UNIT-1 Ginning

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 The

primary object of the ginning consists in separating the fibres from the seed
Perfect ginning operation would be Performed if the separation of fibres from seed was effected without the slightest injury to either seeds or to the fiber.

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cotton first goes through dryers to reduce moisture content and then through cleaning equipment to remove foreign matter.
operations facilitate processing and improve fiber quality.

These

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A typical gin will process about 12 bales per hour, while some of todays more modern gins may process as many as 60 bales an hour.
B.TECH TEXTILE TECHNOLOGY 2nd YEAR 1st SEM

 Previous

to the introduction of Modern Machinery, ginning was performed by hand or by machines of a primitive character such as the "Foot Roller" and its improvement the "Churka". As the cotton industry developed, greater production than these were capable of was necessary, and machines driven by power were introduced.

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 Numerous

forms of gins have been tried, but at the present time only three are used to any large extent. They are

1. KNIFE ROLLER GIN 2. SAW GIN 3. THREE TYPES OF MACARTHY GIN

I. Single acting macarthy gin. ii. Double acting macarthy gin iii. Double roller macarthy gin.

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The ginning roller is the most important and expensive component in the gin stand. Roller-covering material is made from 13 layers of plain-woven cotton fabric cemented together with a white rubber compound. The fabric lays on the bias so that neither the warp or fill yarn are parallel to the direction of cutting; this prevents the material from unraveling from the roller surface. The roller material mounts on to the roller core with the cut edges of the fabric layers serving as the ginning surface.

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 Rotary-knife

roller gin stands separate fiber from seed by using the frictional forces between a moving roller and fixed stationary-knife surface. During normal ginning, the roller-to-fiber force is greater than the stationary knife-to fiber force; therefore, the fiber sticks to the roller surface and slips on the stationary knife surface.

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 Cotton

is ginned as fibers adhered to the roller surface slip under the stationary knife which holds the seed. Each stroke of the rotary knife clears the stationary knife edge of accumulated seed cotton and ginned and partially-ginned seed. Partially ginned seed are either pulled back to the stationary knife and completely ginned or swept along with the seed and carryover and later reclaimed.

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 The

seed cotton is placed in bulk on the table. By means of the reciprocating motion of the table by the crank arrangement, the seed cotton comes into contact with knife roller (formed of a number of knife discs). Auxiliary roller breaks the large cluster of seed cotton and maintains a constant supply of cotton to knife roller.

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 Knife

portion being arranged in such a manner that anything coming into contact with it is given a reciprocal or to and fro motion as well as being subject to a striking action due to its revolution. The seed cotton is carried forward in the direction of knife roller's motion until it is brought into touch with leather roller. This roller, which has a much roughened surface, due spirally-formed saw cuts Has pressing against, it by means of spring and steel doctor Knife.
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 The

cotton fibres brought into contact with the leather adhere to it, and are carried round past the knife. It is impossible for the seeds to follow. So, seeds will remain at the point of contact of the doctor knife and leather roller, with the fibres still connected with it. The essential feature of this gin now comes into play.

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 The

knife roller is so set as to act upon, these adhering seeds, and it gives to them a gentle to and fro motion, repeated very quickly 'and at the same time a slight striking action or pressure also repeated quickly. The combined action soon causes the seeds to separate from the fibres and to fall down through the grid to floor.

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 The

freed fiber passing forward is stripped from the roller by some arrangement of the stripping board. The seed cotton not taken up by one leather roller (on the right of the figure) is brought round into contact with another Leather roller where same process as described above is gone through and to which the same parts equally apply.

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 The

seed cotton is placed on the table. By means of the reciprocating motion of the table by the crank arrangement, the seed cotton comes into contact with the revolving leather covered roller. Some cotton fibres are carried in the direction of leather roller, but seed cottons are arrested by the doctor knife.

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A steel beater blade is connected by means of a connecting rod, with a crank on the driving shaft. Due to the seeds being acted upon by the rapid reciprocating motion given to the beater blade by the crank, the seeds are separated from fibres. Ginned cotton fibres are carried onward in the direction of leather roller, stripping board strip the fibres from the leather roller and empty seeds are thrown into grid, through which they pass into suitable receptacle.

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The vertical movement of the beater blade should be 3/8 inch above the doctor knife. Sharp edge of the doctor knife should not cut the fibres. The degree of pressure of the doctor knife upon the leather roller can be varied according to the tenacity with which the fibres adhere to the seeds. This is done by adjusting the spring and thumb screws. The pressure of the doctor knife and distance between leather roller and doctor knife should be in such a way that no seed will be allowed to pass in the direct ion of leather roller.
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 There

are two leather roller and a doctor knives is pressed against each leather roller. The beater knives act from above, and are given a reciprocating motion from a crank. Crank pin slide in a slot of arm carried by a vibrating shaft. Beater blades are fixed on arms projecting from vibrating shaft Also grid and fingers are fixed on vibrating shaft.

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Seed cotton is fed into hopper -spaces. The crank movement lowers this cotton into contact with leather roller in one side and raises it away from the roller on other side. When the cotton comes into contact with leather roller, some cotton fibres are carried in the direction of leather roller but seed cottons are arrested by the doctor knife due to the seeds being acted upon bythe rapid reciprocating motion given to the beater blade by crank, the seeds are separated from fibres. Ginned cotton fibres are carried forward in the direction of leather roller. Empty seeds are thrown into grid. As the grid lowers, the space in it permit the fixed finger to pass between them, and so shake the seed to cause them to fall out readily.
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 The

seed cotton is fed upon the lattice and carried forward to the spiked roller, which loosens the cotton and throw; it into the hopper. In hopper, the seed cotton comes into contact with rapidly revolving saw roller. Approximately 70 saws are threaded on a shaft.

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 As

the saws revolve, the teeth carry the fibres forward, but it is impossible for the seeds to follow and also, due to the heavier beating of the rapidly revolving saws on the seed cotton, the fibres are separated from seed and taken round until the brush strips the fibre from the teeth. Empty seeds husks and other broken seeds are thrown into grid, through which they pass into suitable receptacle.

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 An

air current from the cage draw the fibres along the trunk passage, and on reaching the revolving cage are brought under the pressure roller and delivered as a sheet, from which it is taken to the baling press.

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 SETTINGS:
An

air current from cage should be optimum to 'suck only fibres.

If air current is high - it will "suck seed also with fibres. If air current is low - fibre accumulation under brush roller causes to block the machine.

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 Saw

gin is suitable to process American cotton and wherever American cotton is grown, such as west Africa- India, Ceylon etc. These cottons are oily type in which the fibres are not too easily separated from the seeds, so heavier beating on seed is required to separate the fibres. This is achieved in this gin by giving heavier beating of the rapidly revolving saws on the seed cotton.
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CAUSES FOR BROKEN SEEDS:

1. 2. 3. 4.

Improper setting between knife roller and rail. Improper setting between knife roller leather roller. Improper setting between beater blade doctor knife in McCarthy gin Improper setting of the adjustable plate, in saw gin.

dish and and Bars

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CAUSES FOR FIBRE DAMAGES:

1. 2.

3.
4. 5.

Too much pressure of doctor knife on leather roller. Knives of the knife rollers are too sharp. Sharp edges of the saw discs. Improper setting between doctor knife and leather roller. Too close setting .between knife roller and dish rail.

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 CAUSES
1. 2.

FOR NEPS FORMATION:

High speed of knife roller and saw roller. Blunt edges of knife and saw disc.

To

avoid defective ginning,

(I) various settings in the gin should be proper (ii) speeds of the rollers should be in correct range (iii) condition of the knife disc and saw disc should not too sharp or too blunt and it should be optimum.
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