Monitoring of the ginning process - Uster Technologies

® 

USTER INTELLIGIN-M 

APPLICATION REPORT 

Monitoring of the ginning 

process 

THE GIN PROCESS CONTROL SYSTEM 

S. Dönmez Kretzschmar, A. Ellison 

April 2010 

SE 639

THE STANDARD FROM FIBER TO FABRIC 

Copyright 2010 by Uster Technologies AG 

All rights reserved. No part of this publication may be reproduced, stored in a retrieval 

system, translated or transmitted in any form or by any means, electronically, 

mechanically, photocopying, recording or otherwise, without the prior permission 

in writing of the copyright owner. 

veronesi\TT\Schulung_Dokumente\On-Line\INTELLIGIN\SE-439_Monitoring of the ginning process 

2 (20) USTER ® PRODUCTS


Contents 

1 Introduction ................................................................................ 5 

2 The total quality control of the ginning process..................... 5 

2.1 What is the function of a cotton gin ............................................ 5 

2.2 Why we should monitor the ginning process.............................. 7 

2.3 Benefits and the opportunities of the USTER ® INTELLIGIN ....... 8 

3 System Features ...................................................................... 10 

3.1 The USTER ® INTELLIGIN –M organization ............................... 11 

3.2 The USTER ® INTELLIGIN-M Reports........................................ 14 

4 Field Test .................................................................................. 16 

5 Conclusion................................................................................ 19 

6 Literature................................................................................... 19 

USTER ® PRODUCTS 3 (20)




1 Introduction 

After the harvest, a producer wants the optimum yield possible and the 

spinner wants the highest quality fiber available. The ginner is asked to 

make both happen. Cotton ginning is an important step in the cotton production 

sequence. The purpose of the ginning operation is separating the 

cotton seed from the lint and removing sticks and coarse trash from the 

input material. Input materials coming from a variety of growing areas are 

processed together and the process acts as a first blending of massive 

quantities of fibers [1]. The true art of ginning is knowing when and how to 

use a technical advantage. Because not all cottons are the same, the ginning 

process requires constant monitoring based on incoming harvest 

qualities, fiber characteristics, picking methods and growing conditions. 

The USTER ® INTELLIGIN-M monitors and/or controls the ginning process 

through a system of online sampling stations located throughout the gin 

from the module feeder to the bale press. Information on fiber moisture, 

trash and color are fed into a main console where software analyzes fiber 

value for optimum dryer temperature and lint cleaning practices. Optional 

bypass valves automatically reroute cotton only through necessary equipment 

preserving fiber quality and reducing processing costs. From an easyto-use 

console, the ginner has a complete picture of all variables and can 

manually adjust the process or set perimeters to allow the process to run 

automatically. The USTER ® INTELLIGIN-M provides total quality control of 

the ginning process. 

2 The total quality control of the ginning process 

2.1 What is the function of a cotton gin 

The principal function of the cotton gin is to separate lint from seed. The gin 

must also be equipped to remove foreign matter, moisture, and other contaminants 

that significantly reduce the value of the ginned lint. 

Gins (Fig. 1) must produce a quality of lint that brings the owner of the cotton 

maximum value while meeting the demands of the spinner and consumer. 

Cotton seed is an important by-product of cotton manufacture and 

most of the seed is crushed for oil or used for animal feed. According to the 

yarn producer, cotton seed represents hazard and excessive seed-coat 

fragments make the spinning process more difficult. 



Fig. 1 

Gin 

On the other hand, the economics of ginning are affected by the sale of byproducts, 

and thus they have some effect on the cost of the cotton mill. The 

cost of the cotton in the mill represents roughly half of the yarn cost. Not 

only the cost but also the quality of the product depends the total quality 

control of the ginning process Therefore the yarn producer must have a 

strong interest in the basic fiber production [1]. 

Fig. 2 

Cotton lint and cotton seed 

Cotton Ginning 

Transportation to 

warehouse 

Warehousing / Storage 

Transportation 

to mill 

Preparation in Mill 

Fig. 3 

Fiber Flow – Field to Sliver 



2.2 Why we should monitor the ginning process 

We should monitor the ginning process because the cotton is a huge variable 

with different: 

Cotton Varieties 

Fiber Characteristics 

Picking Methods (Spindle – stripper – hand ) 

Growing Conditions 

Harvest Conditions 

Market Changing Requirements 

Domestic 

Export 

Because not all cottons are the same, the ginning process requires constant 

monitoring based on incoming harvest qualities, fiber characteristics, 

picking methods and growing conditions. The USTER ® INTELLIGIN-M 

monitors and/or controls the ginning process through a system of online 

sampling stations located throughout the gin from the module feeder to the 

bale press. Information on fiber moisture, trash and color are fed into a 

main console where software analyzes fiber value for optimum dryer temperature 

and lint cleaning practices. The USTER ® INTELLIGIN provides 

total quality control of the ginning process (Fig. 4). Thus the ginner has a 

complete picture of all variables and can manually adjust the process or set 

perimeters to allow the process to run automatically. 

High Moisture – Max Drying 

Intelligin Zone 

Maximum 

Advantage 

High Trash 

Domestic 

Export 

Low Trash 

Intelligin Minimum 

Advantage 

Low Moisture – Min Drying 

Fig. 4 

Process Control Decisions 



2.3 Benefits and the opportunities of the USTER ® 

INTELLIGIN 

In Table 1 and in the following figures (Fig. 5 to Fig. 9) we can see the 

measurement and control opportunities and benefits of the USTER ® IN- 

TELLIGIN-M during the ginning process. 

Ginning 

Process 

Sections of Gin 

Measurement 

Opportunities 

Control 

Opportunites 

Benefits 

Figure 

Seed Cotton 

Entry Into 

Gin 

1. Module Feeder 

2. Suction Telescopes 

3. Big-J Feed Control 

- Incoming Moisture 

- Incoming Trash 

- Feed Rate Seed 

Cotton 

- Gin Performance 

- Trash Levels – 

Cleaning % Efficiency 

Fig. 5 

Seed Cotton Cleaning 

& Drying 

4. Vertical Flow Drier 

5. Incline Cleaner 

6. Stripper Cleaner 

7. Stick Machine 

8. Tower Drier 

9. Incline Cleaner 

10. Impact Cleaner 

- Temperature for 

Drying 

- Quantity of Pre- 

Cleaning Stages 

- Maximized Yield 

- Gin Performance 

- Fiber Quality (Length, 

Neps, Trash, 

Strength 

- Energy Costs 

Fig. 6 

Ginning – 

Separation 

of Seed and 

11. Conveyor Distributor 

12. Feeder 

13. Gin Stand 

- Moisture - Temperature for 

Drying 

- Optimized Moisture 

for Ginning 

- Fiber Quality 

Fig. 7 

Trash Removal From 

Lint 

14. Centrifugal Cleaner 

15. 24-D Tandem Lint 

Cleaners 

- Trash Level in Lint 

- Color 

- Moisture 

- Quantity of Lint 

Cleaners 

- Quantity Grid Bars 

(Louver Control) 


- Fiber Quantity – No 

Unnecessary Cleaning 

- Fiber Quality 

- Maximized Value 

Based on Market Criteria 

Fig. 8 

Baling – Final Package 

16. Battery Condenser 

17. Covered Lint Slide 

17. Moisture Addition 

18. Belt Feeder 

19. Bale Press 

20. Bale Tying 

21. Bale Bagging and 

Conveying 

- Trash Final 

- Color Final 

- Moisture in Lint After 

Cleaning 

- Moisture in Bale 

- Feedback to Prior 

Measurements 

- Moisture Restoration 


- Immediate Knowledge 

Grades for 

Merchandizing 

- Final Color & Trash 

Grades for Allocation 

& Storage 

- Final Moisture Optimized 

- Warehousing Efficiencies 

Fig. 9 

Table 1 The measurement and control opportunities and benefits of the USTER ® INTELLIGIN -M 



Fig. 5 

Seed Cotton Entry Into Gin 

Fig. 6 

Seed Cotton Cleaning & Drying 

Fig. 7 

Ginning - Separation of Seed 

and Lint 

Fig. 8 

Trash Removal From Lint 

Fig. 9 

Baling - Final Package 



3 System Features 

The basic USTER ® INTELLIGIN-M system is for monitoring, information, 

and database collection purposes only. The system includes one measurement 

station at lint flue. The USTER ® INTELLIGIN-M system provides 

leaf grade, % trash, color grade, extraneous matter identification, and lint 

moisture measurement at lint flue. Reports on machine use, moisture, leaf 

and color as well as gas & electricity use on a per bale basis if outputs are 

provided. 

There are also some additional available options or measurements: 

 

 

 

 

 

Louvered Grid Bar Control 

Incoming module moisture 

Final Bale moisture 

Energy Monitoring 

Machine Efficiency Monitoring 

The “Monitor” system gives gins with hands on management the necessary 

tools for processing quality cotton. This system will monitor the gin process 

from manual changes and adjustments. Ginners can use realtime information 

to make decisions for setting dryer temperatures and determining leaf 

grades. The “Control” system constantly controls the gin to set specifications 

without constant manual changes, leaving the ginner to focus on labor 

and maintenance issues. 

Monitor or Control system 

Real-time measurement of fiber color, trash and moisture 

Patented color and trash sensor technology to HVI modules 

Reporting software for an up-to-the-minute data analysis 

Control system only 

Patented decision making software algorithms 

Main console with touch screen controls that integrates into current gin 

control database 

Automatic control of dryer temperature for optimum fiber moisture 

Automatic control of seed cotton and lint cleaner bypass valves 



3.1 The USTER ® INTELLIGIN –M organization 

The following diagrams shows us the USTER ® INTELLIGIN-M organization 

and the system layout of the sampling station and the USTER ® INTELLIGIN 

host console in the gin (Fig. 10 and Fig. 11). 

Gin Office 

Gin 

Internet 

Real Time 

Display 

Real Time 

Display 

Remote 

Service and 

Support 

Process 

Measurements 

Reports 

Remote 

Monitoring by 

Gin Mgmt 

USDA 

Information Input 

for Calibration 

Gin Console 

Sampling Station 

Fig. 10 

The USTER ® INTELLIGIN – 

M organization 

IntelliGin host console 

Sampling Station Fig. 11 

System layout in the gin 

The system has a sampling station and a host console. Positioned just past 

the lint cleaners, this station gives a final reading of fiber moisture, trash 

and color to ensure the accuracy of the decisions made before cotton enters 

the bale press. This information is used to give feedback to ginners so 

that they might make adjustments to the ginning process to optimize fiber 

qualities, yield and moisture content (Fig. 12 and Fig. 13) 



Fig. 12 

Lint Flue Sampling Station 

Fig. 13 

Lint Flue Sampling Station 

In Fig. 14, we can see the sampling station and all sensors such as paddle 

sampler, moisture measuring sensor and the USTER ® HVI color head. 

Paddle Sampler 

Moisture Measuring Sensor 

HVI Color Head 

Fig. 14 

Sampling Station 

Open, showing all sensors 



The main console gives the ginner a complete summary of the ginning 

process. It provides information that is necessary for the ginner to make 

informed decisions to improve fiber moisture levels, and preserve fiber 

properties (Fig. 15). 

Fig. 15 

Gin Host Console 

By using this system, the user can make reliable cotton value decisions by 

using real time information which is obtained by the USTER ® INTELLIGIN – 

M. 

Classer‘s 

Trash 

Leaf Grade 

Measurement 

(% area) 

1 


Specification 

Measurement 

Opportunities 

Control 

Opportunites 

Benefits 

Indication of bark and 

grass 

Automatic Bark & Grass 

Detection 

Quick feedback to producer 

Optimized ginning decisions 

Reduced discounts if 

ginning procedures will 

reduce contamination 

Table 2 

The measurement and control opportunities and benefits of the USTER ® INTELLIGIN-M Texas 

Fig. 17 

Indication of Bark and Grass 

3.2 The USTER ® INTELLIGIN-M Reports 

The USTER ® INTELLIGIN-M gives the user easy-to-read graphical reports 

and provide summaries and in-depth analysis of bale characteristics for 

producers (Fig. 18). 

Fig. 18 

Report 



The trends for process improvement are also available for gin administration 

(Fig. 19). 

Fig. 19 

Display of the USTER ® IN- 

TELLIGIN 

The reporting package delivers analytical reports that detail every level of 

the ginning process. Reports such as color grade, leaf grade and moisture 

provide value to producers, while production and shift reports are essential 

to improving gin profitability.The monitoring of the final bale moisture enables 

the ginner to see the realtime results of the ginning process as it affects 

the moisture of cotton (Fig. 20). 

Fig. 20 

Graphs of the bales 



Moisture of cotton is critical when decisions are being made to optimize the 

dryer settings. The final bale moisture sensor also allows the ginners to see 

the results of any supplemental moisture restoration system. Research 

shows that optimum moisture level in a bale is 7.5%, matching USDA conditions 

for classing cotton. Achieving this balance depends on accurate 

measurements throughout the ginning process (Fig. 21). 

Fig. 21 

Actual dryer temperatures 

4 Field Test 

During a field test, we have taken cotton from the same cotton field. The 

yield has been made under the same conditions and the same amount of 

raw material has been processes first time by using (active) the USTER ® 

INTELLIGIN and the second time without using (passive) the USTER ® IN- 

TELLIGIN. 

These cotton bales are tested by using the USTER ® HVI. When we look at 

the percentage of the total measured bales which are ginned with the 

USTER ® INTELLIGIN, the fibers shorter than 34 mm are only 1%. The 

bales which have fiber lengths of 37 mm or more have a percentage of 

70%. On the contrary, the bales which are ginned without the USTER ® IN- 

TELLIGIN have generally lower mean length values (Fig. 22). 



80 

70 

60 

Without Intelligin 

58 

With Intelligin 

70 

50 

40 

30 

20 

24 

29 

18 

10 

0 

1 

< 34 35 - 36 > 37 

Fig. 22 

USTER ® HVI length values 

When we look at the percentage of the total measured bales which are 

ginned with the USTER ® INTELLIGIN, the fibers with a strength value of 28 

or less are only 24%. The bales which have fiber strength of 30 [cN/tex] or 

more have a percentage of 52%. On the contrary, the bales which are 

ginned without the USTER ® INTELLIGIN have generally lower mean 

strength values (Fig. 23). 

60 

50 

40 

41 



34 

52 

30 

24 25 24 

20 

10 

0 

< 28 29 > 30 

Fig. 23 

USTER ® HVI strength 

values 

In Fig. 24, we can see that the bales which are ginned with the USTER ® 

INTELLIGIN have generally better uniformity values. 



90 

80 

70 

60 

50 

40 

30 

20 

10 

0 

Without Intelligin With Intelligin 

77 

55 

44 

14 

9 

1 

77 - 79 80 - 82 83 - 85 

Fig. 24 

USTER ® HVI uniformity 

values 

In Fig. 25, we can see the quality characteristics of the cotton fibers. The 

mean values of neps, the upper quartile length (w) and short fiber content 

are given. According to the USTER ® AFIS values, we can easily see the 

positive effect of the USTER ® INTELLIGIN on the fiber quality (Fig. 25). 

350 

300 

310 



250 

200 

206 

150 

100 

50 

30 

0 

Neps [1/g] 

16 

Seed Coat Neps 

[1/g] 

12.4 

8.3 

1.13 1.21 

UQL [mm] SFC [%] 

Fig. 25 

USTER ® AFIS values 



5 Conclusion 

The USTER ® INTELLIGIN -M provides a cotton ginner with critical data, 

enabling the gin to process for weight and grade optimization. Using patented 

sensor technology, the USTER ® INTELLIGIN-M monitors the ginning 

process quality through a system of online sampling stations. Online measurements 

provide information on moisture, color and trash for optimum 

processing. The special software analyzes the fiber quality for optimum 

dryer temperature and cleaning practices. Cotton is not over- or underdried 

or over- or undercleaned – preserving grade and bale weight. With the optional 

final bale moisture system, the USTER ® INTELLIGIN also ensures 

that producers get the most value for their cotton while preserving fiber 

quality. 

6 Literature 

1. Lord, P. R., “Handbook of Yarn Production: Technology, Science and 

Economics”, Woodhead Publishing Limited, 2005. 



Uster Technologies AG 

Sonnenbergstrasse 10 

CH-8610 Uster / Switzerland 

Phone +41 43 366 36 36 

Fax +41 43 366 36 37 

www.uster.com 

sales@uster.com 

20 (20) 

USTER ® PRODUCTS

Monitoring of the ginning process - Uster Technologies

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