An Integrated Plastic Contamination Monitoring System for Cotton Module Feeders

Plastic contamination in US lint bales has increased with the adoption of new cotton harvesters that form cylindrical or round modules on the machine. It is of significant interest to the US cotton industry to reduce this contamination to preserve grower profitability and the reputation of the US as a reliable source of clean cotton fiber. The objective of this work is to describe the design and operation of a system for use on cotton gin module feeders that provides monitoring of plastic accumulation on the dispersing cylinders and video data to help document the module wrap condition and unloading/unwrapping procedures that may have caused the potential contamination event on the dispersing cylinders. In 2020, an integrated plastic contamination monitoring system was installed on module feeders at two commercial cotton gins in Texas. The system is comprised of sub-systems that provide images of plastic accumulation on the dispersing cylinders, a log of the processing sequence for round modules, video data of the unloading/unwrapping process for each module and a software program that integrates the data from the two sub-systems. The system was developed to operate on one computer, store the data in a common location, and simplify the process of extracting module specific data for a given event when plastic accumulates on the module feeder dispersing cylinders. The data provided by the system can be useful to manufacturers in comparing performance among module wrap products as well as to gin managers in training gin employees on module handling procedures to mitigate plastic contamination and improve worker safety.