Progress 08/27/04 to 08/26/09
Outputs
Progress Report Objectives (from AD-416) 1. Develop technologies for production, harvesting, and storage that directly impact gin plant operation, gin product quality, and textile mill operation. 2. Develop new and improved processing, sensing and control technologies for superior fiber/seed separation, foreign matter identification and extraction, accurate online cotton properties measurement and efficient process control to produce higher quality fiber more economically for optimal textile utility. 3. Develop new technologies and alternative uses for cotton production systems, ginning equipment, lint, seed, and gin by-products to increase the value of gin-related products. 4. Develop new knowledge and technology for assessent and remediation to assist with ginning industry safety and environmental regulatory compliance. Approach (from AD-416) The approach will be to combine well-defined experiments, testing specific hypotheses, with long-term, higher risk exploration of innovative concepts that may lead to new technologies. The laboratory interdisciplinary team of 5 ARS scientists, 10 Federal employees and various other support personnel brings collaborative relationships and diverse experience together to focus on 17 projects directly supporting the laboratory research program. Significant Activities that Support Special Target Populations The scope of this project covered all aspects of the cotton industry, including new variety development, harvesting, saw and roller ginning, emission monitoring and control, cotton quality effects on textile processing and regional cotton companion and specialty crops. Research cooperators included university, commercial, private, state, & national ginning organizations, & other USDA laboratories. Development of a thermal defoliator for cotton progressed from a laboratory two-row machine to a commercial prototype six-row machine that has been successfully used by an organic cotton producer to defoliate his cotton prior to harvest. This laboratory has worked with the support of Cotton Inc. to develop an experimental spindle-picker that is capable of independently varying ground & picking operational speeds. This unit will be used to quantify cotton fiber quality damage occurring at harvest as well as developing & qualifying experimental picking component designs. Cooperative research on high speed roller ginning supported by Cotton Inc. and transferred to commercial gins by Lummus Industries has resulted in approximately 160,000 bales of upland cotton being roller ginned in California during the 2008/09 ginning season. These numbers are expected to increase, particularly in those areas of the cotton belt that grow extra-long staple upland cottons. Other research continues with the high speed rotary knife roller gin to increase its flexibility by being able to differentially separate more desirable fibers from less desirable fibers, & improving functional components of the gin stand itself. Cotton fiber quality was a central focus of the research & projects concentrating on fiber quality included an industry wide survey on current lint cleaning practices and quality effects, evaluation of commercial cotton moisture sensors for moisture control through the baling process, looking for alternatives to seed-cotton drying other than heated air, improved tooth design for saw gin stands, detection of cotton contaminants such as man-made plastics during the processing of raw cotton, effects of cotton bale storage conditions on ginned fiber & improved lint cleaner grid bar designs. Improving the value of Pima cottonseed thru utilization for biodiesel & improved dairy feed is another project that has made substantial progress under this project. In addition, laboratory engineers have worked with specialty crops such as chile & pecans to apply ginning materials handling & control methods to the mechanical harvest of these regional companion crops. Substantial progress was made on transferring machine vision techniques developed by ARS to identify particular cotton trash components to the AMS for use in classing lines to improve the grading of US ginned cotton. This laboratory also was proactive in transferring technology to the industry through training schools, technical meetings, ginning demonstrations & related talks to students & the general public throughout the project. This laboratory's published research on cotton & frequent contact with the industry has continued to open up new research opportunities on cotton as well as related companion crops. Technology Transfer Number of New CRADAS: 1 Number of Active CRADAS: 3
Impacts
(N/A)
Publications
- Whitelock, D.P., Armijo, C.B., Gamble, G.R. 2008. Evaluating a fiberglass roller covering on a roller gin stand. Journal of Cotton Science. 12:143- 149.
- Hughs, S.E., Armijo, C.B., Whitelock, D.P., Buser, M.D. 2008. Particulate emission profile of a cotton gin. Applied Engineering in Agriculture. 24(2) :145-151.
- Buser, M.D., Wanjura, J.D., Whitelock, D.P., Capareda, S., Shaw, B., Lacey, R. 2008. Estimating FRM PM10 sampler performance characteristics using particle size analysis and collocated TSP and PM10 samplers: Cotton gins. Transactions of the ASABE. 51(2):695-702.
- Faulkner, W., Buser, M.D., Whitelock, D.P., Shaw, B. 2008. Effects of cyclone diameter on performance of 1D3D cyclones: Cut point and slope. Transactions of the ASABE. 51(1):287-292.
- Whitelock, D.P., Armijo, C.B., Gamble, G.R., Hughs, S.E. 2007. Survey of seed-cotton and lint cleaning equipment in US roller gins. Journal of Cotton Science. 11:128-140.
- Chun, D.T., Hughs, S.E., Armijo, C.B., Baker, K.D., Mcalister III, D. 2006. A study of bale moisture addition. Transactions of the ASABE. 50(2):325- 330.
- Baker, K.D., Hughs, S.E., Chun, D.T. 2008. Use of a rotor spray system for moisture addition to cotton lint. Applied Engineering in Agriculture. 24(4) :491-495.
- Lu, Y.Z., Curtiss, J., Miranda, D., Hughs, S.E., Zhang, J. 2008. ATG- anchored AFLP (ATG-AFLP) analysis in cotton. Plant Cell Reports. 27:1645- 1653.
- Macias-Corral, M.A., Samani, Z.A., Hanson, A.T., Smith, G.B., Funk, P.A., Yu, H.W., Longworth, J. 2008. Anaerobic digestion of municipal solid waste and agricultural waste and the effect of co-digestion with dairy cow manure. Bioresource Technology. 99(17):8288-8293.
- Funk, P.A., Eiceman, G.A., White, C.R., White, W. 2008. Laboratory detection of plastics in seedcotton with ion mobility spectrometry. Journal of Cotton Science. 12:237-245.
- Hughs, S.E., Valco, T.D., Williford, J.R. 2008. 100 years of cotton production, harvesting and ginning systems engineering: 1907 - 2007. Transactions of the ASABE. 51(4):1187-1198.
- Funk, P.A., Gamble, G.R. 2009. Fiber properties of saw and roller ginned naturally colored cottons. Journal of Cotton Science. 13:166-173.
- Armijo, C.B., Baker, K.D., Hughs, S.E., Barnes, E.M., Gillum, M.N. 2009. Harvesting and seed cotton cleaning of a cotton cultivar with a fragile seed coat. Journal of Cotton Science. 13:158-165.
- Whitelock, D.P., Armijo, C.B., Buser, M.D., Hughs, S.E. 2009. Using cyclones effectively at cotton gins. Applied Engineering in Agriculture. 25(4):563-576.
|
Progress 10/01/05 to 09/30/06
Outputs
Progress Report 1. What major problem or issue is being resolved and how are you resolving it (summarize project aims and objectives)? How serious is the problem? Why does it matter? The Southwestern Cotton Ginning Research Laboratory (SWCGRL) mission is to develop technologies that solve problems directly affecting, or being affected by, the cotton ginning industry to maximize the economic viability and competitiveness and minimize the environmental impact of the U.S. cotton production and processing system. To carry out this mission our overall objective is to address critical cotton production, ginning, textile processing and regulatory compliance issues, especially those pertaining to high quality Western irrigated Pima and long-staple upland cottons. Cotton ginning is the essential link between the producer of the raw material, the farmer, and the end user of the raw product, the textile manufacturer and ultimately, the consumer. Unlike most other commodities
that pass the farm gate, the farmer does not have a product he can sell until it is processed through a cotton gin. How well the ginning process preserves the inherent quality of the fiber it processes has a significant impact on the textile utility of the fiber and hence on the income of the farmer. This CRIS project has four specific objectives: 1. Develop technologies for production, harvesting, and storage that directly impact gin plant operation, gin product quality and textile mill operation. 2. Develop new and improved processing, sensing and control technologies for superior fiber/seed separation, foreign matter identification and extraction, accurate on-line cotton properties measurement and efficient process control to produce higher quality fiber more economically for optimal textile utility. 3. Develop new technologies and alternative uses for cotton production systems, ginning equipment, lint, seed, and gin by-products to increase the value of gin-related products.
4. Develop new knowledge and technology for assessment and remediation to assist with ginning industry safety and environmental regulatory compliance. The cotton production and processing chain is a vertically integrated system that starts with plant breeders selecting cultivars for yield and other factors. It includes cultural practices and harvest mechanization, seed cotton drying and cleaning, ginning, lint cleaning, bale packaging, shipping, storage, marketing, spinning, weaving, finishing and garment making. As an independent federal laboratory, we are uniquely qualified and positioned to facilitate or perform a large variety of short- and long-term low and high-risk research projects affecting the interrelated steps that sequentially add value to cotton as it progresses from the field to "the fabric of our lives." The research being done falls under National Program 306, Quality & Utilization of Agricultural Products and National Program 203, Air Quality, Component I -
particulate emissions. Part of the current mission statement for National Program 306 is, "To enhance the economic viability and competitiveness of U.S. agriculture by maintaining the quality of harvested agricultural commodities or otherwise enhancing their marketability, meeting consumer needs, developing environmentally friendly and efficient processing concepts...." The research program at SWCGRL directly supports the above-declared goals as related to the U.S. cotton ginning industry. All of the various cotton harvesting and ginning processes have an effect on the quality of the cotton fiber as well as the seed. How well these processes preserve the inherent quality of the fiber and seed has a significant impact on the textile utility of the fiber and the feed and oil quality of the seed and hence on the economic health of the American farmer and the U.S. cotton and textile industries. 2. List by year the currently approved milestones (indicators of research progress)
Milestones FY 2006 - This projects first milestones were originally scheduled at 30 months (FY06) and 60 months (FY09), but have been adjusted to reflect the accelerated progress that was been made during the first and second years. Adjusted milestones are listed as follows: Milestones FY 2006 Continue long-term evaluation of new cotton strains developed by New Mexico State University. Acquisition of data base related to the effects of ginning practices and raw fiber quality on textile utilization will be started. Field tests of thermal defoliation completed and technology transferred. Laboratory tests of experimental full size high speed roller gin will be completed. Survey of current ELS lint cleaning practices and efficiencies will be completed. Laboratory prototype ELS lint cleaning will be designed and installed. Current long-term bale storage moisture tests will be completed and recommendations as to appropriate bale moisture control finalized. Laboratory gin waste utilization
tests related to composting, methane generation, soil amendment testing and pathogen kill will be completed. Full scale testing of post-harvest cleaners for mechanized chile production system will be completed. Scheduled testing of small scale laboratory cyclone prototypes will be completed and results evaluated. Further tests will depend on results of this testing series. Release of one or more new varieties under New Mexico State University's cotton breeding program. Field tests of experimental full size high speed roller gin will be started in a cooperating commercial gin plant. Milestones FY 2007 Complete commercial gin plant tests of seed-cotton moisture measurement system and technology transferred to industry. Ginning and spinning evaluations of existing saw designs will be completed and experimental saw tooth designs in progress. Evaluations of current ELS lint cleaning practices and efficiencies will be completed and the results published. Boundary line measurements of PM10
at several commercial cotton gins will be completed and results analyzed for future use in validation of a particulate emissions model for low level agricultural sources. Gin waste utilization technology will be transferred to industry through commercial prototype test and demonstration. All field tests of the commercial prototype thermal defoliator will be completed and technology transferred to the industry. Further release of one or more new varieties under New Mexico State University's cotton breeding program will be accomplished. Continued long-term evaluation of dust abatement strategies for agricultural systems. Milestones FY 2008 Laboratory and field tests of experimental spindle harvester will be completed. Contamination/smoke sensor laboratory studies will be completed and cooperators for commercial prototype studies will be identified. Bench and small scale laboratory tests of lint trash identification using machine vision will be completed. Fragile seed coat ginning
laboratory tests on newly developed varieties will be completed and possible ginning equipment/process modifications will be planned. Emissions testing of a multi-fueled burner using cottonseed oil and biodiesel will be completed and results reported to the industry. Milestones FY 2009 Full scale evaluation of spindle harvesting commercial prototype will be initiated under CRADA with suitable cooperator. Commercial prototype tests on contamination sensor will be completed and the results transferred to the industry. Implementation of on-line lint trash measurement will be initiated at both the ginning laboratory and with cooperators. Ginning machinery and process modifications for processing fragile seed coat varieties as well as cotton breeder recommendations will be identified and reported to the industry. Cotton ginning and utilization knowledge data base will continue to be added to and refined. 4a List the single most significant research accomplishment during FY 2006. Hot Rod
Roller Ginning Machine harvested U.S. cotton competes in a world market with high quality hand harvested foreign cottons. Roller ginning better preserves both upland and Pima cotton quality but up to now has been uneconomical on a large scale for upland cottons because of low processing rates. Scientists at the Southwestern Cotton Ginning Laboratory, Mesilla Park, NM, in cooperation with Cotton Inc. and commercial cotton gins have increased roller ginning rates by a factor of four on both upland and Pima cottons. These greatly increased ginning rates have been attained while still maintaining the expected high fiber quality of traditional roller ginning. Successful commercialization of this technology will enable U.S. upland cotton producers to deliver a higher quality fiber to world markets. This technology is currently being commercially prototyped for several commercial gins for the 2006 ginning season by a U. S. gin machinery manufacturer (NP306,PM 1.2.1). 5. Describe the
major accomplishments to date and their predicted or actual impact. The accomplishments made under this new project are fully consistent with relevant milestones listed in the Project Plan, and with relevant research components as defined in the National Program 203 and 306 Action Plans. Accomplishments under this project contribute to the fulfilling of the ARS mission statement which in part is: "To enhance the economic viability and competitiveness of U.S. agriculture by maintaining the quality of harvested agricultural commodities or otherwise enhancing their marketability, meeting consumer needs, developing environmentally friendly and efficient processing concepts...." Major accomplishments under this project to date are as follows: Extensive field trials of the 2-row thermal defoliator during the 2004 harvest season documented good performance under a wide variety of conditions. Based on these results, the Propane Education and Research Council committed $363,000 to prototype
a commercial 6-row unit for testing during the 2006 harvest season. The thermal defoliator has the potential for providing an environmental friendly means of managing and defoliating cotton without the use of chemicals. Full-scale testing of an experimental post-harvest cleaner for mechanized red chile production system was completed by the Chile Pepper Task Force and the means of delivering acceptable machine harvested red chile was demonstrated. Some of this cleaning technology is currently being adapted for commercial use. Also, an experimental mechanical chile stand thinner was successfully field tested and the design was transferred to a commercial company to build commercial units available for the 2005 chile growing season. Both the cleaning and thinning technology are important components for developing mechanized chile pepper production systems. 6. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become
available to the end- user (industry, farmer, other scientists)? What are the constraints, if known, to the adoption and durability of the technology products? A. The thermal defoliator technology has been transferred to an industry partner to build a commercial 6-row prototype. A single unit should be available during the 2006 cotton harvest season for further field testing that will be jointly monitored by the industry partner and the USDA. Possible constraints could be the anticipated higher cost of using a ground based rig for defoliation versus air application of chemical defoliants. B. Two components (red chile cleaner and chile thinner) of a mechanized chile production system have been successfully demonstrated by experimental prototypes. Commercial thinners have already been built and are available to chile producers. Components of the cleaner are currently being adapted for use directly on commercial mechanical chile harvesters and will be utilized during the 2006
chile harvest. 7. List your most important publications in the popular press and presentations to organizations and articles written about your work. (NOTE: List your peer reviewed publications below). Armijo, C.B., Whitelock, D.P. 2005. ELS lint cleaning and fiber dynamics research. CI Lint Cleaning Summit, August 15-16, 2005, Cary, NC. Hughs, S.E. 2005. Cotton: field to fiber. 2005 Texas International Cotton School, August 22, 2005, Lubbock, TX. Hughs, S.E. 2005. Cooperative efforts with limited resource farmers. 1st National Conference in Latino Farmers & Ranchers, August 26, 2005, Las Cruces, NM. Herrera, E. 2005. Cotton ginning demonstrations. New Mexico State Fair, Sept 15-18, 2005, Albuquerque, NM. Lightfoot, T. 2005. Cotton research display & presentation. Southern New Mexico State Fair, Sept 27-30, 2005, Las Cruces, NM. Herbon, R., Abernathy, G.H., Siddaiah, M. 2005. Using a color sorter to remove sticks from mechanically harvested red chile. New Mexico Chile Task Force
Report 20. September 2005. Las Cruces, NM. Hughs, S.E., Baker, K., Armijo, C., Funk, P., Whitelock, D. 2005. Cotton Ginning Symposium, November 2-3, 2005, Mesilla Park, NM. Funk, P. 2006. 5 years of thermal defoliation. PERC Staff & Guests at 2006 Beltwide, January 5, 2006, San Antonio, TX. Hughs, S.E. 2006. USDA ginning research, 2006 New Mexico Cotton Conference, January 25, 2006, Ruidoso, NM. Hughs, S.E. 2006. Chile research program. 2006 New Mexico Chile Conference, February 7, 2006, Las Cruces, NM. Abernathy, G.H., Hughs, S.E. 2006. Chile machine harvesting observations. New Mexico Chile Task Force Report 24. February 2006. Las Cruces, NM. Herbon, R., Abernathy, G.H., Hughs, S.E. 2006. Design and development of a prototype mechanical gap sorter for mechanically harvested red chile. New Mexico Chile Task Force Report 25. February 2006. Las Cruces, NM. Abernathy, G.H., Hughs, S.E., Armijo, C.B. 2006. Chile machine harvesting trials. New Mexico Chile Task Force Report 27. In press.
Las Cruces, NM. Abernathy, G.H., Hughs, S.E., Eaton, F.E. 2006. Reclaimer evaluations. New Mexico Chile Task Force Report 28. In press. Las Cruces, NM. Abernathy, G.H., Hughs, S.E., Eaton, F.E. 2006. Red chile pod reclaimer evaluations. New Mexico Chile Task Force. In press. Las Cruces, NM. Funk, P. 2006. Thermal defoliation & contamination detection with ION mobility spectrometry. Cotton, Inc. Staff, March 16, 2006, Cary, NC. Lightfoot, T. 2006. Cotton: field to fabric. Columbia Elementary School, March 28, 2006, Las Cruces, NM. Armijo, C. 2006. Differential roller ginning for variable fiber length cotton. Annual NM ASABE Meeting, March 31, 2006, Bosque Del Apache, NM. Funk, P. 2006. Plastics sniffer for baled seedcotton. Annual NM ASABE Meeting, March 31, 2006, Bos Del Apache, NM. Lightfoot, T. 2006. Kids, kows & more. Farm & Ranch Museum, April 3-5, 2006, Las Cruces, NM. Herrera, E., Hughs, S.E. 2006. Presenters at 2006 Cotton Ginners School, April 3-5, 2006, Lubbock, TX. Herrera,
E. 2006. History of cotton with demonstrations of roller and saw ginning. Glenwood Ranch Days, April 24-26, 2006, Glenwood, NM. Hughs, S.E. 2006. Cotton bale moisture research, Arizona Cotton Ginners Association Meeting, May 4-7, 2006, Prescott, AZ. Lightfoot, T. 2006. Cotton gin tour and presentation. Joranda Elementary, May 2, 2006, Mesilla Park, NM. Lightfoot, T. 2006. Kids, kows & more. Curry County Fairgrounds, May 8- 11, 2006, Clovis, NM. Hughs, S.E., Baker, K., Armijo, C., Funk, P., Whitelock, D. 2006. Presentors at 2006 Cotton Ginners School, May 16-18,2006, Mesilla Park, NM. Lightfoot, T. 2006. Story of cotton. Future Scientists Student Outreach Initiative, May 17, 2006, Las Cruces, NM. Hughs, S.E. 2006. USDA ginning research. California Cotton Ginners Association Meeting, May 30-June 2, 2006, Morro Bay, CA. Whitelock, D. 2006. USDA-SWCGRL research. New Mexico Cotton Ginners Association Meeting, July 13-16, 2006, Ruidoso, NM. Hughs, S.E. 2006. Cotton from field to fiber. 2006
Texas International Cotton School, August 21, 2006, Lubbock, TX. Herrera, E. 2006. History of cotton with demonstrations of roller and saw ginning. New Mexico State Fair, September, 2006, Albuquerque, NM. Funk, P.A. 2006. Propane to power farm operations. Agricultural Research, Science Update, September 2006. p. 23.
Impacts
(N/A)
Publications
- Bundy, C.S., Funk, P.A., Steiner, R.L. 2006. Impact of thermal cotton defoliation on late-season insect populations. In: Proceedings of the Beltwide Cotton Conferences, January 3-6, 2006, San Antonio, Texas. 2006 CDROM. p. 1344-1351.
- Funk, P.A., Armijo, C.B., Lindemann, W.C., Lewis, B.E., Flynn, R.P. 2006. Fertility and toxicity of potting soils prepared for ginning and dairy wastes anaerobic digestate. National Cotton Council Beltwide Cotton Conference. In: Proceedings of the Beltwide Cotton Conferences, January 3- 6, 2006, San Antonio, Texas. 2006 CDROM. p. 402-409.
- Whitelock, D.P., Armijo, C.B., Gamble, G.R., McAlister, D.D. 2006. Performance tests of an experimental roller gin stand covering material. In: Proceedings of the Beltwide Cotton Conferences, January 3-6, 2006, San Antonio, Texas. 2006 CDROM. p. 646-650.
- Armijo, C.B., Van Doorn, D.W., Hughs, S.E., Gillum, M.N. 2006. A new approach to roller ginning to preserve fiber length. In: Proceedings of the Beltwide Cotton Conferences, January 3-6, 2006, San Antonio, Texas. 2006 CDROM. p. 642-645.
- Armijo, C.B., Holt, G.A., Baker, K.D., Hughs, S.E., Barnes, E.M., Gillum, M.N. 2006. Harvesting and ginning a fragile seed coat cotton. In: Proceedings of the Beltwide Cotton Conferences, January 3-6, 2006, San Antonio, Texas. 2006 CDROM. p. 556-566.
- Baker, K.D., Hughs, S.E. 2006. Spindle design effects on cotton quality. In: Proceedings of the Beltwide Cotton Conferences, January 3-6, 2006, San Antonio, Texas. 2006 CDROM. p. 420-424.
- Hughs, S.E., Armijo, C.B., Staten, R.T. 2006. Boll weevil kill rates by gin processing and bale compression. Applied Engineering in Agriculture. 22(1):45-50.
- Baker, K.D. 2005. Temporal assessment of nutrient contributions to waterways from feedlots. Applied Engineering in Agriculture. 21(3):517- 528.
- Whitelock, D.P., Brusewitz, G.H., Stone, M.L. 2006. Apple shape and rolling orientation. Applied Engineering in Agriculture. 22(1):87-94.
- Whitelock, D.P., Hughs, S.E., Armijo, C.B. 2005. Survey of current seed- cotton and lint cleaning practices in US roller ginning plants. ASAE Annual International Meeting. Paper No. 041166.
- Hughs, S.E., McAlister III, D.D., Tristao, D. 2006. Storage effects on quality of polyethylene film wrapped cotton bales: a preliminary report. In: Proceedings of the Beltwide Cotton Conferences, January 3-6, 2006, San Antonio, Texas. 2006 CDROM. p. 606-610.
- Armijo, C.B., Hughs, S.E., Gillum, M.N., Barnes, E.M. 2006. Ginning a cotton with a fragile seed coat. Journal of Cotton Science. 10:46-52.
- Whitelock, D.P., Buser, M.D. 2005. Preliminary results of a series cyclone test. ASABE Annual International Meeting. Paper No. 054014.
- Funk, P.A., Armijo, C.B., Showler, A., Fletcher, R.S., Brashears, A.D., McAlister III, D.D. 2006. Cotton harvest preparation using thermal energy. Transactions of the ASABE. 49(3):617-622.
- Bancroft, J.S., Hutmacher, R., Godfrey, L., Goodell, P., Mcguire, M.R., Funk, P.A., Wright, S. 2006. Comparison of sticky cotton indices and sugar composition.. Journal of Cotton Science. 10:97-104.
- Funk, P.A., Hughs, S.E., Gamble, G.R., Fleury, A. 2006. Cotton stickiness mitigation by bacteria. Proceedings of the American Society of Agricultural and Biological Engineers International (ASABE). Paper No. 061078.
- Faulkner, W.B., Whitelock, D.P., Gamble, G.R., Shaw, B.W. 2006. Formation of neps in pima cotton during mechanical harvesting. Proceedings of the American Society of Agricultural and Biological Engineers International (ASABE). Paper No. 061080.
- Armijo, C.B., Gillum, M.N., 2005. Modifying the stationary knife on a roller gin stand to gin upland cotton. Applied Engineering in Agriculture. 21(5):777-785.
- Baker, K.D., Hughs, S.E. 2006. Spindle speed effects on cotton quality. Proceedings of the American Society of Agricultural and Biological Engineers International (ASABE). Paper No. 061079.
- Armijo, C.B., Whitelock, D.P., Hughs, S.E. 2006. Efficiency of current seed-cotton and lint cleaning machinery at US roller gins. ASABE Annual International Meeting. Paper No. 051101.
- Showler, A., Funk, P.A., Armijo, C.B. 2006. Effect of thermal defoliator on cotton leaf desiccation, senescence, post-harvest regrowth, and lint quality. Journal of Cotton Science. 9:229-237.
- Faulkner, W.B., Buser, M.D., Whitelock, D.P., Shaw, B.W. 2006. Effects of cyclone diameter on performance of 1D3D cyclones: Collection efficiency. American Society of Agricultural and Biological Engineers. Paper No. 064165.
|
Progress 10/01/04 to 09/30/05
Outputs
1. What major problem or issue is being resolved and how are you resolving it (summarize project aims and objectives)? How serious is the problem? What does it matter? The Southwestern Cotton Ginning Research Laboratory (SWCGRL) mission is to develop technologies that solve problems directly affecting, or being affected by, the cotton ginning industry to maximize the economic viability and competitiveness and minimize the environmental impact of the U.S. cotton production and processing system. To carry out this mission our overall objective is to address critical cotton production, ginning, textile processing, and regulatory compliance issues, especially those pertaining to high quality Western irrigated Pima and long-staple upland cottons. Cotton ginning is the essential link between the producer of the raw material, the farmer, and the end user of the raw product, the textile manufacturer and ultimately, the consumer. Unlike most other commodities that pass the
farm gate, the farmer does not have a product he can sell until it is processed through a cotton gin. How well the ginning process preserves the inherent quality of the fiber it processes has a significant impact on the textile utility of the fiber and hence on the income of the farmer. This project has four specific objectives: 1. Develop technologies for production, harvesting, and storage that directly impact gin plant operation, gin product quality and textile mill operation. 2. Develop new and improved processing, sensing and control technologies for superior fiber/seed separation, foreign matter identification and extraction, accurate on-line cotton properties measurement and efficient process control to produce higher quality fiber more economically for optimal textile utility. 3. Develop new technologies and alternative uses for cotton production systems, ginning equipment, lint, seed, and gin by-products to increase the value of gin-related products. 4. Develop new
knowledge and technology for assessment and remediation to assist with ginning industry safety and environmental regulatory compliance. The cotton production and processing chain is a vertically integrated system that starts with plant breeders selecting cultivars for yield and other factors. It includes cultural practices and harvest mechanization, seed cotton drying and cleaning, ginning, lint cleaning, bale packaging, shipping, storage, marketing, spinning, weaving, finishing, and garment making. As an independent federal laboratory, we are uniquely qualified and positioned to facilitate or perform a large variety of short- and long-term low- and high-risk research projects affecting the interrelated steps that sequentially add value to cotton as it progresses from the field to "the fabric of our lives." The research being done falls under National Program 306, Quality & Utilization of Agricultural Products and National Program 203, Air Quality, Component I particulate
emissions. Part of the current mission statement for National Program 306 is, "To enhance the economic viability and competitiveness of U.S. agriculture by maintaining the quality of harvested agricultural commodities or otherwise enhancing their marketability, meeting consumer needs, developing environmentally friendly and efficient processing concepts..." The research program at SWCGRL directly supports the above-declared goals as related to the U.S. cotton ginning industry. All of the various cotton harvesting and ginning processes have an effect on the quality of the cotton fiber as well as the seed. How well these processes preserve the inherent quality of the fiber and seed has a significant impact on the textile utility of the fiber and the feed and oil quality of the seed and hence on the economic health of the American farmer and the U.S. cotton and textile industries. 2. List the milestones (indicators of progress) from your Project Plan. Milestones FY 2006 This projects
first milestones were scheduled at 30 months (FY06) and 60 months (FY09), but have been adjusted to reflect the accelerated progress that has been made during the first year. Adjusted milestones are listed as follows: Milestones FY 2005 Continue long-term evaluation of new cotton strains developed by New Mexico State University. Acquisition of data base related to the effects of ginning practices and raw fiber quality on textile utilization will be started. Current long-term bale storage moisture tests will be completed and recommendations as to appropriate bale moisture control finalized. Milestones FY 2006 Field tests of thermal defoliation completed and technology transferred. Laboratory tests of experimental full size high speed roller gin will be completed. Survey of current ELS lint cleaning practices and efficiencies will be completed and laboratory prototype ELS lint cleaning will be installed. Current long-term bale storage moisture tests will be completed and
recommendations as to appropriate bale moisture control finalized. Laboratory gin waste utilization tests related to composting, methane generation, soil amendment testing, and pathogen kill will be completed. Full-scale testing of post-harvest cleaners for mechanized chile production system will be completed. Scheduled testing of small-scale laboratory cyclone prototypes will be completed and results evaluated. Further tests will depend on results of this testing series. Milestones FY 2007 Release of one or more new varieties under New Mexico State Universitys cotton breeding program. Complete commercial gin plant tests of seed-cotton moisture measurement system and technology transferred to industry. Ginning and spinning evaluations of existing saw designs will be completed and experimental saw tooth designs in progress. Field tests of experimental full size high speed roller gin will be started in a cooperating commercial gin plant. Evaluations of current ELS lint cleaning
practices and efficiencies will be completed and the results published. Boundary line measurements of PM10 at several commercial cotton gins will be completed and results analyzed for future use in validation of a particulate emissions model for low level agricultural sources. Gin waste utilization technology will be transferred to industry through commercial prototype test and demonstration. Milestones FY 2008 All field tests of the commercial prototype thermal defoliator will be completed and technology transferred to the industry. Laboratory and field tests of experimental spindle harvester will be completed. Contamination/smoke sensor laboratory studies will be completed and cooperators for commercial prototype studies will be identified. Bench and small scale laboratory tests of lint trash identification using machine vision will be completed. Fragile seed coat ginning laboratory tests on newly developed varieties will be completed and possible ginning equipment/process
modifications will be planned. Emissions testing of a multi-fueled burner using cottonseed oil and biodiesel will be completed and results reported to the industry. Milestones FY 2009 Full-scale evaluation of spindle harvesting commercial prototype will be initiated under CRADA with suitable cooperator. Commercial prototype tests on contamination sensor will be completed and the results transferred to the industry. Implementation of on-line lint trash measurement will be initiated at both the ginning laboratory and with cooperators. Ginning machinery and process modifications for processing fragile seed coat varieties as well as cotton breeder recommendations will be identified and reported to the industry. Cotton ginning and utilization knowledge data base will continue to be added to and refined. 3a List the milestones that were scheduled to be addressed in FY 2005. For each milestone, indicate the status: fully met, substantially met, or not met. If not met, why. 1. Continue
long-term evaluation of new cotton strains developed by New Mexico State University Milestone Fully Met 2. Current long-term bale storage moisture tests will be completed and recommendations as to appropriate bale moisture control finalized. Milestone Fully Met 3. Acquisition of data base related to the effects of ginning practices and raw fiber quality on textile utilization will be started. Milestone Fully Met 3b List the milestones that you expect to address over the next 3 years (FY 2006, 2007, and 2008). What do you expect to accomplish, year by year, over the next 3 years under each milestone? Year 1 (FY2006) - Field tests of thermal defoliation completed and technology transferred. Impact Cotton producers will have another production tool that does not rely on chemicals, aids in insect control and can be used with both organic and standard cotton production systems. Laboratory tests of experimental full size high speed roller gin will be completed. Results This laboratory
test will demonstrate new roller ginning technology that will increase cotton quality and be economically competitive with saw ginning for processing upland cottons. Survey of current ELS lint cleaning practices and efficiencies will be completed and laboratory prototype ELS lint cleaning will be installed. Outcome A resource for updating current industry ELS lint cleaning practices will be available. Current long-term bale storage moisture tests will be completed and recommendations as to appropriate bale moisture control finalized. Impact Basic questions concerning the quality effects of long term outside versus inside storage in arid conditions will be answered. Laboratory gin waste utilization tests related to composting, methane generation, soil amendment testing, and pathogen kill will be completed. Results Alternative gin/dairy waste disposal and utilization technology will be available that is both economically and environmentally friendly. Full-scale testing of
post-harvest cleaners for mechanized chile production system will be completed. Outcome An important step in the development of a mechanical chile production system as part of an entire crop production/rotation system will have been taken. Scheduled testing of small-scale laboratory cyclone prototypes will be completed and results evaluated. Further tests will depend on results of this testing series. Impact The results of these tests will be applicable to gin particulate emission controls across the entire cotton belt. Year 2 (FY2007) Release of one or more new varieties under New Mexico State Universitys cotton breeding program. Impact - There is expected to be a release of a new Acala 1517 variety with both the Bt and Roundup-ready genes. This release will give back to regional cotton producers a very high quality upland cotton with significantly increased yields and lower production costs. Complete commercial gin plant tests of seed-cotton moisture measurement system and
technology transferred to industry. Results The cotton industry will have an alternative seed cotton moisture measurement system that is mechanically very robust and also sensitive to moisture changes. Ginning and spinning evaluations of existing saw designs will be completed and experimental saw tooth designs in progress. Outcome Increased knowledge of the basic design of the gin saw tooth that will lead to designs that better preserve fiber quality during the ginning process. Field tests of experimental full size high speed roller gin will be started in a cooperating commercial gin plant. Impact Successful development of a high speed roller gin that is compatible with both upland and Pima cottons will enhance the quality of U.S. cotton. Evaluations of current ELS lint cleaning practices and efficiencies will be completed and the results published. Results Evaluation will serve as a guide to the roller ginning industry in selection of lint cleaning equipment to better preserve
ELS fiber quality. Boundary line measurements of PM10 at several commercial cotton gins will be completed and results analyzed for future use in validation of a particulate emissions model for low-level agricultural sources. Impact These data are necessary for any future particulate emissions model development and validation. A realistic prediction model for low level agricultural sources is needed for an economic alternative to source testing or boundary line monitoring. Year 3 (FY2008) The second milestones for this project are at 60 months (FY2009). We expect many of the projects completed at the first 30 month milestones to result in technology to be transferred to the industry. We also expect some of the completed projects to point the way to other work that needs to be done, but it is too early at this time to predict what the listing will look like in FY2008. 4a What was the single most significant accomplishment this past year? Chemical Free Cotton Harvest Preparation.
Extensive field trials of the 2-row thermal defoliator during the 2004 harvest season documented good performance under a wide variety of conditions and proved that the concept is applicable to commercial cotton production systems. Based on these results, the Propane Education and Research Council committed funds to prototype a commercial 6-row unit for testing and transferring this technology to the private sector during the 2005 harvest season. The thermal defoliator has the proven potential for providing an environmental friendly means of managing and defoliating cotton without the use of chemicals. 4b List other significant accomplishments, if any. Development of a Mechanical Chile Production System. Full-scale testing of an experimental post-harvest cleaner for mechanized red chile production system was completed by the Chile Pepper Task Force and the means of delivering acceptable machine harvested red chile was demonstrated. Some of this cleaning technology is currently
being adapted for commercial use. Also, an experimental mechanical chile stand thinner was successfully field tested and the design was transferred to a commercial company to build commercial units available for the 2005 chile growing season. Both the cleaning and thinning technology are important components for developing mechanized chile pepper production systems. 5. Describe the major accomplishments over the life of the project, including their predicted or actual impact. The accomplishments made under this new project are fully consistent with relevant milestones listed in the Project Plan, and with relevant research components as defined in the National Program 203 and 306 Action Plans. Accomplishments under this project contribute to the fulfilling of the ARS mission statement which in part is to, "To enhance the economic viability and competitiveness of U.S. agriculture by maintaining the quality of harvested agricultural commodities or otherwise enhancing their
marketability, meeting consumer needs, developing environmentally friendly and efficient processing concepts...". The first major accomplishment under this new project is as follows: It was demonstrated in the laboratory, utilizing a full size rotary- knife roller gin stand, that sustained ginning rates could be maintained of 4 bales/hour for upland cotton and 6 bales/hour for Pima cotton without increased fiber damage or excessive ginning roll temperatures. Normal rotary-knife roller ginning rates for upland and Pima cotton are approximately 1 and 1.5 bales/hour respectively. It is currently not possible to roller gin upland cottons at the 1 bale/hour rate and be economically competitive. Therefore, upland cottons in the U.S. are normally processed through saw gins and only Pima cottons are currently roller ginned. Roller ginning cotton results in a fiber, regardless of the variety, that has better length and nep properties than comparative cottons processed through a saw gin
stand. The increased rotary-knife roller ginning rate has the potential of significantly increasing U.S. upland cotton quality by changing the ginning method used. 6. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end- user (industry, farmer, other scientists)? What are the constraints, if known, to the adoption and durability of the technology products? The thermal defoliator technology has been transferred to an industry partner to build a commercial prototype 6-row prototype. A single unit should be available during the 2005 cotton harvest season for further field testing that will be jointly monitored by the industry partner and the USDA. Possible constraints could be the possible higher cost of using a ground-based rig for defoliation versus air application of chemical defoliants. Two components (red chile cleaner and chile thinner) of a mechanized chile production system have been
successfully demonstrated by experimental prototypes. Commercial thinners have already been built and are available to chile producers. Components of the cleaner are currently being adapted for use directly on a chile harvester. 7. List your most important publications in the popular press and presentations to organizations and articles written about your work. (NOTE: List your peer reviewed publications below). Comis, Don. 2005. Processing hot peppers like cotton. Agricultural Research Magazine, February 2005, p. 18-19. Valco, T.D., Anthony, W.S., Byler, R.K., Pelletier, M.G., Hughs, S.E., Norman, W.M. 2004. Moisture restoration of cotton. Cotton Gin and Oil Mill Press, September 4, 2004. p. 5-8. Hughs, S.E. 2005. Air quality and EPA impacts on cotton gins. New Mexico Cotton Growers 9th Annual Cotton Conference, January 26, 2005, Ruidoso, New Mexico. Hughs, S.E., 2005. Updates on the mechanical thinner, cleaning equipment, improving mechanical harvester operations. 2005 New Mexico
Chile Conference, February 1, 2005, Las Cruces, New Mexico. Hughs, S.E., Lightfoot, Tye. 2005. Cotton ginning basics. 2005 Ag Fest, February 17, 2005, Santa Fe, New Mexico. Funk, P., Baker, K. 2005. Progress in thermal defoliation and issues in spindle picking of cotton. New Mexico Section American Society of Agricultural Engineers, March 4, 2005, Truth or Consequences, New Mexico. Lightfoot, Tye. 2005. Kids, kows, & more. Farm & Ranch Museum, April 5, 2005, Las Cruces, New Mexico. Hughs, S.E. 2005. Ginning quality cotton. Arizona Cotton Ginners Association Meeting, April 28, 2005, Prescott, Arizona. Hughs, S.E. 2005. USDA ginning research program. New Mexico Cotton Ginners 2005 Meeting and Regional Research Liaison Committee Meeting, July 7, 2005, Ruidoso, New Mexico. Hughs, S.E., Armijo, C., Baker, K., Lightfoot, T. 2005. Joint ARS and NMSU research. NMSU 3rd Annual Academic and Research Field Day, July 27, 2005, Las Cruces, New Mexico.
Impacts
(N/A)
Publications
- Funk, P.A., Armijo, C.B., Hanson, A.T., Samani, Z.A., Macias-Corral, M.A., Smith, G.B., Riordan, J.T. 2005. Converting gin and dairy wastes to methane. Transactions of the ASAE. 48(3):1197-1201.
- Hughs, S.E., Armijo, C.B., Whitelock, D.P., Buser, M.D. 2005. Particulate concentration measurement at a New Mexico cotton gin. In: Proceedings of the Beltwide Cotton Conferences, January 4-7, 2005, New Orleans, Louisiana. p. 553-559. 2005 CDROM.
- Baker, K.D., Hughs, S.E., Mcalister, D.D. 2005. Bale moisture addition with a rotor spray system. In: Proceedings of the Beltwide Cotton Conference, January 4-7, 2005, New Orleans, Louisiana. p. 808-812. 2005 CDROM.
- Whitelock, D.P., Armijo, C.B., Hughs, S.E. 2005. Investigation of the effects of lint cleaning machinery loading on fiber quality at a commercial roller gin. In: Proceedings of the Beltwide Cotton Conferences, January 4-7, 2005, New Orleans, Louisiana. p. 789-794. 2005 CDROM.
- Siddaiah, M., Hughs, S.E., Lieberman, M., Foulk, J. 2005. Comparison of small trash measurements between imaging techniques and afis. In: Proceedings of the National Cotton Council, Beltwide Cotton Conferences, January 4-7, 2005, New Orleans, Louisiana. 2005 CDROM. p. 2362-2372.
- Funk, P.A., Armijo, C., Brashears, A. D., Showler, A.T., Fletcher, R.S., Hutmacher, R.B., Godfrey, L.D., McGuire, M.R., Bancroft, J.S. 2005. Thermal defoliation in 2004. In: Proceedings of the National Cotton Council, Beltwide Cotton Conferences, January 4-7, 2005, New Orleans, Louisiana. p. 648-656. 2005 CDROM.
- Baker, K.D., Hughs, S.E., Buser, M. 2004. Comparison of source testing and boundary line testing for emissions from a cotton gin. American Society of Agricultural Engineers. Paper No. 044011.
- Baker, K.D., Hughs, S.E., McAlister, D.D., Mackey, J. 2004. Quality of spindle-picked cotton. American Society of Agricultural Engineers. Paper No. 041052.
- Capareda, S.C., Buser, M.D., Whitelock, D.P., Green, J.K., Parnell, Jr., C. B., Shaw, B.W., Wanjura, J.D. 2005. Particle size distribution analysis of cotton dust and its impact on PM10 concentration measurements. In: Proceedings of the Beltwide Cotton Conference, January 4-7, 2005, New Orleans, Louisiana. p. 631-642. 2005 CDROM.
- Wanjura, J.D., Buser, M.D., Whitelock, D.P., Armijo, C.B., Hughs, S.E., Green, J.K., Norman, B.M., Capareda, S.C., Hamm, L.B., Parnell, Jr., C.B., Shaw, B.W., Lacey, R.E. 2005. An engineering analysis of a method used to determine property line setback distances for cotton gins. In: Proceedings of the Beltwide Cotton Conference, January 4-7, 2005, New Orleans, Louisiana. p. 614-629. 2005 CDROM.
- Buser, M.D., Whitelock, D.P., Holt, G.A., Armijo, C.B., Wang, L. 2005. Preliminary evaluation of the baffle-type pre-separator in terms of baffle location, critical air velocity, and loading rate. In: Proceedings of the Beltwide Cotton Conference, January 4-7, 2005, New Orleans, Louisiana. p. 469-485. 2005 CDROM.
- Backe, E., McAlister III, D.D., Hughs, S.E. 2004. Bale moisture addition - a case study, part II. Proceedings of the Beltwide Cotton Conference, San Antonio, TX, January 5-9, 2004. p. 3002-3007.
- Chun, D.T., McAlister III, D.D., Hughs, S.E., Cobb, D.R. Microbial census and cotton bale moisture during a 6-month storage. Beltwide Cotton Conferences, National Cotton Council, Memphis, TN. 2004. p. 2425-2431.
- Foulk, J.A., Mcalister Iii, D.D., Himmelsbach, D.S., Hughs, S.E. 2004. Mid- infrared spectroscopy of cotton rotor dust. Journal of Cotton Science, Vol. 8, Issue 4, 243-253.
- Foulk, J.A., McAlister III, D.D., Himmelsbach, D.S., Hughs, S.E. Identification of trash. Cotton Incorporated 16th Annual Fiber Selection (EFS) Conference Proceedings. 2004. Available from: www.cottoninc. com/efsnew/Proceedings03/FoulkJ%20EFSCONF03.PDF
- Zhang, J., Lu, Y., Adranga, H., Hughs, S.E., Cantrell, R.G. 2005. Genetic improvement of New Mexico ACALA cotton germplasm and their genetic divergence. In: Proceedings of the Beltwide Cotton Conference, January 4-7, 2005, New Orleans, Louisiana. p. 886-891. 2005 CDROM.
- Macias-Corral, M.A., Samani, Z.A., Hanson, A.T., Dela Vega, P., Funk, P.A. 2005. Producing energy and soil amendment from dairy manure and cotton gin waste. Transactions of the ASAE. 8(4):1521-1526.
|