Transcript
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
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