Technologies Under Development

Technologies Currently Under Development

Saw Band Pre-Cleaner for Mechanically Picked Cotton

Saw Band Pre-Cleaner for Mechanically Picked Cotton

Description and salient Technical features

CIRCOT has developed a saw band cleaner to remove fine trash, burrs etc. from mechanically picked seed cotton. A saw cylinder cleaner works on the sling off principle of saw cylinders and scrubbing action of cylinder cleaners was used for cleaning of fine trash particles and a small amount of sticks and burs remained in cotton from machine picked seed cotton.

This machine consists of hopper, feeder, two cylinder cleaners, a saw band cleaner and a reclaimer cylinder. The feeder rollers receive cotton from the hopper and deliver it to cylinder cleaning stage of the machine where from the seed cotton is kicked to saw band-cleaning stage. In the saw band cleaning stage, the saw band cylinder is used to clean the seed cotton with the help of combing and centrifugal actions of its cylinders. Finally, the seed cotton is fed to reclaiming stage of machine and trash is collected in trash chamber.

Salient technical specifications:

Spike cylinder Diameter:270 mm
Spike cylinder speed:670 rpm
Saw cylinders diameter:435 mm and 215 mm
Saw cylinders speed:430 rpm and 360 rpm
Doffing brushes diameter & speed:314 mm, 1400 rpm
Cylinder length:900 mm
Power requirement:3.73 kW and 0.74 kW for feed roller
Machine size:1.4 x 1.5 x 2.7 m

Safety: All the belts and chains are properly covered

Performance Results

Output capacity: 800-850 kg seed cotton / h
Stick removal efficiency:18-20%
Fine trash removal efficiency:25-30%
Labour requirement:Two persons

Cost: Rs.3.5 Lakh

How the new technology will impact the income of the farmers / end users:

The saw band cleaner can be used for removal of fine trash and a small amount of burs and sticks remained in the machine picked cotton after cleaning by stick machine. It improves quality of lint and reduces wear and tear of machine. Due to improved grade of cotton, ginners / traders fetch premium rates which indirectly benefit the cotton farmers.

Stick Removal Machine for Mechanically Picked

Stick Removal Machine for Mechanically Picked

Description and salient Technical features

In India, all the seed cotton is handpicked by human labour mainly women. Hand picking is very tedious, and in order to meet the scarcity of labour and timeliness of operation, efforts are being made on mechanization of cotton harvesting. It is observed that the machine picked seed cotton contains around 15-20% trash content including sticks, burrs etc.

CIRCOT has developed stick removal machine to remove the large sized vegetative trash components from mechanically picked cotton. This machine utilizes centrifugal force of high speed rotating saw cylinders to sling off cotton, the stripping action of round grids extracts the trash from seed cotton. The machine consists of hopper, feeder, kicker cylinder, saw cylinders, doffing brush cylinders, loading brushes, grid bars and deflectors. There was no measurable fibre damage observed during trash removal operations, however, slight improvement in uniformity ratio was observed in cleaned cotton mainly because of removal of short fibres during cleaning operation.

Salient technical specifications:

No. of saw cylinder:03
Cylinder length and diameter:600 and 420 mm respectively
Speed of cylinder and doffing brush:360 and 1080 rpm respectively
No. of doffing brushes:02
Doffing brush diameters:398 mm and 314 nun
Power requirement:3.73 kW and 0.74 kW
Machine size:1.4 x1.5 x 2.8m

Safety: All the belts and chains are properly covered

Performance Results

Output capacity: 750-800 kg seed cotton / h
Stick removal efficiency:80-85%
Fine trash removal efficiency:35-40%
Labour requirement:Two persons

Cost: Rs.3 Lakh

How the new technology will impact the income of the farmers / end users:

The stick machine can be used for removal of sticks, burs, leaves, fine trash content etc. from the machine picked cotton. It improves quality of lint and reduces wear and tear of machine. Due to improved grade of cotton, ginners / traders fetch premium rates which indirectly benefit the cotton farmers.

Banana Fibre Yarn Making Machines

Banana Fibre Yarn Making Machines

Description and salient Technical features

Banana yarn making machine consists of mechanical softening machine, Staple fibre cutting machine, carding machine, Gill drawing machine and Ring spinning machine. These machines can be used for spinning banana fibres to spun yarn counts in the range of 600 to 60 tex.

Banana fibre mechanical softening machine: This machine has helically fluted top rollers and bottom rollers with a feed lattice for feeding the banana fibre strands. The fibre gets softened because of the crushing action that takes place between the rollers and normally 2 to 3 passages are given for banana fibre.

Banana staple fibre cutting machine: Machine consists of calendar rollers, stationery and oscillating blade. At present the banana fibres are cut in the range of length of 15 to 20 cm.

Banana fibre carding machine: The machine consists of various elements namely conveyor, feed roller, first set of worker-stripper assembly, second set of worker-stripper assembly, doffer, crush rollers, funnel tray, delivery rollers and crimper. Except crush rollers and delivery rollers all the other rollers are clothed with metal pins. The main function of this machine is to clean the mechanically extracted banana pseudo stem fibres by removing pith and gummy matter from the fibre surface and make the fibres suitable for yarn formation on a spinning machine.

Banana fibre gill drawing machine: This machine consists of a set of back roller and front roller, steel combs etc. Four to five slivers are fed to this machine and the slivers are doubled and drafted to required thickness.

Banana fibre ring spinning machine: This machine has 4 spinning heads with a 3/3 slip draft system having top and bottom aprons for controlling the fibre movement. The sliver is drafted to suitable thickness and twist is inserted to the yarn and wound on to a bobbin of 8 inches diameter. The machine has digital display for spindle speed, front roller speed and back roller speed.

Performance Results

Ring spinning 
Production/ spindle:1.0 kg/h for 600 tex/1s Ne yarn
Efficiency:90%,
Yarn Realisation:80%
Manpower:3 skilled workers

Cost:

Fibre to Yarn conversion cost: Rs.25/kg
Cost of Machinery: Rs.40 lakh

How the new technology will impact the income of the farmers / end users:

Fibre production per year will be around 27,000 kg, if machine is operated 8 hours per day. Assuming a banana fibre production of 600kg per ha, one set of machine requires around 50 ha of banana cultivation.
Banana crop generate huge quantity of biomass in the form of pseudostem, leaves, suckers etc.

At present, this biomass particularly pseudostem is absolute waste in most of the states of India. Not only this, but for disposing pseudostem presently farmers are spending about Rs. 8000 to 10000 per ha.By making banana yarn at village level, farmers can add value to the fibre and earn a profit of Z 40 per kg of yarn and it works out to earning of Rs. 24,000 per ha.

Social/environmental/other benefits

Disposal of pseudostem in a routine ways i.e., dumping on field bunds and burning, disposing in nalla/natural drains etc. causes environmental problems. The yarn making process is totally a mechanical process and no chemicals are used during processing. Apart from benefit to farmers, there is an opportunity for rural employment.

Status of commercialization / IPO rights etc.

Technology is underdevelopment

An Accelerated Process for the Preparation of Bio-enriched Compost from Cotton Plant Residues

An Accelerated Process for the Preparation of Bio-enriched Compost from Cotton Plant Residues

Description and salient Technical features

Conventionally cotton growing farmers are burning the cotton stalks in the field itself. The technology gives an alternative solution for cotton growing farmers for utilization of cotton crop wastes and converts into nutrient rich compost. Farmers can prepare compost at nearby field within shorter period of time (three months) by using accelerated process developed by CIRCOT using efficient microbial strains.

Compost is suitable for better crop growth and yield of agricultural and horticultural crops.

Salient features of compost:

  • Total NPK >4%
  • CN ratio < 20 %
  • Enriched with plant growth promoting microorganisms

How the new technology will impact the income of the farmers / end users:

The technology would help in generation of additional income to cotton growing farmers and improvement of soil health.

Social/environmental/other benefits

  • Avoids burning of cotton stalks in the field itself andreduces the greenhouse gases emission to the atmosphere
  • Additional revenue for farmers
  • Improvement of soil health.

Status of commercialization / IPO rights etc.

Technology is underdevelopment

Segregator Machine for Coconut Fibre

Segregator Machine for Coconut Fibre

Description and salient Technical features

The segregator will assort the coconut fibres into different grades, which can be used for development of high value products. It works on the principle of air drag and gravity for quality based segregation of fibres. Opening roller of the machine opens the fibres and throws them into a chamber. A high speed blower sucks the fibre mass through a dumb bell shaped conduit.

The geometry of conduit is so designed that it will suck only light fibres by the air drag force generated due to cyclone inside the chamber. The heavy fibres will remain stationed in the chamber and will be later carried forward by a delivery conveyor. Coconut fibres are clearly distinguished into two grades, fine and coarse. Coarse fibres are subjected to second treatment to obtain medium grade fibres. Segregation trials on the newly developed machine are in progress.

Performance Results

The machine outturn : 50-60 kg/h
Efficiency is one-third of fine fibres produced out of the total bulk processed. Operating cost Rs. 40 – 50/ h.

Cost: Rs.2.5 Lakh


How the new technology will impact the income of the farmers / end users:

Segregated fibres will fetch higher price and give good monetary returns to coconut growers.

Social/environmental/other benefits

Innovative products can be designed and produced for fine segregated fibres which is a value addition. Coconut will be considered as bio industrial crop in technical textile sector which is an emerging sector. Further dust produced due to coconut pith can be reduced which is a health hazard in industry.