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Chintan panchal | PRAMUKH STEEL INDUSTRIES | September 18, 2015

Fully Automatic Cotton Ginning Machine HOW TO CONVERT MANUAL GINNING PLANT IN TO FULLY AUTOMATIC GINNING PLANT

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Introduction: PRAMUKH STEEL INDUSTRIES

Found in 2007 by it’s young & visionary founders, Mr. Dinesh Panchal & Mr. Naimesh

Panchal, PRMUKH STEEL INDUSTRIES is nowadays leading engineering company

engaged in the Manufacturing of Best Quality Equipment’s for Cotton Roller

Gin, Cotton Baling Press Manufacturing & as well as Automatic Trolley System For

Feeding Raw Cotton Into Ginning Machine, Handling, Packing & Feeding Systems.

The Product range of Gin machinery includes wide range of equipment’s like Automatic

seed conveyor, Double Roller Gin Stand, Cotton Lint Cleaner, Automatic Cotton Baling

Press, Automatic Sensor Trolley Systems Plc Basis etc. PRAMUH STEEL also offers

Manual Machinery & Automatic Cotton Storage, and other cotton ginning machinery.

PRAMUKH STEEL INDUSTRIES is having its Manufacturing Facility at Ahmedabad

town of Gujarat State in INDIA. The company is having the Facility of Fabrication

Shop, Machine Shop Install (C.N.C, V.M.V & H.M.C), and Design Section & Assembly

Line to produce Best Quality Machinery. The Company is having well experienced team

of Engineers & Workers who are well experienced & very familiar to standard

manufacturing processes & work with Quality Practices to ensure Best Quality &

Performance of Equipment’s. The Company is also having the team of Service Engineers

to provide Best after sales services to the client.

About Indian Ginning System:

There are many cotton ginning factory’s in India as well as Some African Countries,

India Ranks First in area Under Cotton cultivation area spreading out to about 126.55

lakh hectares & the second largest producer of cotton fiber in the world, the Indian

cotton production was about 40 million bales in year 2014-15.(as per cotton advisory

board meeting report).

There are more than 65000 cotton factory in India, all cotton Factory or Cotton Ginnery

use only Double Roller Ginning Machine. And install 6 to 100 Roller Stand different

cotton lint production. Having Manual, Semi-Automatic & Fully Automatic Machinery.

The Fully Automatic cotton ginning factory running continuously and given best output

of cotton lint/cotton fiber in compare of manual or semi-automatic plants because in fully

automatic cotton factory use & instal best quality ginning, cleaning, feeding, & Pressing

machinery, But in semi-automatic or manual plant having big problem because they use

so many labors, now in days Labor Cost continuously grown up, and working capacity

is very low, so that the manual or semi-automatic plants can't compare with fully

automatic plant. Manual or semi-automatic plant capacity is very low because there is

not enough machinery in there cotton units.

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Different Between Automatic, Semi-automatic & Manual Cotton Plants:

MANUAL COTTON PLANT FULLY AUTOMATIC COTTON PLANT

MACHINERY FULLY

AUTOMATI

C PLANT

SEMI

AUTOMATI

C PLANT

MANUA

L

PLANT

A. PRE-CLEANER YES YES YES

B. STORAGE BOX YES YES NO

C. RAW CONVEOR YES YES NO

D. AUTOMATIC FEEDING SYSTEM

1. TROLLEY SYSTEM

2. CONVEYOR SYSTEM

YES NO NO

E. STEEL PLAT FORM NO YES YES

F. DOUBLE ROLLER STAND YES YES YES

G. COTTON LINT SUCTION SYSTEM YES NO +4

H. LINT COTTON BOTTOM BELT YES YES NO

I.. BLOER & CYCLONE YES YES NO

J. DUST COLLECTING ROOM YES NO NO

K. COTTON AIR SAPRATOR YES YES NO

L. COTTON PRE-CLEANER YES YES YES

M. COTTON LINT BELT TO PRESS YES NO NO

N. FULLY AUTOMATIC BALING PRESS

TWO BOX REVOLVING

YES NO NO

O. SINGLE BOX AUTOMATIC PRESS YES YES YES

P. MANUAL BALING PRESS NO NO YES

Q. AUTOMATIC BALE PACKING YES NO NO

R. AUTOMATIC BALE WEIGHT YES NO NO

S. FIRE DETECTION SYSTEM YES NO NO

T. AUTOMATIC REMOT SYSTEM YES NO NO

R. TOUCH SCREEN ELECTRICAL

PANEL

YES NO NO

S. SEED CONVEYOUR YES YES NO

T. ELEVATOR YES YES NO

PRAMUKH COTTON GINNING MACHINERY : FULLY AUTOMATIC PLANT

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In above table we have seen that many machinery not used in manual or semi-automatic

plants, like Automatic Trolley System for Raw Cotton Feeding, so the manual plant &

semi-automatic plant production capacity is lower compare of Fully Automatic plant. In

manual ginning plant ginners use so many labor for feeding a raw cotton in to gin

machine. It is very costly & labor cannot given same output compare of automatic trolley

system (feeding raw cotton in to Roller Gin Stand). Producer prices struggling to this

suffering, we resolve this problem after producing the automatic cotton feeding system

known as AUTOMATIC TROLLEY SYSTEM machine, which increases the production

and decrees cost of production.

What is Automatic Trolley System (raw cotton feeding system) & how is it viable:

The Automatic Trolley system is a Machine that sends (feed) raw cotton in to a Double

Roller Ginning Machine. In Manual plant Raw Cotton Feed by workers (by Hand).

Sometimes too much raw cotton is put into the double roller machine by cotton workers,

& this time the machine works from a very low power and it is very loaded so that the

repairing cost of the machine Constance increases, The second thing is that, Sometimes

less raw cotton is put into the machine by workers Subsequently, the machine rotates

half empty so that the production of cotton bales is low.

Due to these difficulties, Our Company PRAMUKH STEEL INDUSTRIES began the

production of the automatic feeding system (trolley system). This trolley system feed raw

cotton into double roller ginning machine continuously. And Provides uniform raw

cotton, the machine works on only 3 h.p motor. So the cost of trolley system is low in

compare of workers salary.

Automatic Trolley System (Automatic Raw Cotton Feeding system):

Automatic Trolley is working like a train, the machine goes forward and then come back

also deliver continues raw cotton in to double roller gin machine. It runs on tracks, and

the tracks are made from hardened solid steel so increasing the longevity of the machine.

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Trolley System: How it works as it should

A: Trolley Box Filling System:

When Raw Cotton Pass Through Pre-Cleaner Or Storage Box, that Time raw Cotton Comes

on Rubber Conveyor Belt And falls in the trolley box. Thereafter, the trolley takes a walk.

And raw cotton is put into each double roller gin machines. When the box is empty it is

return again at the same place again and again begins the task of filling the box.

RAW COTTON FEED INTO TROLLEY BOX

In this box we put a sensor that can automatically act in the box, which never allow extra

raw cotton, when the box is full sensor starts its work and stop to supply raw cotton also stop

Pre-Cleaner or Storage & Conveyor belts systems.

B: Feeding Points:

There are two feeding points in Trolley System, Left Side & Right side, both sides roller gin

get raw cotton, Cotton, which has been in the Trolley box of this machine is taken out from

the side of the points. The raw-cotton feeding system is work on automatic leaser sensor. The

Leaser System Auto Feeder (pressing machine) inside the cotton and're looking for It is a

watch that is less than cotton in feeder, it adds more cotton And the cotton is equal to go

down further.

C: leaser system:

In this trolley we install 6 automatic leaser. This leaser system works on Plc basis. We insert

our program we to run in the trolley we install our software in this plc system, so that trolley

works properly. What is plc system??????

D: PLC SYSTEM & ITS WORK:

A programmable logic controller, PLC, or programmable controller is a digital computer

used for automation of typically industrial electromechanical processes, such as control of

machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in

many machines, in many industries.

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ABOUT MANUAL OR SEMI-AUTOMATIC : COTTON GINNING FACTORY

In India or African Countries some cotton ginning factory use a platform system, in

semi-automatic plant raw cotton comes through conveyor belt or by suction system, but

in manual cotton plant, when pre-cleaner extract raw cotton The labor force, it fills in

the basket and Up the platform to deliver. And then the second class of workers, who are

working on platform of the raw cotton by hand, laying in auto-feeder (cotton ginning

machine). It's a very long, expensive and harmful process.

HOT TO CONVERT MANUAL OR SEMI-AUTOMATIC PLANT IN TO FULLY

AUTOMATIC PLANT

Generally, in cotton plant the Double Roller Ginning machines are placed in two lines.

Like this picture.

MANUAL COTTON GINNING PLANT : PLATFORM BASIS

This is a platform base cotton ginning plant. This types of ginning plant working in india

or some africancountries. But now the times when cotton demand is growing. The cotton

ginners are planning to increase their production And also wants to reduce production

costs.

Install trolley system against platform system…..

There are lots of cotton factory in india who change manual platform plant in fully

automatic trolley system plant. And increase cotton production & reduce production

cost.but what is a process to convert manual plant in to automatic plant.

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HOW TO CONVERT PLANT : (Manual To Automatic)

This is a system to remove old platform and install automatic trolley system.

Before we Start our work our Engineers visit sites (cotton factory or ginnery). And it will

check that Double Roller Cotton Ginning Machine deadline is at a distance, Whether it

is appropriate or not.What is the total height Godown, it's OK or not Whether the cotton

fiber belt is laid down,check all RCC foundation, it is proper or not all little They are

looking after all of the small things.

A ) Remove old platform & steel Structure

B ) Install Raw Cotton Rubber Conveyor System

C ) Install New Foundation Bolts (For New Structure)

D ) Install New Steel Structure (Ramp For Trolley)

E ) Install Trolley on Steel Structure

F ) Install All Sensor & Electronic componuns

G ) Install PANNEL Plc System

Contact us : www.pramukhgroups.com EMAIL ID : info@pramukhgroups.com