Eco-friendly rubberized cotton fabric roller for ginning machines

This article discusses the pollution caused by chrome composite leather-clad (CCLC) rollers commonly used in cotton roller ginning mills and suggests an alternative roller material. CCLC rollers contain about 18,000 to 36,000 mg/kg (ppm) total chromium in trivalent and hexavalent forms, which are toxic to human health and carcinogenic. When seed-cotton is processed in double roller (DR) ginning machines, the lint is contaminated with chromium, and chromium particles are carried into the spun yarns and cotton by-products. Specifically, due to persistent rubbing of the leather-clad roller over the stationary knife during the ginning process, the lint is contaminated with about 140 to 1990 ppm of chromium, and the spun yarns and cotton by-products contain about 100 to 200 ppm, far in excess of the standard limit of 0.1 ppm. Gin and mill workers are directly exposed to this carcinogenic substance. To offset this problem, pollution-free rubberized cotton fabric (RCF) rollers have been fabricated and tested in roller gins. The RCF roller covering is made of multiple layers of fabric bonded together using a white rubber compound, which has a surface finish conducive to high ginning efficiency. This eliminates chromium contamination and pollution during the ginning process. On the basis of the design and development of various test rollers and subsequent evaluation studies, the performance of pollution-free RCF rollers has been demonstrated with reference to their commercial benefit and eco-friendliness in cotton ginning mills.