bo5 bajaj - international cotton advisory committee · 2017-10-26 · Ø excellent source for...

26/10/17

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Producing&ConservingBy-productsintheCottonValueChain–

AGinningMachineryManufacturer’sPerspective

ByMr. LavBajaj,Bajaj Steel Industries Ltd,Nagpur,Maharashtra,India

At5th Breakout Session of 76th Plenary Meeting ofInternational Cotton Advisory Committee atTashkent,Uzbekistanon26thOct,2017

ABSTRACT Ø  Each and every part of the cotton crop including its stems, flowers and

roots barks are valuable & have tremendous potential to enhance the

profitability of all stakeholders including Farmers & Ginners.

Ø  Very stiff competition from manmade fibers has resulted in shrinking of

profit margins of all stakeholders.

Ø  There are several cotton by-products which are either under utilized or

disposed off without any value addition.

Ø  Large amount of cottonseeds are still processed world-wide using

traditional methods leading to loss of linters & less recovery of oil.

Ø  Cotton stalks, a valuable source for generating renewable energy in

addition to producing briquettes & pellets, are still burnt in field causing

environmental pollution & soil degradation.

INTRODUCTION Ø  Cotton sector - Generates employment & income, alleviates poverty &

helps in sustainable development.

Ø  Seed Cotton - Total dependency of farmers & ginners on production,

marketing & processing of seed cotton is no longer remunerative.

Further value addition for sustainability & profitability.

Ø  Share of cotton in textile products - Depleting day by day & therefore,

uses of its by-products need to be explored.

Ø  Two levels of by-products involved in the cotton value chain :

1) By-products available at farm level – i.e. Cotton stalk & other

Cotton plant residues.

2) By-products available after ginning – i.e. Cotton Seeds, Gin Wastes,

Linters & its derivatives.

2. VALUE ADDITION OF COTTON CO-PRODUCTS / BY –PRODUCTS

2.1 Cotton by-products available at Farm Level prior to Ginning :

Cotton Stalk - The major by-product available at the farm level is Cotton

Stalk after picking of seed cotton.


2.1 Cotton by-products available at Farm Level prior to Ginning :

100 mn tons of Cotton Stalk is generated every year and mostly left

unutilized & burnt in the field.

Ø  It can be used to manufacture - briquettes, pellets, particle boards, pulp

& paper, corrugated boxes, cellulose derivatives, etc.

Ø  Excellent source for generating renewable energy.

Ø  Net energy of 39,028 MJ/ha can be produced from a cotton field.

Ø  Root Barks, Leaves and Flowers - The entire cotton plant can generate

extra revenue to farmers.

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2.11. Cotton Stalk Briquettes :

Ø  Briquetting - A process of densification of agro-residues to produce

homogeneous uniformly sized solid pieces of high bulk density.

Ø  Used as Boiler fuel

Ø  Piston Press & Screw Extrusion – High pressure technologies used

for preparation of Biomass Briquettes.


Machines & different value added products that can be economically

prepared from Cotton Stalks & other plant parts are shown -


2.12. Cotton Stalk Pellets :

Ø  Pelleting - A process of densification of biomass into homogenous,

uniformly sized solid circular pieces of 6-12 mm dia & 25-30 mm length.

Ø  Easy to handle & burn easily due to its uniform shape & size.

Ø  Environmental concerns of cutting woods have forced the wood pellet

manufacturers to use agro-biomass based fuel pellets.

Ø  Biomass based pellets – Used as fuel for different applications i.e.

heating, power generation, cooking etc.

Ø  Premium grade pellets can be easily prepared from cotton stalks.

Ø  Cotton Stalk Pellets - replaced LPG cylinders for cooking food in several

restaurants in India as it costs less and provide smokeless flames.





Ø  Plants of 60 - 80 TPD commercially used for manufacturing pellets.

Ø  Small scale pelletizer machines of 3 - 5 TPD capacity is also available in

the market.

Ø  Power requirement is a concern to the pellet manufacturers.


2.13. Cotton Stalk Particle Boards :

Ø  Particle Board – A panel product produced by compressing small

particles of wood while simultaneously bonding them with an adhesive.

Ø  Particle Board – A substitute for wood in many applications i.e. paneling,

partitioning, false ceiling & furniture making.

Ø  It is also used for decorative and acoustic purposes, AC duct covering,

door panel inserts, wall panels, floor ceiling tiles, etc.

Ø  ICAR – Central Institute for Research on Cotton Technology (CIRCOT),

Mumbai, India has standardized the process for preparation of particle

boards from cotton stalks.

Ø  A ton of cotton stalk can produce finished particle boards of about 650

kg weight.

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Ø  Preparation –

Ø  1st Step - Chipping of stalks to 15-20 mm sizes

Ø  2nd Step - Milling of chipped particles to 8-20 mesh sizes

Ø  3rd Step - Drying of milled material to 1-2 % moisture level

Ø  4th Step - Mixing of chips with synthetic binders

Ø  5th Step - Hot pressing of conditioned material

Ø  6th Step - Preparation of a 3-layered mat

Ø  These boards can be made water proof, fire proof, termite resistant etc.




2.14. Power Generation From Cotton Stalks :

Ø  Power Generation - Good source for generating clean renewable

energy. 1 MW electrical energy per hour can be generated from 2 tons

of cotton stalks.

Ø  Great potential to replace fossil fuels resulting in mitigation of

greenhouse gas emissions which is responsible for climate change &

global warming.

Ø  Method of generating electricity from Cotton stalks –

Ø  1) Chipped cotton stalks of 10-15 mm sizes are fed to a boiler.

Ø  2) Steam generated is used for operating steam turbines that produce

electricity.


2.15. Medicines from Cotton stalk root barks :

Ø  Root barks – Used as a herb to alleviate labour pains.

Ø  Medical practitioners also administer a tea prepared form the cotton root

to treat irregular menstruation cycles.

Ø  Medicinal value derived from cotton root is also used to treat diarrhea,

dysentery & asthma.


2.16. Medicines from Cotton flowers & leaves:

Ø  Cotton Flowers - Very good medicinal properties. Can help treat cough,

cold & acidity.

Cotton leaves - Infused in vinegar & applied externally to heal headaches.

Used as a balm.

2.17. Other Potential Uses of Cotton Stalks :

Ø  Used for preparation of biochar, bio enriched compost and 2nd

generation bio-ethanol, etc. Also used for Biomass driven industries.

Ø  Ginning Machinery manufacturers need to be geared up to provide the

required machinery for setting up of briquetting, pelleting & particle

board manufacturing plants.

3. CO-PRODUCTS /BY- PRODUCTS AFTER GINNING OF SEED COTTON

3. By Products after Ginning of Seed Cotton –

Ø  Two Major By-Products - Cottonseeds & Gin wastes.

Ø  1) Cottonseed contains about 8% linters, 27% hulls & 65% kernels

which contains 18-20% oil.

Ø  2) Ginning wastes consists short fibres, bracts, cotton stems, leaves etc.

Ø  Cotton seed is normally processed by two ways :

•  Traditional Methods.

•  Scientific Methods.

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Traditional Methods of Cottonseed Processing :

Ø  Traditional method - Adopted due to requirement of few number of

machines, less investment, less power requirement etc. In this method,

1) Whole cottonseed is directly crushed in screw type expellers without

removal of linters & hulls.

2) Two-third oil is extracted from cottonseed while remaining one-third

goes with the cakes.

Ø  Linters are lost in this method.

Ø  Cakes produced are low in protein & have high fibrous content.


Scientific Methods of Cottonseed Processing :

Ø  Entire oil content, linters & hulls are recovered from cottonseed.

Ø  De-oiled cake is free from harmful fibers & has high protein content.


Scientific Methods of Cottonseed Processing :

Several Valuable products are obtained from cottonseed, which are

otherwise lost. E.g. India is the largest producer of Cottonseed, but only 5%

is scientifically processed.

Non-adoption of Scientific processing is high power requirement, high

energy consumption, large size of machineries available in the market, etc.

There is a need for energy efficient machineries, small capacities for

economically viable scientific seed cotton processing.


3.1. Cottonseed Oil :

Ø  Cottonseed oil – One of the best vegetable oil available for human

consumption.

Ø  Most suitable for cooking.

Ø  Safe store period higher than other oils.

Ø  Neutral taste, enhances natural taste of foods.

Ø  Heart friendly oil rich in Vitamin E and free from bad cholesterols and

contains polyunsaturated fatty acids and linoleic acid.


3.2. Cottonseed Meal :

Ø  Rich source of protein (40-42%) for animal feed.

Ø  Rich in essential amino acids except lysine.

Ø  Improvement of lysine content & reduction of gossypol content makes it

a valuable protein for non-ruminants feed application.

Ø  A pilot plant facility for degossypolization of cottonseed meal is

developed with 100 kg/day capacity at ICAR- CIRCOT , Nagpur, India.


3.3. Cotton Linters :

Ø  Linters - Fuzzy short fibres attached to the surface of cottonseed.

Ø  Rich in cellulose and are used for the manufacture of a number of

cellulosic products.

Ø  Uses – Preparation of currency grade paper, filter paper, stuffing

beddings etc. Bleached cotton linters used by ordinance factories.

Ø  First cut linters are longer & whiter & are used in non-chemical markets.

Ø  Second cut linters are mainly used in chemical industry.

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3.4. Cottonseed Hulls :

Ø  Hulls - Outer covering of cottonseed

Ø  Used as roughage in cattle feed. Also blended with cottonseed meal to

prepare the balanced rations for cattle.

Ø  Used in petroleum drilling operations for filling the drilled holes.


3.6. Gin Wastes :

Ø  Small fibres coming out during the cleaning process – Used as

substitute for linters.

Ø  Sticks & burs – Used for preparation of composts, briquettes, pellets,

cotton based mulches and bio-degradable packaging materials, etc.

4. CONCLUSION

Ø  Shrinking Profit Margins - The market share of cotton fibres are

decreasing day by day as compared to manmade fibres.

Ø  The processing of by-products is either neglected or insignificant,

leading to loss of valuable materials & opportunities for all stakeholders.

Ø  Significant progress has been made towards utilization of cotton by-

products for development of newer & innovative products such as nano-

cellulose from linters, briquettes & pellets from cotton stalks as

renewable fuels and biodegradable packaging materials from gin

wastes.

Ø  This has opened a new avenue for development & supply of latest up-

to-date machinery for Gin Machinery Manufacturers.

Thanks ! Call us for More Details: Mr. Lav Bajaj Mobile : +91 9325132302 Email : [email protected] Web : www.bajajngp.com

bo5 bajaj - international cotton advisory committee · 2017-10-26 · Ø excellent source for...

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