200 206 150 100 50 30 0 Neps [1/g] 16 Seed Coat Neps [1/g] 12.4 8.3 1.13 1.21 UQL [mm] SFC [%] Fig. 25 USTER AFIS values 18 (20) USTER PRODUCTS
5 Conclusion The USTER INTELLIGIN -M provides a cotton ginner with critical data, enabling the gin to process for weight and grade optimization. Using patented sensor technology, the USTER INTELLIGIN-M monitors the ginning process quality through a system of online sampling stations. Online measurements provide information on moisture, color and trash for optimum processing. The special software analyzes the fiber quality for optimum dryer temperature and cleaning practices. Cotton is not over- or underdried or over- or undercleaned preserving grade and bale weight. With the optional final bale moisture system, the USTER INTELLIGIN also ensures that producers get the most value for their cotton while preserving fiber quality. 6 Literature 1. Lord, P. R., Handbook of Yarn Production: Technology, Science and Economics, Woodhead Publishing Limited, 2005. USTER PRODUCTS 19 (20)
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