Modeling and Optimization of High-Capacity Experimental Reclaimers to Minimize the Seed and Lint Loss during Roller Ginning of Upland and Pima Cotton

Abstract

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.