INDEX:

NAME OF INDUSTRY

TYPE OF INDUSTRY

CERTIFICATE OF INDUSTRY ON COMPANY LETTERHEAD

INTRODUCTION TO GINNING PROCESS

PROBLEM/ISSUE IDENTIFIED AND THEIR SOLUTION

METHODOLOGY OF DATA COLLECTION

DATA COLLECTED

GINNING PROCESS AND FLOW CHART

METHOD OF ANALYSIS

RESULT AND CONCLUSION

NAME OF INDUSTRY: HARSHANIL AGRO INDUSTRIES PVT LTD.

UMRI, WARDHA (M.H)

PIN: 442001

NATURE OF OWNERSHIP: PRIVATE LTD. Company.

TYPE OF INDUSTRY : Cotton extraction small scale industry

SPECIFICATION :

1.EMPLOYEE 50-workers

2.RAW MATERIAL: SEED COTTON

3.FINISHED PRODUCT: PURE COTTON

4.MACHINE COST: 1.20 LAKH

5.NO.OF MACHINES: 5

6.CAPITAL INVESTMENT: 7 LAKHS

INTRODUCTION:-

Cotton ginning process is the mechanical separation of cotton fibres

from the seed-cotton (kapas). The roller ginning process for cotton was

invented by Fones McCarthy in 1840. This process mechanically separates

cotton fibres from seeds by means of one or more rollers to which fibres

adhere while the seeds are impeded and struck off or pulled loose. Most of

the ginning operations is performed by using double roller (DR) gins which

serve an important role in the ginning industries. The roller is the major

component of DR gins and one requiring considerable attention. The

peculiar gripping action or adherence of the cotton fibres to roller covering

surface is an important element in the success of roller ginning process.

PROBLEMS / ISSUES IDENTIFIED :

1.Workers have to operate under extremely unprotected conditions

where the ginning process generates miniscule fibres. Inhaling of cotton

fibres leads to the serious disease of Byssinosis.

2.when seed-cotton is processed in double roller ginning machines, the

lint is contaminated with chromium, and chromium particles are carried

into the spun yarns and cotton by-products. Specifically due to

persistent rubbing of leather clad roller over the stationary knife, during

the ginning process, very much pollution occurs, one of this is that the

lint is contaminated with chromium that is far in excess as compare to

the standard limit, gin and mill workers are directly exposed to this

carcinogenic substance.

3.The friction rate of the leather roll clad is more and diameter reduces

effectively which results in change of rolls after every 5 to 6 months and

it goes very costly.

4.With the increase in gap between leather roll and fixed snap, there is a

possibility that along with the cotton the seeds in the broken form will

also get passed.

SOLUTION:

1)To live protected from miniscule fibres, use of respirators is recommended.

However, in none of the factory any masks are provided to workers. Workers

start falling sick soon after they start working. Morbidity is very high, especially

in initial days, until workers get acclimatized. The workers repeatedly suffer

from respiratory diseases and skin related diseases.

2)To offset this problem, pollution-free rubberized cotton fabric (RCF) rollers

have been fabricated and tested in roller gins. The RCF roller covering is made

of multiple layers of fabric bonded together using a white rubber compound,

which has a surface finish conducive to high ginning efficiency. This eliminates

chromium contamination and pollution during the ginning process.

3)The friction rate of the rubberized cotton fabric (RCF) is very much less than

that of leather clad roll or chrome composite leather clad (CCLC), So we prefer

RCF roller.

FIG: Wear Rates During Dust-producing Grinding of Chrome Roller

And Eco-friendly Roller (RCF)

4)To maintain the standard gap between roller and knife we have to add a

gradually increasing load which will increase gradually with given time. That is

the load will be added at the centre of assembly (lather roll and fixed knife) or

by finding the centreline of the machine, we can add equal amount of load to

the leather rolls as shown in following figure.

fig:- Addition of load to the leather clad

METHODOLOGY OF DATA COLLECTION:

1.First overall view of ginning mill is taken.

2.We referred the manual of ginning mill machinery.

3.We made a group discussion with the workers to get the proper

information about their health issues.

4.One of the machine was made open for us, so we were able to

understand and observe the working and problems related to the

machine.

5.We keep finding the solutions related with the problems and got the help

from journal ‘Prayas Centre For Labour Studies And Action’.

DATA COLLECTED:

Cotton gin, machine is used for separating cotton fibers from the seeds. Firstly

the moisture content in the seed-cotton if present is removed. After removal

of moisture it is supplied to the hopper through supply system (by workers).

Then it is collected in the collecting drum and then pulled out with the help of

rotating trap. After collecting it is placed on the oscillating snap. At the both

side of snap plate the leather roller is present. In between roller and snap small

gap is present. The snap is oscillating, and because of oscillatory motion the

gap is alternately varying in between snap and roller, because of this small gap

only the cotton is passed through this gap the seed are thrown away through

the filter and the seed are flowing through the duct.

This ducts then meets to the screw conveyor and then this seeds are then

transferred to the seed container. The cotton extracted from the roller is then

collected and this extracted cotton is pressed with the help of hydraulic press.

The cotton is pressed up to which the weight of bell is 160-200 kg.

Fig : working principle of cotton roller ginning process

Fig: Drawing of chrome composite leather clad (cclc) washers the comprise the roller

of double roller ginning machine(all dimensions in mm)

Fig- Actual working

Fig: Inner View

Process flow Chart

Ginning Processes:

Seed Cotton Conditioning and Cleaning

Cottonseeds with fiber still attached, usually arrive at the gin in large trailers or

modules used for hauling it from the field and for storing it until ready for ginning.

From the storage area, conveyor pipes transfer it to various stages of the ginning

process, using large volumes of air to make the flow of the cotton easier and faster.

Typically, seed cotton is first dried in large driers using heated air to reduce its

moisture content. A cylinder cleaner then removes the leaves and other small trash

from the seed cotton by shaking it with spiked cylinders, while conveying it across a

screen with small openings that sift the trash released from the seed cotton by the

impact action of the cylinders.

Next, a stick machine removes any large sticks or hulls (the dried bolls that form a

shell around cotton as it grows) with revolving channel saws. These saws grab the

seed cotton and whip it over metal bars to sling off its trash. If the seed cotton

requires additional drying and cleaning, gins will often run it through another drier

and another cylinder cleaner and stick machine.

Mechanical harvesters have made seed cotton drying and cleaning necessary.

Although mechanical harvesting is much faster than hand harvesting, but

mechanical harvesters also pick more trash with the cotton, which usually contains

a high amount of moisture. Trash, as well as moisture, can adversely affect the

quality of the fiber and lead to costly operating and processing expenses at the gin

and at the textile mill.

Excessive moisture is common to cotton grown in the more humid regions of the

Cotton Belt, while cotton produced in the Southwest can be too dry because of the

region's arid climate. Lack of moisture at ginning can also lower the quality of the

fiber and contribute to ginning problems.

To prevent fiber damage and to facilitate ginning, gins try to balance the moisture

content in the seed cotton during drying, so that it is neither too wet nor too dry.

With unusually dry cotton, gins will skip the drying stage and will, at times, add

moisture to it with a special humidifier that blows warm, humid air through the

gin's conveyor pipes.

Ginning the Seed Cotton

The seed cotton is now ready for ginning. Pima cotton is conveyed to the roller gin,

while upland cottons are conveyed to the saw gin for separation of seed and fiber.

After being ginned, the cotton fiber is often referred to as lint.

Lint Cleaning

Lint cleaners remove the small trash from the ginned lint left behind by the cylinder

cleaner and stick machines. Saw-lint cleaners grab the lint with a cylinder saw and

whip it over metal bars to dislodge its trash. Lint cleaning of roller ginned cotton

usually involves a combination of three machines: a cylinder cleaner, an impact

cleaner which uses cylinders to agitate and release the trash from the lint, and an

air-jet cleaner which removes the trash from the lint using high velocity air.

Packaging the Lint:

In the final stage, a bale press compresses the ginned lint into bales that weigh

between 450 and 500 pounds. The bales are then wrapped with a protective cover,

ready for delivery to the warehouse where they are sold to various textile mills.

ANALYSIS AND METHOD OF ANALYSIS:

For the analysis of the machine problem and difficulties related to it we

referred the manual on the mill and then actual working of the machine was

studied, we were then gone through the overall view of the machine from

inside and outside and all the points were noted. Finally we come to know that

there is, one problem related to the gap maintaining between the leather clad

roll and the other problem was with the health issue of the workers. Then for

obtaining solution, we made a group discussion with the labours and find the

solution with the help of health journals, research paper of Prayas Centre For

Labour Studies And Action, our own logics and made a report.

RESULT AND CONCLUSION:

1.From the analysis we concluded that by applying all the mentioned

solutions, the productivity, efficiency can be increased.

2.The workers can be protected from the harmful miniscule fibres of

cotton and excess chromium content of leather roll.

REFERENCES:-

1.Ginning mill manual

2.Research paper of Prayas Centre For Labour Studies And Action

3. Journal of the Textile Association – March-April 2007

4.www.wikipedia.org