Quality is never an accident; it is always the result of intelligent effort, says John Ruskin. A.T.E. brings the best technology to one more area - ginning -- to improve quality.

The conventional ginning refers to "spreading cotton fibres from seed". But due to high production spinning machines, the expectation from ginning machines have increased a lot. In essence, the modern cotton gin enhances the value of cotton by separating the cotton from the seed, removing objectionable foreign matter by preserving the inherent qualities of the fibre and packing in a compact form. While there are different types of ginning technologies; the double roller ginning technologies from Bajaj Steel Industries offers district advantages and commercial viability.

Studies conducted at some spinning mills shows that quality ginning and cleaning reduces the load on blowroom and carding machines and results in better yarn realisation, higher spinning production and power saving at blowroom/carding filters. In short, better ginning save a lot of spinning.

This article highlights the special features of Bajaj Double Roller ginning technologies; a partner in "Enhancing Spinning Performance".

Bajaj Steel Industries Limited (BSIL), established in 1961 is the largest manufacturer of cotton ginning and pressing equipment. BSIL has the following technical collaborations and quality certificates: · Central Institute for Research on Cotton Technology (CIRCOT) ICAR, Govt of India · Samuel Jackson Incorporation Lubbock USA for Cotton Humidification Systems · Continental Eagle Corporation, Prattville, Alabama USA for Saw Gins, Rotobar Gins, Single Roller Gins, Cotton Baling Presses, Delinting & Decorticating Machinery etc.

BSIL products are approved by the following institutes:

• Ministry of Textiles, Govt of India under TUF vide Resolution No 28/1/99-CTI Dated 31.03.1999
• Technology Mission on Cotton (TMC)
• Andhra Pradesh State Financial Corporation
• Karnataka State Financial Corporation
• National Small Industries Corporation
• The Tamil Nadu Industrial Investment Corporation Ltd etc

Double roller ginning technology

Salient features of Double Roller Gin:

• Gentle ginning and hence no fibres damage.
• Low Ginning temperature and hence better fibre parameters.
• Retention of natural luster and moisture.
• Low nep contents.
• Most techno economic with respect to energy and man power cost.
• Higher Outturn of Fibre: On 'Bajaj' DR Gin the out turn for the fibre increases by about 2% due to extra length.
• Flexibility in processing different type of seed cotton.
• Savings in Costs:
  (a) Energy/Electricity/Power Cost
  (b) Manpower Cost
  (c) Capital Cost.

The cleaners and automation from BSIL:

• High efficiency pre-cleaners.
• Cotton conveying system.
• Auto feeding system.
• Fibre friendly lint cleaner.

When the seed cotton is fed to the ginning machine in action, fibres adhere to the rough surface of the roller and are carried in between the fixed knife and the roller such that the fibres are partially gripped between them. The oscillating knives (moving knives) beats/drags the seeds from top to opposite direction causing separation of fibres from the seed end. This process is repeated a number of times till all spinnable fibres are separated from the seeds. The fibres so detached from seeds are carried forward on the roller and drop out of the machine. The ginned seeds drop down through the slots provided on seed grid and the gap between end of seed grid and rail. The grid is part of beater assembly and oscillates along with the moving knives helping quick removal of the seeds. The new "Jumbo Model" of double roller gin is having a capacity of ginning about 90 kg lint/hour.

High efficiency Pre-cleaners:

Cotton conveying and feeding system: This is the first step where the seed cotton is fed through pre-cleaner. Yellow/pre-matured balls, trash, stones and other heavy impurities are effectively removed. The cleaners are very robust design and almost maintenance free.

The manual conveying of seed cotton to ginning hall is history; thanks to efficient and reliable solution by BSIL. The well designed, suitable capacity by BSIL. The well designed, suitable capacity and power efficient pneumatic suction system pulls the cotton directly from hips. Also, the maintenance free screw type conveyor system feed the cotton to gins. This has relived the ginners from the main power related problems and improved overall ginning efficiencies and reduction of contamination. Similarly, the lint collecting chutes and pneumatic feeding to lint cleaner further reduces requirement of labour.

Fibre-friendly lint cleaners:

Automatic bale press and online bagging arrangements: The double roller gins with automation, cleaner's and bale press offers best solution with respect to:

• Good technology.
• Low project cost.
• Simple design and minimum maintenance.
• Minimum man power requirement.

The installation of lint cleaning is very important specially for the spinning. The lint cleaner removes seed coats, leafy matter, micro dust and short fibres. Depending on the requirement, the cleaner can be equipped with three, four or even five beaters. This machine offers gentle cleaning and hence ensuring fibre quality.

BSIL in collaboration with Continental Eagle Corporation, USA offers completely automatic bale press to suit international standards of bale density and dimensions. Its heavy duty structure and high pressure power pack of German technology ensures highest quality and safety. The bale press is available in three capacities (from 15 bales per hour to 35 bales per hour).

Apart from cotton ginning, BSIL also offers value addition to gins, like:

• De-linting.
• De-corticating.
• Oil milling.

De-linting - The delinting is a process of removing the short fibres from the seed after the gin. The small cellular size fibres are dissolved and processed to make paper for currency note etc. Moreover, the oil extraction efficiency from these black seed further improves.

De-corticating - New revolution of separating the hull and cotton seed meat. The hull is one of the best cattle food and oil extraction from cotton seed meat increases the oil removal percentage by 2 - 3%.

(Contributed by Laxmikant Rathi, Vice-President, Textile Engg - Spinning Accessories & Exports. Email: l_s_rathi@ateindia.com)