In the present study, two high-capacity experimental roller gin reclaimers, (a) a modified 3-saw cylinder stick machine (three-saw) and (b) a modified 2-saw cylinder gin stand feeder (700), were optimized with respect to reclaimer saw cylinder speed and carryover/seed ratio to minimize the seed and lint loss for both Pima and Upland cotton varieties and were compared to a conventional roller gin reclaimer operated by the ginning industry under standard conditions. Developed regression models adequately described the seed and lint loss phenomena during the reclaiming process. Surface plots indicated that the reclaimer saw cylinder speed and carryover/seed ratio impacted the seed and lint loss for both the 3-saw and 700 reclaimers. Under optimized conditions, the 700 reclaimer resulted in lower lint and seed loss compared to the 3-saw reclaimer when using Upland cotton. In the case of Pima cotton, under optimized conditions, the 3-saw reclaimer had 38% lower lint loss and 24% higher seed loss compared to the 700 reclaimer. The regression equations of both 3-saw and 700 reclaimers were further used to optimize the reclaimers in parallel arrangement to minimize the seed and lint loss. With Upland cotton, the economic loss was about 2.5 times greater with the conventional reclaimer compared to the 3-saw and 700 reclaimers ($15.97/bale loss for the conventional, $8.63 for the 3-saw, and $6.44 for the 700 reclaimers). With Pima cotton, the conventional reclaimer resulted in a lower economic loss ($3.44/bale) compared to the 700 reclaimer which had a loss of about $3.59/bale.

Developing cotton ginning methods that improve fiber length uniformity index to levels that are compatible with newer and more efficient spinning technologies would expand market share and increase the demand for cotton products and give U.S. cotton a competitive edge to synthetic fibers. Older studies on lint cleaning machines showed that the most widely used feed mechanism that places fiber on the cleaning cylinder damages the fiber and reduces uniformity. The present study evaluates how conventional and experimental feed mechanisms affect uniformity. The lint cleaners were used with both saw and roller gin stands. Four diverse cotton cultivars from the Far West, Southwest, and Mid-South were used in the test. Statistical analysis used a random effects modeling approach which included constructing a 95% confidence interval for each ginning treatment around the predicted mean for the fiber property of interest, and then examining which treatments overlap (for comparison). Results show that the micro-saw gin with the direct-feed lint cleaner had the best uniformity at 85.8%. Prior research has shown that roller ginning is consistently higher in uniformity than any type of saw ginning. In this study, the roller ginning treatments had uniformities of 85.3 and 85.6%, so it is encouraging that the saw gin stand with the direct-feed lint cleaner had very high uniformity. This suggests that it may be beneficial to place fiber directly onto the lint cleaning saw without changing direction. Additionally, the saw gin-coupled lint cleaner had a uniformity of 84.3% which is also a respectable level of uniformity. These results indicate that the direct-feed lint cleaner and coupled lint cleaner warrant further testing under better controlled conditions.

Current saw- and pin-type lint-cleaning systems used by the ginning industry have challenges retaining lint quality. The objective of the research was to test a novel pneumatic fractionator for the lint cleaning of an Upland cotton variety that was both saw- and roller-ginned. The process variables tested were initial lint moisture content in the range of 5.5–15% w.b., line pressure in the range of 276–552 kPa, and residence time in the range of 15–45 s. Experiments were conducted based on a central composite design. Models based on response surface methodology (RSM) were developed for final lint moisture, total trash extracted during lint cleaning, and High-Volume Instrument (HVI) fiber quality. The RSM models adequately described the pneumatic fractionation process, as indicated by the coefficient of determination, predicted vs. observed plots, and residual values. The results indicated that the interactions among initial lint moisture content, residence time, and line pressure significantly affected lint quality. At the optimized pneumatic fractionator process conditions, the predicted lint quality attributes were better for both roller- and saw-ginned lint compared to lint cleaned with saw- and pin-type lint cleaners. The upper half mean length increased by 1 mm, the uniformity index was higher by 0.5–1 percentage points, the strength was 1–2 g/tex higher, and the short fiber content was reduced by more than one percentage point. Color grades were better for pneumatic fractionated lint compared to saw- and pin-type lint cleaning methods. Lint value was approximately 4 cents/kg higher for both saw- and roller-ginned pneumatic fractionated lint, compared to lint cleaned using saw- and pin-type lint cleaners. The novel pneumatic fractionator, when compared to industry-standard saw- and pin-type lint cleaners, effectively cleaned lint while retaining fiber quality and removing most of the motes and trash.

Research is needed to improve walnut drying throughput and energy consumption in hulling plants, but current methods for sampling nuts in commercial drying bins and measuring nut moisture content limit the capacity to investigate the drying process thoroughly. A novel apparatus for obtaining walnut samples at multiple depths and locations in stadium drying bins and a novel rapid method for accurately determining walnut in-shell moisture content were developed. A second rapid moisture measurement method involving near-infrared light (NIR) was also investigated. The sampling apparatus consisted of three sampling columns installed in each walnut drying bin. Each column had gate valves at four elevations, admitting approximately 30 in-shell walnuts to rectangular buckets hanging on a cable just below each gate valve. To collect samples, the gates were opened and closed, the buckets were withdrawn, the nut samples were collected and sealed in labeled bags, and then the buckets were returned to the column to be ready for the next sampling interval. This configuration, sampling nuts at four levels across three locations in the drying bin, allowed better moisture content variability investigation during in-bin walnut drying. The rapid moisture content measurement method consisted of selecting twelve representative in-shell walnuts from each sample and grinding them in a mill. Twelve grams were sub-sampled from the well-mixed ground material and dried in an oven at 105 ± 1 °C for 3 h, then reweighed to determine moisture loss. The coefficient of variation for sub-samples within an individual sample (n = 4) averaged 2.65% for moisture contents ranging from 6% to 47% dry basis. The rapid moisture content measurement method reduced the drying time from 24 h to 3 h compared to conventional oven drying method, with an accuracy of ±0.5 to 1.5% of the full moisture content range. The best correlation observed between the NIR methodology and the rapid moisture content method was 0.74 R². These new in-bin walnut sampling and moisture-content measurement methods will accelerate future research aimed at improving walnut drying at commercial huller facilities.