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2006-ag-246

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INTRODUCTIONINTRODUCTION

Today’s slogan in the international textile or Today’s slogan in the international textile or any other market is quality, so the production any other market is quality, so the production or yield % stand at second priority, no doubt or yield % stand at second priority, no doubt high production is an even demand of world high production is an even demand of world population.population.

Contamination free textiles are the ultimate Contamination free textiles are the ultimate target of the manufacturer along with other target of the manufacturer along with other quality control applications. quality control applications.

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Cotton sorter is used for foreign material Cotton sorter is used for foreign material

detection in the blow room. The contaminants detection in the blow room. The contaminants

are removed by means of very fast pneumatic are removed by means of very fast pneumatic

ejectors. Cotton sorter is useful to improve the ejectors. Cotton sorter is useful to improve the

quality of raw material and also upgrade the quality of raw material and also upgrade the

low quality cotton bales by removing low quality cotton bales by removing

contamination. contamination.

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Definition of contaminantsDefinition of contaminantsContaminants in cotton can be described as a deviation in color and sizeContaminants in cotton can be described as a deviation in color and size

The line camera interprets a defect as color level deviationsThe line camera interprets a defect as color level deviations The contaminant size is defined as a combination of contaminant width and The contaminant size is defined as a combination of contaminant width and

contaminant lengthcontaminant length

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Some contaminant RegionsSome contaminant Regions

High level of High level of contaminationcontamination

India, Pakistan, Sudan , India, Pakistan, Sudan , Uzbekistan, Syria, EgyptUzbekistan, Syria, Egypt

Lower level of Lower level of contaminationcontamination

Argentina, Israel, Mali, Argentina, Israel, Mali, USA, China, Turkey, USA, China, Turkey, Sudan, Zimbabwe, Sudan, Zimbabwe, Uganda, South AfricaUganda, South Africa

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TThe he CottonSorterCottonSorter in the blow line in the blow line

Detect Detect foreign fibresforeign fibres and and contaminantscontaminants in raw in raw cottoncotton▪ ▪ jute parts, packaging material, parts of cloths, jute parts, packaging material, parts of cloths,

burnt tufts, oil, dirt, plastic, feathers, etc.burnt tufts, oil, dirt, plastic, feathers, etc.▪ ▪ wood, leaves, branches, stones, etc.wood, leaves, branches, stones, etc.

Remove the contaminants by means of very Remove the contaminants by means of very fast pneumatic ejectorfast pneumatic ejector

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Affect of contamination (present in Affect of contamination (present in cotton bale) on constructed fabriccotton bale) on constructed fabric

If If a 3cm by 3cm contaminating rag is present in a a 3cm by 3cm contaminating rag is present in a cotton bale thencotton bale then

Output of the card is 20 meter contaminated sliverOutput of the card is 20 meter contaminated sliver

Output of a two step drawing process (E=8x8) is 1280 meter Output of a two step drawing process (E=8x8) is 1280 meter contaminate sliver.contaminate sliver.

Output of a spinning spindle (E=150) is 192.000 meter Output of a spinning spindle (E=150) is 192.000 meter contaminated yarn.contaminated yarn.

In this yarn there will be a contamination each 5 meter.In this yarn there will be a contamination each 5 meter.

The fabric construction will result in 6 contaminations/cm .The fabric construction will result in 6 contaminations/cm .

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Cotton Sorter in Blow Room LineCotton Sorter in Blow Room LineAuto-PluckerAuto-Plucker

↓↓Multi MixerMulti Mixer

↓↓3-Roller Opener3-Roller Opener

↓↓Cotton-SorterCotton-Sorter

↓↓Heavy Particle RemoverHeavy Particle Remover

↓↓Integrated OpenerIntegrated Opener

↓↓Vertical OpenerVertical Opener

↓↓DedusterDeduster

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COTTON SORTER in practiceCOTTON SORTER in practice

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CharacteristicsCharacteristics Enclosure sealed for dust Enclosure sealed for dust

protectionprotectionW=1.75 m H=1.24m W=1.75 m H=1.24m

L=1.55 mL=1.55 m

Power consumption 2 kW Power consumption 2 kW

Rectangular ducts to guide Rectangular ducts to guide the cotton in a perfect way the cotton in a perfect way through the sensor tubethrough the sensor tube

Pneumatic ejector to remove Pneumatic ejector to remove the contaminantsthe contaminants

Waste basket for ejected Waste basket for ejected contaminantscontaminants

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The key words of the The key words of the Cotton SorterCotton Sorter

Installed in the opening line after the first openerInstalled in the opening line after the first opener

Using 4 very fast CCD camerasUsing 4 very fast CCD cameras

No influence of environmentNo influence of environment

Easy to operateEasy to operate

Easy to maintainEasy to maintain

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Working principleWorking principlecamera’s

speed sensor

ejectors

mirror

windows

waste basket

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The COTTON SORTER in The COTTON SORTER in practicepractice Pneumatic ejectorPneumatic ejector

Ejector areaEjector area

Waste basketWaste basket

Detection areaDetection area

Electronic cabinetElectronic cabinet

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Inside the COTTON SORTERInside the COTTON SORTER

Tube with windows for camera’s Tube with windows for camera’s

100% transparent (glass 100% transparent (glass plate)plate)

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Inside the COTTON SORTERInside the COTTON SORTER• CCD line scan cameras

– 2594 pixels

• Illumination by 16 light tubes

– High frequency light (28 kHz)

– White light spectrum– Two year life time

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The ejection systemThe ejection system

20 valves-10 msec. reaction time-50 msec. blow 20 valves-10 msec. reaction time-50 msec. blow timetimeEjection of about 10 grams of material Ejection of about 10 grams of material Pneumatic requires 80 psi filtered airPneumatic requires 80 psi filtered air

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CottonSorter: CottonSorter: LayoutLayout

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SPECIFICATIONSSPECIFICATIONS Detection of color deviation in cottonDetection of color deviation in cotton

Minimum 1x1 cm² detection surface guaranteedMinimum 1x1 cm² detection surface guaranteed

(85-90)% effectiveness at stable flow (compensation (85-90)% effectiveness at stable flow (compensation with speed sensor)with speed sensor)

▪ ▪ with cotton tufts smaller than the size of a fistwith cotton tufts smaller than the size of a fist

▪ ▪ with clean opticswith clean optics

▪ ▪ optimal setting of parametersoptimal setting of parameters

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Comparison of Cotton Sorter Comparison of Cotton Sorter BARCO and LoptexBARCO and Loptex

Cotton Cotton SorterSorter

EfficiencyEfficiency

(%)(%)

Production Production Rate Rate

Kg/hrKg/hr

Detection Detection MethodMethod

Speed Speed SensorSensor

BARCOBARCO 85-9085-90 12001200 CamerasCameras Yes Yes

LoptexLoptex 80-8580-85 10001000 SensorsSensors NoNo

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Keep it coolKeep it cool

Air conditionerAir conditioner

Eliminate the influence of outside Eliminate the influence of outside temperature fluctuations.temperature fluctuations.

Keep the inner side of the cabinet Keep the inner side of the cabinet in perfect operating conditions.in perfect operating conditions.

Avoid penetration of humidity Avoid penetration of humidity inside the enclosure.inside the enclosure.

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Why install a COTTON Why install a COTTON SORTER ? SORTER ?

Independent of the operator’s Independent of the operator’s goodwill goodwill

Upgrade possibilities for low Upgrade possibilities for low quality cotton balesquality cotton bales

Improve the quality of raw Improve the quality of raw material inputmaterial input

Evaluation of cotton suppliersEvaluation of cotton suppliers Higher and constant quality Higher and constant quality

of the end productof the end product Higher efficiency in the Higher efficiency in the

spinning and winding spinning and winding processes processes

Less complaints from Less complaints from customerscustomers

65 girls/shift – Bangladesh65 girls/shift – Bangladesh

200 girls/shift – Mainland China200 girls/shift – Mainland China

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THANKSTHANKS