Professional Documents
Culture Documents
1
Dr.Vijayan Gurumurthy Iyer Techno-Economic-Environmental Study and Check Consultancy Services,
Vijayan Gurumurthy Iyer GSTIN/UIN: 33AIZPG9735D1ZW, OLPE Counsellor and Co-ordinator, The EDI of
India
2
Professional Engineer, Engineering Council of India (ECI), A-2/31, Kendriya Vihar-II, Paruthipattu, Avadi,
Chennai-600 071, India
Abstract: The roller gin can be defined as a cotton gin in which the lint cotton is pulled from the seed-cotton (or kapas)
by a roller covered with vegetable-tanned leather from walrus (roller leather) and assisted by a fixed knife and moving
knife. Walrus (a large sea mammal) has a thick layer of blubber (Whale fat). Blubber is an important part of a walrus
marine mammal’s anatomy. It stores energy, insulates heat, and increases buoyancy. Energy is stored in the thick oily
layer of blubber. Blubber covers the entire body of walruses except for their fins, flippers, and flukes. Walrus leather is
extremely exotic. It has a deep and strong grainer skin and texture interfibrillar that is situated between fibrils for lint
cotton cellulose fiber adherence. The innovative chrome-free leather product does not contain hazardous chrome heavy
metal and acidic substance. In a standard chrome tanned leather, there is chromium content of between 3% to 5% of
chromium fixed to the fibril, and the standard value for extractable Cr(III) is 50-1000 ppm (mg/kg) as per the tanning
process condition and tightly bound to the collagen fibril proteins. Chromium as Cr(VI) is known to be toxic to animals
and humans so it needs to be used and handed under extremely high safety precautions. The permissible
environmentally friendly limit of total chromium in leather is 0.1 ppm (mg/kg). About 85% of the World’s leather is chrome
tanned leather. The covering leather washer packing is chrome tanned leather from buffalo skins for packing the rollers
of cotton ginning machinery. The covering leather hide washer or "Packing" used for cotton roller gin roller is very
important to the operation and maintenance of the gin and is supposed to be a major expense item for a commercial
double roller (DR) ginning machine. It is important to conduct research experiments on various roller covering materials
to find a suitable material that enables faster ginning, longer wearing results, maintenance of good fibre quality, cheaper
and eco-friendliness. A major research project was performed at the Belgaum roller ginning industries to compare the
performance of different roller covering materials.
*Address correspondence to this author at the Professional Engineer, Chromium is a carcinogenic substance. The
Engineering Council of India (ECI), A-2/31, Kendriya Vihar-II, Paruthipattu,
Avadi, Chennai-600 071, India; E-mail: vijayaniyergurumurthy@rediffmail.com chromium leakage is so alarming that it leads to a
higher prevalence of cancer among cotton ginning mill development of an eco-friendly, pollution-free chrome
and textile workers. Chromium can cause serious less roller [1].
health hazards to those who wear cotton garments.
There are rubberized cotton fabric (RCF) rollers, felt
No attempt was made to find an eco-friendly (90% wool) rollers, fibre glass woven (FGW) rollers,
method for cotton fibre separation for many years. and vegetable dyed tanned leather rollers to replace
Since several progressive ginning and pressing unit the CCLC rollers, but the mill owners are not buying
owners showed interest in the alternate roll materials them because of ginning problems and high price.
for their double roller gins, this major research project However, few ginning machinery manufacturers are still
has been attempted to find a suitable material that not sure about the commercial success of the
enables faster ginning, longer wearing results, alternatives to CCLC rollers and enormous awareness
maintenance of good fiber quality, cheaper and eco- is required to be created among the ginning industries.
friendliness while comparing performance to primarily
eliminate the contamination of cotton and its products, 2. MATERIALS AND METHODS
air pollution in cotton ginning mills, and other ginning
When two or more materials are combined to
problems at the source through the design and
produce a new material, which possesses many
Evaluating Gin Roller Covering Materials for Cotton Double Roller Gins World Journal of Textile Engineering and Technology, 2021, Vol. 7 51
superior properties to any one of the constituent increase friction and to enable the fibres removed
materials. Such a material is known as composite smoothly after ginning operation [4].
materials/ composites. Mechanical tests were
conducted to determine the best materials by knowing CCLC roller is pressed against the stationary knife
mechanical engineering properties such as durability, at considerable pressure. The roller rotates at a speed
strength, and hardness and cotton technological as of 100 revolutions per minute. This enables the pulling
well as environmental properties [2]. of fibres from the seed-cotton (or kapas) due to
abrasion between rollers and knife, leads to a
2.1. Roller Construction, Covering, Testing, and continuous rate of wear and tear of the rollers. This
Maintenance action is known as the dust-producing grinding action
of the CCLC roller and adds to the chromium burden of
The roller gin roller is the major component of a the environment. This contaminates and pollutes the
roller gin stand. CCLC rollers are commonly covered surroundings as powdered chrome-specific dust (CSD).
with a packing made of CCLC bonded and stitched Data is given in table.
together in the form of 78 to 80 numbers compressed
disk washers, depending upon thickness. These CCLC 2.2. Mechanical Testing
washers are mounted on a hexagonal or square steel
shaft at a maximum handheld pressure through a 2.2.1. Hardness Test
conventional hand press and these roller washers A hardness test can be defined as the resistance of
should be sufficiently pressed on the roller shaft. the material to localized plastic deformation. In this
Leather tanneries supply this type of CCLC leather process of hardness test, the specimen is indented by
washers in a bulk quantity to the ginning industries in a special tip which may be a steel ball or a diamond
turn employed as CCLC rollers in DR gins [3]. The cone. The tip first overcomes the resistance of the
washers should be sufficiently turned and polished on material to elastic deformation and then a small amount
the lathe to obtain a smooth surface. The hardness of of plastic deformation. Hardness measurements for
the pressing roller should be such that if the hard determining the properties of roller covering have been
pressure of the thumbnail is applied on the smooth found to select a better material and to design a new
roller surface the nail mark should be seen. Such roller. The hardness of roller covering materials was
rollers are well-pressed rollers. This could also be measured at the ginning surface after the rollers have
known by hearing the peculiar sound. One can become been tried. Brinell’s Hardness Test has been carried
familiar with this by sufficient practice and experience out by pressing a steel ball known as the indenter into
in the line. The fully pressed, finished and spirally the roller covering. The mean diameter of the
grooved gin roller is finally used in gins every day to indentation left on the specimen is measured after the
Table: Chromium Pollution Consolidated Samples’ Report and Relevant Eco-Standards for the season-I
load is removed. The value of the hardness of various woven fibre glass roller covering, rubberized cotton
roller covering materials is mathematically calculated fabric roller, felt (90% wool) covering roller. The
by the formula and is given in Brinell’s Hardness physical characteristics of the are materials are what
Number (B.H.N.). B.H.N. (Brinell’s Hardness Number) given the gin roll it is frictional and wear properties that
= Load on ball / Area of Indentation; make the roller ginning process possible. During the
ginning process, the covering material is worn away
3. RESULTS AND DISCUSSIONS and must eventually be replaced.
3.1. Environmental Impact Assessment (EIA) 3.2. Evaluation of Different Roller Coverings
Mitigation Study Materials on a Roller Gin Roller
Virtual research was done to compare the ginning The roughness of the covering and its tendency to
performance of various roller covering materials. The remain rough seems a likely cause of the greater
Roller gin separates the fibre from the seed-cotton ginning rate of the proposed experimental coverings.
(kapas). Rollers have been experimented with made The work focuses on this property and may provide a
from Pandharpur leather - paper washers, coconut coir better understanding of the relationships between
material, chrome composite leather cladding, covering construction, roller life, ginning rate, and fibre
vegetable-tanned walrus leather covering, eco-friendly properties [5].
tanned leather covering, coir board roller covering,
Evaluating Gin Roller Covering Materials for Cotton Double Roller Gins World Journal of Textile Engineering and Technology, 2021, Vol. 7 53
Table 2: Roller Covering Materials and Construction Details of the Trial Rollers; Roller Covering Material: Chrome
Composite Leather Clad Roller (CCLC) Covering
3.3. Evaluating Vegetable Tanned Walrus Leather solution are used for processing the walrus and buffalo
Roller Covering leather. The time required to tan a considerable
quantity of hides and skins is two to three days. This
Vegetable Tannins are complex glycosides of process is cheaper than the chrome-tanned leather
tanning acids obtained from tree barks and woods. process. However, the ginning rate with the cost of the
Traditionally vegetable tanning was carried out by
eco-friendly tanned leather covering is not enough to
immersing hides in a pit of water with layers of tannin-
warrant changing from the conventional CCLC rollers
bearing bark or wood sandwiched between them. The
being used in the industry.
objectives of this experiment were to define the
physical properties of a roller material that contribute to Physical Characteristics of Various Trial Rollers
its ginning rate potential to produce good quality
chrome-free-lint cotton and to search for a better roller Roller code = ECO, VT, CCLC, FRP, RPR, RCF, WFG,
covering material. However, the ginning rate with the
Roller length = 190 mm
cost of the vegetable-tanned walrus leather covering
material is not enough to warrant changing from the Roller diameter = 185 mm
conventional CCLC rollers being used in the industry.
Roller hardness = 89-106 B.H.N.
3.4. Evaluating Eco-Friendly Tanned Leather Roller
Covering Layers of fabrics = Good number of fibres; Moderate
number of fibres
Eco-friendly tanning leather is an innovative eco-
friendly technology. This uses only neem oil and liquid Fabric fibre color = White /Brown
soap solution. 2-4 % neem oil and 1-3% liquid soap
54 World Journal of Textile Engineering and Technology, 2021, Vol. 7 Vijayan Gurumurthy Iyer
Figure 5: Systems Diagram modelling for environmental impact of chromium sepcific dust.
Table 3: Roller Covering Materials and Construction Details of the Trial Rollers; Roller Covering Material: Vegetable
Tanned Walrus Leather Clad Covering
Table 4: Roller Covering Materials and Construction Details of the Trial Rollers; Roller Covering Material: Eco-Friendly
Neem Tanned Leather Clad-Roller Covering
Figure 6: A graph of wearing rate of dust – producing grinding of chrome roller and ECO – friendly roller.
Layers of fabrics at ginning surface = Yes/No 3.5. Evaluating a Coir Board Roller Covering on a
DR Gin
Approximate distance fibre bristles protrude above
rubber surface: 0.5 to 1 mm An experimental covering made of a coir board was
tested. Final removal of the ginned fibers from the
Rubber compounding: Resilient condition; Rubber roller-gin cylinder presents problems that depend upon
Board Standards the nature of the covering [6].
56 World Journal of Textile Engineering and Technology, 2021, Vol. 7 Vijayan Gurumurthy Iyer
Table 5: Roller Covering Materials and Construction Details of the Trial Rollers; Roller Covering Material: Coir Board
Roller Covering
3.6. Evaluating Woven Fibre-Glass Roller Covering better than the CCLC roller coverings they ginned at
on a DR Gin 1.5 times the rate and resulted in less roller heat, there
were significant differences in the fibre quality and
An experimental DR gin roller covering, made from spinning test measurements.
woven fibre glass fabrics (FGF), was tested on a DR
gin to evaluate its ginning performance and effect on However, the ginning rate with the cost of the
fibre quality. The experimental covering was much woven fibre glass material is not enough to warrant
better than the present CCLC covering; it ginned at 1.5 changing from the conventional CCLC rollers being
times the present rate and the lint quality is very good. used in the industry.
The roller temperature has been reduced to 4 to 5 °C
(39° C) as compared to 45°C in other coverings. 3.7. Evaluating Rubberized Cotton Fabric (RCF)
Roller Covering Material
Analysis showed that the fiberglass fibres did not
contaminate knitted cloth made from the lint ginned
The RCF rollers both for laboratory and commercial
with the roller. Final removal of the ginned fibers from
studies have been designed, fabricated, and
the roller-gin cylinder presents problems that depend
experimented on special-built GRED and DR gins.
upon the nature of the FGF covering. If the fibres are
These rollers are covered with packing-type roller
returned to the ginning point, jamming and chokes,
covering material made from multiple layers of cotton
commonly known as “back-lash”, occur.
fabric bonded together with a rubber compound. Four
Woven fibre glass roller covering-Roller-II has been types of roller covering material with different rubber
evaluated for fibre quality and ginning performance in a compounding and multiple fabrics composition were
DR gin. This type of woven fiberglass roller covering on tested in GRED and DR gins. Two rollers are
a roller gin cover has pulled more fibres under the fixed abandoned primarily due to higher wear and tear rate,
knife, increasing ginning rates reducing heat generated adhesive failure, and ginning is not carried out properly.
at the surface of the roller at a roller speed of 100 Two RCF rollers were found effective and successful in
revolutions per minute. The fibre quality and quality of ginning out the seed-cotton in an eco-friendly way
knitted fabrics were good compared to the CCLC besides resulting in higher productivity in terms of
covering results and thus free from contamination ginning rate potential and cotton technological
problems. However, in a DR gin, the covering failed parameters. The RCF rollers made with experimental
after thirty-five hours of normal ginning. The covering materials are tested (1) to find obvious
experimental gin roller coverings (Roller-II) are much shortcomings in performance such as short roller life,
Table 6: Roller Covering Materials And Construction Details of the Trial Rollers; Roller Covering Material: Woven
FibreGlass Fabrics (FGF) Roller Covering
Figure 7: Engineering drawing of the cladding of chrome composite leather washers comprising of roller of a double roller
ginning machine.
Figure 8: Assembly drawing of rubberized cotton fabric (RCF) washers for making RCF rollers of double roller gins.
temperature, and lint contamination (2) to establish the technology, design engineering features, and assembly
existence of some ginning rate potential. One of the experience show that the RCF roller covering can be
specimens of roller gin covering material is the most selected with the following characteristics: hardness of
superior among all types tested in respect of ginning 106 B.H.N. (type Brinell Hardness Number), 7 to 10
rate potential (kg of cotton ginned per unit of time at layers of fabrics 20 mm length, and fabric thickness of
maximum feed rate) and amount of energy consumed fabrics 1.2 mm, The rubber compound is resilient and
(work required to gin a kg of lint). Conventional fabric fibre bristles protrude 0.76 mm beyond the rubber
and rubber roller gin covering material is selected with surface is maintained despite wear [7].
the following characteristics viz. The manufacturing
58 World Journal of Textile Engineering and Technology, 2021, Vol. 7 Vijayan Gurumurthy Iyer
Figure 9: Pollution-free rubberized fabric washer for roller of cotton rolling gins.
Based on the design and development of various industry. However, the ginning rate with the cost of the
rollers with subsequent performance evaluation RCF is not enough to warrant changing from the
studies, pollution-free RCF roller has been conventional CCLC rollers being used in the industry.
demonstrated concerning techno-economical and eco-
friendliness in ginning industries. The newly developed 3.8. Evaluating Felt (90% Wool) Packing Roller
Covering
RCF rollers are successful and effective in functioning
and in ginning out seed cotton. Environmental
An experimental covering made of rubber packing
parameters of CCLC roller and RCF roller ginneries are
was tested. Final removal of the ginned fibers from the
given stating cost economics in a table. Eco-friendly
roller-gin roller presents problems that depend upon
RCF ginnery sounds better in all aspects about cotton
the nature of the covering [8].
technological parameters, techno-economical and
environmental aspects. The research was done to compare the ginning
performance of a felt material (90% wool) against the
Comparative economics have been worked out for
commonly used CCLC covering material. This
the chrome-less RCF roller ginneries and CCLC rollers
particular felting used is soft to perform satisfactorily
ginneries; that is for the 'System before and after
over a long period without wear. This felt material wore
modifications' and for commercialization to the ginning
well, ginned at an optimum rate while maintaining fibre
Table 7: Roller Covering Materials and Construction Details of the Trial Rollers; Roller Covering Material: Rubberized
Cotton Fabric Roller Covering
Table 8: Roller Covering Materials and Construction Details of the Trial Rollers; Roller Covering Material: 90% Wool
(Felt) Roller Covering
quality. However, the ginning rate with the cost of the with CCLC covering. Also, these roller materials were
felt material is not enough to warrant changing from the soft to perform satisfactorily over a long period without
conventional CCLC rollers being used in the industry undue wear. Further work will be done with other
[9]. materials to see if an alternative roller covering material
can be found.
4. CONCLUSION
For further reading is given below eBooks of High
The heart of the cotton roller ginning machine is the Impact SCI Published by International Publishers with
gin roller. A cotton roller gin separates the fiber from ISBN/ISSN;
the seed-cotton (or kapas) using the interaction and
interrelation of a fixed knife that rides with some 1. Iyer, Vijayan Gurumurthy (2019). “Gastric, Lung and
pressure against a rotating roller (known as gin roller), Oral Cancer Prevention Through Hazardous EIA
pulling fibres from the seed. Walrus hide, which was Process”, (ISBN: 978-620-0-32776-5) Edited By
used till 1940, was thought to be unequaled for roller Ijardan and Project ID: 198692 Published by LAP
coverings. The physical characteristics of this covering LAMBERT Academic Publishing of OmniScriptum
material are what give the gin roller its frictional and Publishing (September 23,2019). Group,17,Meldrum
wear properties are worn away and must eventually be Street, Beau Bassin 71504, Mauritius; 61.90 € Euro.
replaced. Replacement of the roller washer is done Paper back 152 pages.ISBN -10: 6200327769, ISBN-
subsequently. A common material made from a 13: 978-6200327765. Amazon.com, Paperback
composite of chromium tanned leather is used to cover $68.00 DOI:
the gin roller by the roller ginning industry. When cotton 10.13140/RG.2.2.21456.66565.Certificate of
is processed the ginned lint would contain about 180 to Appreciation and adopted for the essay submitted on
250 ppm of Cr (III) and Cr (VI) which are known to be Stomach and food pipe cancer prevention, precaution
highly carcinogenic. The roller ginning industry would & perseverance in treatment during the Independence
benefit if a satisfactory, cheaper, longer wearing roller day celebrations 15 th August 2019 ESOINDIA.
covering material and eco-friendly could be found.
Research and experiments show the possibility of 2. Iyer, Vijayan Gurumurthy (2017).“Self-Bibliographical
obtaining a substitute. Ginning investigations have References of Prof.(DL)Dr.Vijayan Gurumurthy Iyer,
been carried out to help meet the objective of designing Sub title: “Sustainable Self-Bibliographical References
and developing eco-friendly roller coverings for cotton About Sustainable Literature by Prof.(D.SC.,LL.D.,DL)
double roller (DR) gins. Various eco-friendly substitutes Dr. Vijayan Gurumurthy Iyer ”, (ISBN-13: 978-3-330-
and methods have been studied and devised, such as 06124-8) ISBN-10: 3330061243 EAN:
felt (90% wool) , vegetable-tanned leather, woven fibre 9783330061248) and published by LAP LAMBERT
glass fabrics, neem oil-tanned leather, 100% wool Academic Publishing of OmniScriptum GmbH & Co.
material, alternative rubber, and rubber-processing KG Bahnhofstraße 28, D-66111 Saarbrücken,
technology, and modification of the commonly Germany; 64.90 € Euro. Number of Pages 196.
employed CCLC roller gins. The research was done to Published on 24.03.2017.
compare the ginning performance of rollers against the
3. Iyer, Vijayan Gurumurthy (2011).“Properties of
commonly used CCLC roller. Tests showed that the
Covering Materials of Roller Used in Cotton Roller
ginning rate of some rollers was significantly very good
Gin”, Sub title: “Unsafe Chromium Contamination and
Evaluating Gin Roller Covering Materials for Cotton Double Roller Gins World Journal of Textile Engineering and Technology, 2021, Vol. 7 61
Project ID: 115451, This book is Polish Translation 219008,, Category: General Natural Sciences, Date of
from the Original Published under ISBN: 978-620-3- Publication: 14 th June, 2021. Publisher: LAP
86970-5. Publisher: LAP LAMBERT Academic LAMBERT Academic Publishing (OmniScriptum
Publishing (OmniScriptum S.R.L. Publishing Group), S.R.L. Publishing Group). https://www.lap-
PP.97. https://www.sciencia-scripts.com, Translation publishing.com/
Published by Sciencia Scripts. https://issuu.com/vijayangurumurthyiyer/docs/life_scie
https://issuu.com/vijayangurumurthyiyer/docs/ebook_i nce_ebook_978-620-3-91144-2_2_
n_polish_poland_1_isbn_978-620-3-74782-9_1
ACKNOWLEDGEMENTS
8. Iyer,Vijayan Gurumurthy (2021). Title of e.book
entitled “Covid-19 Crisis and Environmental Law- The author is thankful to the editor of World Journal
Opportunties for Improvement” and subtitle of book of Textile Engineering and Technology (WJTET) and
entitled “Environmental Health Impact Assessment Publishers M/S Scientific Array for publication of the
(EHIA) Process & Strategic Crisis and Environmental present manuscript.
Assessment (SCEA), ISBN: 978-613-8-95389-0, Book
REFERENCES
Project ID: # 12241 Published by Scholars Press,
Republic of Moldova, Europe, Editor: aplatonova, SIA [1] Vijayan Iyer G. Book of the Properties of Covering Materials
OmniScriptum Publishing, www.scholars-press.com of Roller Used in Cotton Roller Gin, Lap Lambert Academic
Publishing GmbH & Co.KG, Germany 2011; 160(1): 1.
9. Digital Flip book sustainable agricultural business [2] Vijayan Iyer G. Journal of Textile Association (India) 2005;
66(3): 265.
management- case study and check,
[3] Vijayan Iyer G. Journal of Agricultural Safety and Health
https://issuu.com/vijayangurumurthyiyer/docs/sustaina 2006; 13(1): 33.
ble__agricultural_business_management__dr. https://doi.org/10.13031/2013.22310
[4] Vijayan Iyer G. WSEAS Transactions on Environment and
10. Iyer,Vijayan Gurumurthy (2021). Short title entitled “ Development 2006; 2(4): 425.
[5] Vijayan Iyer G. Journal of the Textile Association (India)
Sustainable Agricultural Business Management Case
2010; 71(2): 60.
Study & Check” and Sub title entitled Honorary https://doi.org/10.1111/j.1751-3928.2010.00115.x
Doctoral Degree in Business Administration / Public [6] Vijayan Iyer G. Journal of the Textile Association (India)
Administration DBA/DPA (Honoris Causa) By 1998; 59(7): 87.
[7] Vijayan Iyer G. Journal of Textile Association (India) 2005;
Research (ISBN: 978-620-3-87022-0) “ Editor
65(3): 265.
acosciuc, Book Project ID # 218880 Publisher: LAP [8] Vijayan Iyer G. Journal of Textile Association (India) 2007;
LAMBERT Academic Publishing (OmniScriptum 67(3): 255.
S.R.L. Publishing Group). [9] Vijayan Gurumurthy Iyer. “Environmental Impacts on the
Design and Arts Environment For Industry 3.0 Cotton Roller
Ginning Process”. New Trends and Issues Proceedings on
11. Iyer,Vijayan Gurumurthy (2021). eBook Title entitled “ Humanities and Social Sciences (e.ISSN 2547-8818) , Open
Strategic Environmental Assessment (SEA) Process Journal Systems (OJS), Volume 08, Number 1 (2020) PP.22-
for Sustainable Life Sciences ”, Sub titled ‘ Evaluating 34 (13 Pages) , https://un-
pub.eu/ojs/index.php/pntsbs/article/view/5788, 9 th World
Cotton Gin Walrus Roller Covering Materials for Conference on Design and Arts (WCDA-2020) , Date of
Cotton Double Roller Gins’ (ISBN-13: 978-620-3- Publication 4 th June 2021, Publishers: Birlesik Dunya
Yenilik Arastirma ve Yayincilik Merkezi. The Academic Event
91144-2, ISBN-10: 6203911445, EAN: Group (TAEG), BD Center, Turkey., PP. 22-34.
9786203911442) “ Editor acosciuc, Book Project ID: # https://doi.org/10.18844/prosoc.v7i4.5788
DOI: https://doi.org/10.31437/2415-5489.2021.07.7