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“Mining The White Gold” By S. Z. Alvi Textiles Committee Hyderabad

“Mining The White Gold” By S. Z. Alvi Textiles Committee Hyderabad. Composition of Ginning & Pressing Units In India as on 2002. State/Region-wise installed capacity. 1. Organic Matter. CAUSES Non Irrigated Varieties- AKH4, Y-1 ( AP MCU-5) “Piece Rate of Wage System”

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“Mining The White Gold” By S. Z. Alvi Textiles Committee Hyderabad

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  1. “Mining The White Gold” By S. Z. Alvi Textiles Committee Hyderabad

  2. Composition of Ginning & Pressing Units In India as on 2002.

  3. State/Region-wise installed capacity

  4. 1. Organic Matter • CAUSES • Non Irrigated Varieties- AKH4, Y-1 ( AP MCU-5) • “Piece Rate of Wage System” • Ginning on Job work basis & yield % • Selection of Type of Ginning M/c SR or DR. Saw etc. • PROBABLE REMEDIES • Good Pre-cleaning specially in case of non irrigated varieties. • “Time Rate of Wage System coupled with Training/Awareness. • Creating awareness and setting bench marks and incentives. • SR Gins to be avoided.

  5. 2. Due to Poor House Keeping,Packing,Storage, Personal Belongings and Transportation • Absence of Adequate Storage & Transporting Facilities at all the stages. • Neither Covered godown nor enough Pucca (cemented) Platforms. • Transportation of lint from Gin House to Press, in jute bags. • Bags are cut open at pressing stage after rolling on soiled/muddy ground. • Packing of bales with see through jute cloth. • Bale marking with fast colors and use of rusty iron hoops..

  6. 3. Excessive Water Content 1) 100 = 66+35 ? 2) How to Burn Cotton Lint? • causes • Merit of King Cotton , Moisture Regain has become it’s biggest enemy. • For 1-2 % gain water Poured on lint filled jute bags instead of appropriate methods of Humidification. • Yellowness and Mildew formation. • Poor Color grade of cotton • Low yarn realization at Spinning stage. • Excessive water content is good for ginning? A myth- ctd

  7. 3. Excessive Water Content Ctd. - • SUGGESTIONS • Very difficult to control as related to commercial aspects. • Novel System of deciding Kapas/ Cotton price. • Rate is related to moisture present in kapas (Seed Cotton). • Use of Atomizers or in built moisturizers in bale press line • Creating awareness regarding ill effects of wrong methods of Humidification of cotton.

  8. 4. MICRO DUST • It is one of the main constraint in obtaining good efficiency on O.E Spinning and Quality of Open End Yarn. • Farmers are not at all aware about ill effects of micro dust. • No Seed cotton heap to be kept without covering it with tarpaulin if closed godown are not available. • In rural area most of the gins are located on kaccha road side • Easy Method of testing of presence of micro dust is not available.

  9. 5. Oily/Greasy Cotton Lint • Very harmful to “Carding Quality” as causes Cylinder loading. • Hampers smooth working of subsequent Spinning. • CAUSES • S.R Ginners found to be very careless in oiling of SR s. • Oil spills over Machine, Hopper as well as on the floor is common. • Over oiling by untrained oilman with less intervals is also common. • DR gins,where grease is used as lubricant, due to careless greasing, lumps of grease found in the hopper and floor where lint is stored. • Removing of balls of grease nipples should be discouraged. • SUGGESTIONS • Creating awareness, providing”Oiling Treys” to oimen their training and good house keeping are few suggestions.

  10. 6. Mixed Varieties • Bale Marks are not true all the times: • e.g. inferior quality of JKHY1 or H4 is marked as Y-1 or LRA. • MAIN CAUSES • For Making lot of 50 bales when in-coming kapas is less than requirement..Word “Similar” is used to describe only staple length. • Combined storage and/or transportation of different varieties. • Supply of mixed seeds to farmer. • IDENTIFICATION • By examining seeds present in the lint e.g: • H-4 Relatively soft shell, rounded and greenish in Colour. • Y-1 Hard Shell, Oval shape, Blackish colour and sharp tip.

  11. 7. Non Eco-Friendly (Toxic) Substances • Premium paying EU is very particular and has banned various suspected to be carcinogenic and quantitative restraints has been fixed by them. • Toxins present in the cotton are mainly traces of Pesticides. • PERMISIBLE LIMITS OF PESTICIDES (M.S.T ECO STDS) • 1. DDT 1.0 mg/kg • 2. HCH 0.5.mg/kg • 3. Lindan 1.0 mg/kg • 4. Alfrin 0.2 mg/kg • 5. Dieldrin 0.2 mg/kg • 6. Toxaphen 0.1 mg/kg • ctd

  12. 7. Non Eco-Friendly (Toxic) Substances Ctd. • CONCEPT OF ECO-FRIENDLY METHOD OF CULTIVATION • Organic, Green labeled or Eco- Friendly Cotton. • Cultivation under 100% buy back arrangements with farmers (Contract Farming). • No chemical fertilizer and Pesticide will be used, only organic manure is allowed. • Declined in the yield per acre is compensated by premium. • Successful only in the areas where abundant of irrigation is available. ( Banks of Narmada,MP, TN and Karnataka) • Few Non irrigated varieties (AKH4) in Maharashtra are almost inherent Eco- friendly as no pesticide is used.

  13. IMP. FACTORS AFFECTING THE FIBRE QUALITY • 1) FAULTY SETTING OF “CUT OFF”. • It denotes the distance at which moving knife overlaps fixed knife. • Variable with staple length • Should be 1/3 of the staple length. • Faulty setting can cause rupture/length loss and lint loss too. • Very few fitters are changing this setting as per the fibre length. • Training of Fitters at Institute for Cotton Ginning Nagpur & strict supervision are recommended.

  14. IMP. FACTORS AFFECTING THE FIBRE QUALITY Ctd. • 2) CUTTING OF GROOVES ON LEATHER ROLLS: • Distance between 2 grooves- 1.25 to 1,5 times the staple length. • Depth should not allow seed to enter to avoid cut seeds. • May be done once in 3 shifts. • 3) SHARPENING OF KNIVES: • At least once in a shift by Hand only to avoid cut/crushed seeds

  15. FEW GOOD PRACTICES OBSERVED AND ADVICED • A) KOWDI(IMMATURE BALL) PICKING OUT OF SEED COTTON (KAPAS) • Gin Operators are asked to segregate kowdis out of kapas and keep in separate basket. He gets incentive for every kg of kowdi picked. • Very effective and good manual combing process. • B) YELLOW PICKING • Locally developed method of collection of ginned kowdi (yellow cotton) tends to go up with roller and caught by coir string & collected manually by a worker. • C) BALE PACKING IN COTTON CLOTH • Modern Spg Mills started paying attention to ginning quality. • Jute cloth packing of bale found to be a main culprit for jute fibre contamination in cotton Different dye affinity causes colored flecks. • Marking with washable ink and head gears to all workers.

  16. New Technical Developments • 1) Extraction of foreign matter through scanning • Cameras are placed in chamber from where lint is passed after cleaning and most of the remnant foreign matter is caught & removed by this system (Vision Shield). • Well accepted by Spg. units, worth experimenting by Ginning . • 2) Fibre Testing lab with HVI, Moisture Meter etc. • To avoid human error/bais. • To have transparency in deciding rate of seed cotton to farmers • 3) Trading Cotton with Brand Names • Progressive ginners are selling well tested cotton with their own Brand Names, in place of variety mark & assuring declared fibre quality parameters ( l , m, u,gpt, t% & moisture).

  17. Thank you

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