Progress 05/29/09 to 07/07/10
Outputs
Progress Report Objectives (from AD-416) New markets for cotton fibers are demanding a more uniform, high-quality product. This requires innovative new designs and methods in the harvesting and ginning process that will require: (1) developing handling and cleaning systems for cotton strippers that will improve the cleanliness and quality of seed cotton; (2) developing non-contact moisture sensors, and integration of these sensors into controls to continuously evaluate seed cotton moisture, along with new methods for detecting and removing contaminates and other foreign materials from seed cotton and lint that minimize fiber damage and maintain producer returns; (3) air quality research to evaluate cotton gin particulate matter emissions, current methods of measuring particulate matter emissions emitted from cotton gins, and abatement devices commonly used by cotton gins in reducing particulate matter emissions; (4) identifying and assessing techniques for improving the value and utility of gin byproducts; and (5) developing improved lint/seed separation techniques that will improve fiber quality and turnout. Approach (from AD-416) Handling and cleaning systems for cotton strippers that will improve the cleanliness and quality of seed cotton will be investigated. Non-contact moisture sensors will be developed and integrated into controls to continuously evaluate seed cotton moisture while processing. A new method for detecting and removing contaminates will be developed for seed cotton and lint. The detection and cleaning system will minimize fiber damage and maintain producer returns. Air quality research will be conducted to evaluate cotton gin particulate matter emissions, along with improved methods for measuring particulate matter emitted from cotton gins. Efficiency of abatement devices commonly used by cotton gins will have to be significantly improved to meet future standards for particulate matter emissions. Additional processing methods for cotton gin byproducts that improve the market value, turning financial liabilities into viable marketable products, will be developed. Additional projects will identify and assess techniques for improving the value and utility of gin byproducts. Operating parameters for the power roll gin stand technology will be developed to optimize seed, fiber, and yarn quality. This project, Harvesting And Ginning Processes To Enhance The Profitability Of Stripper Cotton, 6208-21410-006-00D, was terminated in July of 2010 and replaced with Enhancing the Profitability and Sustainability of Upland Cotton, Cottonseed, and Cotton Byproducts through Improvements in Harvesting, Ginning, and Mechanical Processes, 6208-21410-007-00D. Evaluation of stripper and picker based cotton harvest systems showed that pickers offer advantages to producers in terms of higher productivity under high yield conditions, lower ginning costs, and improved fiber/yarn quality. Ginning tests were conducted at the Lubbock Cotton Production and Processing gin lab to investigate the influence of various seed cotton cleaning machinery sequences and processing rates on lint turnout and fiber quality for picker and stripper harvested cottons. The results provide producers and ginners useful information on proper post-harvest processing techniques to maximize producer returns. A new seed cotton cleaning machine was developed for use onboard stripper type harvesters. Tests were conducted on the machine to maximize cleaning performance and minimize seed cotton loss. This machine will be used in a new harvesting system that provides improved productivity and seed cotton cleanliness. Additional laboratory and field studies were conducted to evaluate the influence of grid bar cross section geometry on commercial field cleaner performance. Experimental grid bars were identified that exhibited improved cleaning efficiency and reduced seed cotton loss compared to the conventional round grid bars used. A microwave moisture sensing developed at the lab had limited acceptance due to interference from metal bale ties used in cotton baling systems. Research was conducted to allow for use of the microwave moisture sensing system in the remaining market. Work is also ongoing to transfer the technology to other locations in the ginning industry and the geo- sciences for soil moisture sensing. Several tests were run using processed cotton byproducts as filler in composite boards. Composite samples were compared to industry standards, and a commercial thermoplastic composite board manufacturer volunteered to test the product on a commercial production line for next year. Accomplishments 01 Use of cotton byproducts in bio-materials. Expanded Polystyrene (EPS) a Expanded Polypropylene (EPP) are used to make non-biodegradable protecti packaging materials, a $2.2 billion industry. We developed six cotton byproduct blends and mechanical processing techniques that allowed for t cooperator to manufacture 100% biodegradable packaging composites, using their technology, which outperformed EPS and EPP. The cotton byproduct protective packaging material resulting from this research allowed the cooperator to launch the product in 2010 with a Fortune 500 company and gain the interest of two other Fortune 500 companies. More widespread us of cotton byproducts is expected within the next few years. 02 Critical cotton stripper harvesting operating factors identified by ARS researchers at Lubbock, Texas. The brush-roll cotton stripper is the dominant harvest method used in the Southern High Plains region where crops are produced under rain-fed or deficit irrigation conditions. Research on stripper-based harvest systems identified critical machine configuration and operating factors as well as pre-harvest crop conditioning practices that maximize harvesting efficiency and producer returns. This information is useful to cotton producers (farmers) in the Southern High Plains region who use stripper-based harvest systems under varying crop conditions. The findings of this work were summarized in various publications and disseminated via web-based media.
Impacts
(N/A)
Publications
- Wanjura, J.D., Holt, G.A., Byler, R.K., Brashears, A.D., Baker Jr, R.V. 2009. Development of a high-capacity extractor cleaner for cotton stripper harvesters: Machine design and optimization. Transactions of the ASABE. 52(6):1821-1829.
- Boykin Jr, J.C., Whitelock, D.P., Armijo, C.B., Buser, M.D., Holt, G.A., Valco, T.D., Findley, D.S., Barnes, E.M., Watson, M.D. 2010. Predicting Fiber Quality After Commercial Ginning Based on Fiber Obtained with Laboratory-Scale Gin Stands. Journal of Cotton Science. 14:34-45.
- Villalobos, C., Avila, M., Richardson, R., Holt, G.A., Bezanilla, G., Britton, C. 2009. Cotton by-products supplementation for steers grazing tobosagrass (Hilaria mutica [Buckl.] Benth.) rangeland. The Texas Journal of Agriculture and Natural Resources. 22:17-31.
- Holt, G.A., Laird, J.W. 2010. Power roll gin stand technology: Evaluation and optimization of rib rail angle and ginning point modifications on a retrofitted Lummus gin stand. Applied Engineering in Agriculture. 26(2) :209-215.
- Boykin Jr, J.C., Armijo, C.B., Whitelock, D.P., Buser, M.D., Holt, G.A., Valco, T.D., Findley, D.S., Barnes, E.M., Watson, M.D. 2009. Fractionation of Foreign Matter in Ginned Lint Before and After Lint Cleaning. Transactions of the ASABE. Vol. 52(2): 419-426.
- Bajwa, S., Bajwa, D., Holt, G.A. 2009. Optimal substitution of cotton burr and linters in thermoplastic composites. Forest Products Journal. 59(10) :40-46.
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