November 2003 Steamroller/Lint Moisture Restoration Update

Optimum Bale Moisture...Revisited

Back in the May 2003 Steamroller Update, I wrote a section on determining the proper bale moisture for your operation.  Bale moisture has remained a hot topic and in the past few weeks there have been several articles and notices warning of excessive moisture and recommendations of limiting bale moisture to 7.5%.  Because of the importance of this issue and my goal of keeping you updated with the latest and best information, I decided to address this issue again.

Sometimes part of my job is to find a diplomatic way to communicate messages, but in this case I am not going to mince words.  The importance to our industry is too high and the potential consequences for you are too costly to risk not being perfectly clear.  If you are spraying water directly on cotton you are doing harm to the cotton,  your press, the mills who buy your cotton, the reputation of your gin, your growers, and yourself.

It's no coincidence that all of the recent reports of  damage, mold, discoloration, misshaped and rejected bales have appeared at the same time that water sprayers have re-emerged.  The explanation is simple.  Water spray applies moisture to the cotton in layers.  A bale with some wet layers of cotton at 14% and dry layers at 4% may have an overall moisture of 8.0%, but deterioration and damage can occur long before the moisture within the bale equalizes.  Currently, the most optimistic research for spraying water suggests that spraying less than 1% moisture regain may be safe.  Anything beyond that poses a definite risk, which can be very costly.

The solution to this problem is not to create an across the board  recommended limit to bale moisture and decrease the limit until the problem goes away.  The solution requires the recognition of differences between moist air restoration and spraying water and treat them accordingly.  To do any different is not only dishonest, but dangerous, as the reputation of the cotton industry is at stake.

Moist air applies moisture to cotton evenly throughout the bale, allowing more moisture to be applied safely.  Modern moist air applicators, such as the Steamroller, can restore moisture to reasonable desired levels in safe and effective manner.  Moist air restoration offers benefits to the growers, gin, and mills.  If you are looking for a method to restore moisture to lint, the good news is the choice is clear.  Using moist air is the way to go.  Want even better news?  Read on and see what the Sam Jackson engineering team is doing to increase your options.

New Invention Means More Options For You...Introducing the MoistureTracker

Lint moisture restoration at the press has basically had two options from our company since 1997.  The option for smaller gins and those looking for an economical way to get started adding moisture has been a Lint Slide Grid.  Higher capacity gins and those looking for top performance opt for a Steamroller.  Several customers have found themselves somewhere in between those two chioces.  They were looking for more performance than a Grid offered and a cheaper price tag than a Steamroller.  Martin Mehner, our Vice-President of Engineering, saw the potential for just such a device and put his design skills to work.  The result is the MoistureTracker.

Development of the MoistureTracker has been fast and furious and remarkable progress has been made in a short amount of time.  The concept went from paper to production to installation to running in about six weeks.  Refinements and adjustments continue to be made, but the full scale prototype is installed and operating at Meadow Farmer's Coop in Meadow, Texas. 

This site was selected for several reasons, including their proximity to our factory in Lubbock, but the primary reason was the great staff at Meadow Coop.  Last year the folks at Meadow installed a complete Sam Jackson Drying System in less than a week during their season!  This year they have provided great support to this project and made it possible to get the MoistureTracker up and running in a short amount of time.  Pictured at right are Mike, Tony, Johnny, and Jaime.  Thanks guys!  And a special thanks to Dan Jackson, manager of Meadow Farmer's Coop.  Dan's commitment to his growers fueled his desire to implement the MoistureTracker for the benefit of all of his customers.

  

 

Is your curiosity up?  Are you wondering what a MoistureTracker looks like and how it works?  Do you want to know what benefits a MoistureTracker offers?  I hope so!  Let me see if I can answer a few of your questions.

Like the Steamroller, the MoistureTracker is positioned between the battery condenser and the press.  Unlike the Steamroller, it doesn't require a completely new lint slide or a special feed apron.  The MoistureTracker simply requires a section of the existing slide to be removed and minor modifications that allow it to be bolted in place (additional support is required, due to the weight of the machine).

Inside the machine are two sets of trac-wheels, which keep the cotton moving across a stationary screen.  Moist air enters the top, passes through the batt giving it moisture, and exits through the perforated screen on the bottom.  The second set of trac-wheels feeds the batt over an embedded moisture sensor and out of the machine on its way to be pressed.  The embedded sensor makes automatic control of bale moisture possible.

  

Early results show that performance is much better than a Grid, but not as high as a Steamroller.  In other words, it is exactly what you would expect for a device designed to be a compromise between the economical option and the high performance option.  Testing will continue through the season and I will keep you updated on the results.

Steamroller, Steamroller, Steamroller, Steamroller

The MoistureTracker appears to be well on its way to being an important product in our line, but if you are looking for the highest performing, fastest return on investment, number one attraction for growers, and best for your press moisture applicator the answer is Steamroller, Steamroller, Steamroller, Steamroller.

Several new installations have been commissioned this season, including:

Thanks and congratulations to all of our Steamroller customers, new and old!  You have helped make the Steamroller the success it has become and in doing so have provided your growers and gin with a great service.  And for those of you who are still waiting...what are you waiting for?  Get your Steamroller and put it to work for you!

Steamroller Operating Tips From Martin

Last month, I asked Martin to offer some tips for Conditioning Hopper users.  This month he shares his tips for Steamrollers.

 

  

                                          Martin's Steamroller Tips

1. After the Humidaire has a chance to stabilize, make sure the  actual temperature matches the setpoint.  If discrepancies exist, call the factory for help.

2. The latches on the clean-out door can become difficult to operate over time.  You can help alleviate this by spraying them with WD-40 every three days or so as a part of regular clean up.

3. If your Moisture Mirror is automatically controlling your Humidaire and your bale moisture isn't reaching its target, try raising the air temperature setpoint up a few degrees at a time until you hit your target. 

4. Another helpful tip when you are having trouble getting your bale moisture to match your target is to utilize your Turbo Nozzle.  If you don't have one, click here for more information.

5. If you are having trouble with excessive moisture on start-up using automatic control, especially during cold weather, increase the warm-up time and initial temperature spread parameters.  Call the factory for assistance.

6. Spend time with all of your ginners who are responsible for the system, making sure they are comfortable with making adjustments and know the required clean-out procedure. 

 

Early Bird Discount is Available Now

Whatever your moisture control plans are for next year, it's not too early to act on them.  We offer a 10% Early Bird Discount for orders of new equipment purchases made before January 16, 2004.  Give us a call for full details.

In the Next Update...

 

As always, if you have any problems, questions, or suggestions, please give one of us a call.  You can reach our Lubbock office at (806)795-5218 or me at (214)695-0158.

 

Lint Moisture Restoration Updates are written on a periodic basis to keep our customers informed of the latest developments. 

To receive this update by e-mail or to be removed from this  update recipient list,

please contact Neil Turner at (214) 695-0158 or by e-mail at neil@samjackson.com.