4 Filtration Unit

2 Filtered oil
storage tank

1 Dust Dust
Filtered Oil
Holding Tank
Filtered oil
Cyclone Cyclone Introduce a Magnet at Filtered oil
Introduce a this section to ensure
damper to seed pre cleaning is Filtration unit
minimize rate 3
of sunction
Light Light effective HT Tank
foreign foreign
materials materials

Storage Bin

Filtration Cake

Conditioned cotton seeds dosing

Sorting Machine
Cotton seeds
Damper Cake Cooler Cake
bagging
Light materials machine
Unfiltered Oil
Feeding Hopper
Test run without
Small seeds
Small stones
2
then bigger size Fine soil/dust
impurties sieve

screw
due to nature Seed Destoner Cooker PRESS
cotton seed fibers
Hot Cake

collected in sacks
Clean Cotton seeds
Sorted Cotton seeds

The conveyor size will

Limit the feed rate, we
can introduce a By Cooker Feeding 3 Cake Recirculation
Cooled
Cake Bagged Cake

5
pass to avoid material Screw Conveyor
clogging.
Large Stones
collected here
Boiler

Eliminate / Remove this conveyor due

to design size thus limiting feed rate
Introduce a direct by pass into press
hopper.
The cooker will ensure consistent flow
rate of feed stock into the hopper
thus acting as holding bin.
 UNIT OPERATION STRENGTHS
1

Seed Precleaning Assets availability for easy modifications

Ability to resume to current settings if design
doesn’t work
No training required
No programming required

No additional manpower

Team Brain storming on Trails

2 The machines are available andworking

Preconditioning efficiently
Easy flow rate adjustments

No training required

No programming required
 No additional spares

No additional manpower

3
Pressing Ability to press the feedstock with hulls and lints

No design change

No training required

No programming required

No additional spares
No additional manpower
Ability to optimize the pressing efficing due to
cake recirculation function
Elemination of hulls and uncuts in the bales
and the bales
4 Filtration & Oil storage Ability to handle the oil even with hot air
Low residual oil in dried filtration cake (TBC)
No design change
No training required
No programming required
No additional spares
No additional manpower

5
No design change. Only a few adjustments to
Cake cooling & Bagging accommodate the fluffy cake
No training required
No programming required
No additional spares
No additional manpower
Enough capacity to accommodate the cake

Quality control Availbility of equiped lab

No change of feedstock quality requirements
Quality parameters of the products resemble
the Farmet A

Residual oil contet in the cake= Oil content in

cake+uncuts oil in bales (Farmet A)
No new standard required
No training required
No additional manpower
No addition lab apparatus and equipment
required
WEAKNESSES OPPORTUNITIES

Hopper 1BN2.1 Design change

Feeding hopper grills small since were meant for
castor feeding Alternative grills customized for cotton seeds
Absense of magnetic separator Incorporate magnet
Hopper 2BN2.1 Contractor engagement
Blockages of screw conveyor 2TS2.1 under the
hopper Change from tubular to trough
Small sized screw conveyor. Inappropriate design
for cotton feedstock Increase the size of the screw
Material clogging at discharge due to nature of
cotton seed mass.

Proper utilization of Equipment and

Machineries

Sorting Machine

Possibility of light seeds carried up to the cyclone

Due to nature of cotton seed fibres will limit
effectiveness of pre cleaning process.
Blockages especially at infeed due to machine
design.

Size is not sufficient

Seed Destoner
Hopper to destoner is offset causing blockages and
downpipe size is small Adjust the hopper and increase downpipe size
Check possibility of adjusting the cyclone blower
Destoning inefficient, low flowrate and smaller size to carry the seeds
Space constraint for manual seeds collection More space available considering the opportunity above
The manual seeds handling exercise is tedeous and
time consuming Experiment with air extraction for seed cleaning
Modify Recu bin to act as holding bin for
precleaned seeds
Challenges in the manual feedstock feeding due to Modify Recu bin to act as holding bin for
the material characteristics precleaned seeds
Absence of magnet Incorporate a magnet
Frequent screw conveyor jams leading to frequent
poking Will be eliminated
To be solved if recu bin modification will be a
Space constraints success
 To be solved if recu bin modification will be a
Ergonomics issues success

Tubular cooker feeding screw which is

inappropriate for the transportation of the
feedstock Change the design to trough design
Inconsistent flow of the feedstock making Will be resolved by implementation of trough
calibration a challenge screw

Possibility of cooker screw entanglement due to

lints in the feedstock Consider delinted feedstock

Small cooker outlet opening to the dosing screw

Small sized dosing screw in size and speed Install bigger screw conveyor
Inability to gain initial pressing temperatures to Introduce basket heating system to boost initial
enable pressing optimization temperatures of the basket
Possibility of accelerated wear and tear of screw
inserts (TBC) Cost Benefit Analysis

Will be reolved by the screw design changes and

Material flowabilty issues causing press starving delinting the feedstock/purchase of delinting
hindering optimization machine
Increase of basket temperature especially at
discharge to almost safety set point. Contractor engagement
Unbalance press machine torgue(M) due to Maximization of cottons hulls to zero waste
inconsitent of feed stock.

Presence of redundant filtration unit in case one fa

Cake flow issues due to fluffy nature of the cake Adjust the gates
Packaging issues to to fluffy nature of the cake Get a bigger size of the sack to accommodate 50kgs
Market price factor High cake yield

Abilitity to optimize to <10% thorough in process

High residual oil of >11% in cake QC and cake recirculation
Inconsistent results from NIR machine Calibtration of NIR machine is underway
 THREATS

Design change budget

Ergonomics issues due to manual handling

Lengthy spares lead times

Change management of design needs
OEM advise

Breach of machine Warranty insurance

Due presence hulls machine life span will

be mostly affected especially the screw
insert thus increasing the of cost
Maintenance by double

The overall cost of production i.e, utilities

consumption of Power verse as finished
product current market price.

Design change enhancing machine safety

concerns i.e, Incorperating additional By
pass.

Spillages leading to product loss

opportunity above

Cross contamination
Rainy weather can hinder the operations of
the extraction unit

Lifting operations constraints

Lengthy spares lead times
 Difficulties in Engaging supply of delinted
seeds or purchase of delinting machine

Additional power consumption

Contractor engagement

Lengthy spares lead times

Lengthy spares lead times

modate 50kgs

High moisture content in feedstock due to

weather conditions