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PROJECT TEAM
Dr. R. H. Balasubramanya (PI)Associates
Dr. A. J. Shaikh Dr. P. G. PatilDr. R. M. Gurjar Mr. V. G. Arude
Dr. K. M. Paralikar Dr. S. V. ShuklaDr. P. V. Varadarajan
ICAC
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PRIVATE PARTY PARTICIPANTS
• M/s Ecoboard Industries Ltd.
• M/s Jollyboard Industries Ltd.
• M/s East India Cotton Association
ICAC
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NAGPUR
DELHI
ICAC
Area 327.8 m.ha
27 States and 7 UT’s
Southern Zone
Northern Zone
Central Zone
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Objectives• Analysis and optimization trials of required logistical
arrangements for collection and transportation of cotton
stalks from the field to the Particle Board Manufacturing
Plant, including possible setting-up of pre processing units
at the field level;
• Trials for minimum and optimum level of cleaning and pre-processing of cotton stalk into chips suitable for processing
at field level and factory site;
• Pilot production of cotton stalks-based particle boards;• Evaluation of technical/financial feasibility of the proposed
processes.
ICAC
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ICAC
Availability of Cotton Stalks in India
Zones States Area*(million
ha)
Availability of Stalks
(million
tonnes)**
Northern(Area 1.471 m.ha
Stalks 4.06 mt)
Central (Area 6.205 m.ha
Stalks 14.86 mt)
Southern(Area 1.471 m.ha
Stalks 3.41 mt)
1. Haryana
2. Rajasthan
3. Punjab
4. Madhya Pradesh5. Gujarat
6. Maharashtra
7. Orissa
8. Andhra Pradesh
9. Tamil Nadu
10. Karnataka
11.Others
Total
0.533
0.350
0.588
0.6302.390
3.124
0.060
0.962
0.133
0.370
0.035
9.175
1.60
0.70
1.76
1.267.17
6.24
0.12
2.4
0.27
0.74
0.07
22.33
*CAB Estimate (March 09,2007)
** Cleaned Stalks
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Chemical Composition of Cotton Plant Stalks
Species Holo-
Cellulose(%)
Lignin (%) Ash (%)
G.arboreum 67.3 25.8 7.0
G. herbaceum 69.1 28.1 8.3
G. hirsutum70.0 27.1 6.7
G.barbadense 69.2 28.2 8.1
Desi Hybrids 67.3 27.6 6.8
Hirsutum Hybrid 68.6 24.3 5.9
Mean Value 69.1 27.0 7.1
Range of
Values
67.3 to 70.0 24.3 to 28.2 5.9 to 8.3
ICAC
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Uses of Cotton Stalks
Particle Board Hard BoardSoft Board
Medium density fiber boardMushroom
growing
Briqueting
Domestic fuel
ICAC
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ICAC Cotton stalk used as domestic
fuel to cook the food.
Cotton stalk stored near the
farmers houses
Wall of a house made usingcotton stalk
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Board Industries
Benefits of using stalk as Raw Material by Board Industries
Additional income
to cotton farmer
Saves Forest Wealth Establishment of cotton stalk
supply chain
Generation of
Rural Employment
Protects
environment
Renewable raw material
to board industries
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Limitations in utilization of cotton
stalks by Industries
• Absence of an established cotton stalk supply chain
(weakest link)
• Industry’s hesitation to use any new raw material• Dependence on forest based material (timber)
• Lack of legislation on ecological considerations
• Uncertainties in dry land agriculture leading toinconsistent supply of raw material
• Lack of awareness about market acceptability of
composite boards from cotton stalks
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Conceptual Logistic Models of CottonStalk Collection
Model 1
• Transportation of cotton stalks directly from the field
to factory
Model 2
• Chipping of cotton stalks by farmers and
transportation to the factory
Model 3
• Collection and transportation of cotton stalks by
farmers from the field to the chipping center, chipping
and subsequent transportation to the factory by an
entrepreneur
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Model 1
•Transportation of cotton stalks directly from the field to factory.
Mode of
Transport
Cotton Stalk
carrying
capacity (Kg)
Bullock Cart 325
Tractor Trolley 575
Lorry 1500
Advantage : No need of pre-processing
centre at village level
Limitations : Less carrying capacity.
: Not economically viable.
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Model 2
• Chipping of cotton stalks by farmers and transportation to the
factory
Advantage :
• Load carrying capacity, 4 times more
Limitations :
• Purchase of cotton stalk chipper, not affordable by
individual farmer • Shortage of electrical power in rural areas/non availability of
appropriate power source for chipper in and around farm
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Model 3
• Collection and transportation of cotton stalks by farmers from
the field to the chipping center, chipping and subsequenttransportation to the factory by local entrepreneur
Advantages1. It is easy for farmer to collect and transport cotton stalk to the
nearest chipping centre.
2. Entrepreneur can purchase tractor operated chipper, as
sufficient quantity of cotton stalk at one place is assured
3. Assured and timely supply of cotton stalk chips to the Board
Industry
• Model 3 appears to be economically feasible
ICAC
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Flow Chart on the
Availability of Cotton Stalks in Nagpur District, Maharashtra, India
3.0 tonnes/ha 40% moisture
2.4 tonnes/ha 25% moisture
1.7 tonnes/ha 20%moisture
1.5 tonnes/ha 15%moisture
1.3 tonne/ha 10% moisture
Uprooted cotton stalks immediately after the
completion of last picking of seed cotton (contains
green leaves, boll rinds and unopened bolls)
Devoid of leaves after 5 days of drying in open in the
field (leaves contribute to about 5%)
Manual cleaning of cotton stalks (Removal of boll
rinds, unopened bolls and small branches which
contribute to about 25%)
Chipping of whole cotton stalks (loss during
chipping, about 10%)
Transportation of chips to a maximum distance of
50 km (loss during loading, unloading and
transportation, 5%)
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Uprooting
Collection
Chipping
Loading
Transportation
Logistics of Cotton Stalk Collection
Chipping & Transportation
Cleaning
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Collection of Cotton Stalk ICAC
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Effect of Impurities on the Quality of Board
Particulars Density
(g/cc)
Thickness (mm)
BendingStrength
(MOR)
(kg/cm2)
InternalBond
Strength
(N/mm2)
Water Absorption
(%)
2 h
Dried cotton stalks with
boll rinds
0.78 13.0 105 0.25 128
Dried cotton stalks with
boll rinds partly removed
0.78 13.2 113 0.26 115
Cleaned cotton stalks
(No boll rinds)
0.78 13.5 106 0.31 96
Debarked cleaned cotton
stalks
0.78 12.8 181 0.60 77
Therefore it is felt necessary to design and develop a cotton stalk cleaning
system.
Advantages of cotton stalk cleaning :
• Significant reduction in water absorption by bark removal• Enhanced Modulus of Rupture after cleaning and bark removal
• Improvement in Internal bond strength
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Cotton Stalks Cleaning System
System Comprises of :
Scratching system (peeler)
Conveyor system
Air blowing chamber
Air suction chamber
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COTTON STALK
CLEANING SYSTEM
( FEEDING UNCLEANED
STALKS )
COTTON STALK
CLEANING SYSTEM(CLEANED STALKS )
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Cleaning SystemICAC
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UNCLEANED COTTON STALKS BOLL RIND
LEAVESBARK
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Performance Evaluation of Cotton Stalks Cleaning System*
Initial
Weight of
Cotton
Stalks (Kg)
Moisture
Content
(%)
Weight of
Stalks after
Passing the
system
(Kg)
Moisture
Content of
cleaned
Stalks
(%)
Weight of
Removed
Material
(Kg)
Moisture
Content of
peeled
Material
(%)
1 2 3
100 10.5 77 11 16.0 0.6 6.2 6.0
*Performance is based on 5 trials1. Material collected in the first unit
2. Material collected in cyclone
3. Material Collected at the end of conveyor
PS : Moisture content of stalk is around 11% whereas that of wastes (boll rinds,leaves, lint and small branches) is around 6%
ICAC
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Storage Studies
1. Stalks stored in the open cemented platform
2. Chipped stalks stored in the open cementedplatform
3. Chipped cotton stalks placed as such inside a shed
4. Chipped cotton stalks packed in gunny bags andstacked inside a shed
5. In addition to this about 35 tonnes of chips packed
in gunny bags covered with tarpaulin sheets werestored outside the commercial factory for ninemonths
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Chemical analysis of cotton stalk chips stored in open ground and in shed
Sr.No
MONTH + MOISTURE (%) LIGNIN(%)
HOLO CELLULOSE(%)
ETHER EXTRACTIVES(%)
1* 2** 1* 2** 1* 2** 1* 2**
1 July 14.2 16.0 26.6 25.4 82.1 77.1 7.1 7.2
2 August 14.0 15.9 26.1 25.0 81.4 76.4 7.0 7.1
3 September 12.0 11.9 26.0 24.8 81.2 75.7 7.0 7.2
4 October 11.2 12.9 25.9 24.5 81.1 75.4 6.5 6.8
5 November 11.8 11.4 25.8 24.2 80.9 75.2 6.8 7.1
6 December 11.1 11.2 25.5 24.1 80.7 75.2 6.7 6.5
7 January 11.3 11.4 25.2 24.1 80.5 75.1 6.7 6.8
8 February 11.3 11.4 25.5 24.7 81.1 75.0 6.5 6.3
9 March 11.2 11.4 25.5 24.6 80.9 74.7 6.9 4.5
10 April 11.0 11.1 25.6 24.5 80.5 75.1 6.6 6.4
11 May 10.1 11.5 25.3 24.7 80.4 74.9 6.5 6.4
12 June 13.2 14.1 25.2 24.4 81.0 74.8 6.4 6.3
1*– Stored in shed 2** – Stored outside + Month wise meteorological data recorded
ICAC
• No significant change in the chemical composition in case of chips stored inside• Slight reduction in holocellulose content in case of chips stored outside
Flow Chart of Particle Board Demonstration Plant
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ICAC
FineCoarse
Mat
Glue
Silo
Mat
Silo
GlueGlue service
tank
Resin, Wax, Hardener etc
Glue service
tank
Finished Board
Cut to size saw
Sanding M/c
Trimmed Board
Cold press
Hot Press
Raw Board
Carrier plate
Fine particle layer Fine particle layer Coarse particle layer
Cotton Stalk
Over Size particle
Chipper
Hammer Mill
Dryer
Rotary Screen
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Particle Board
Demonstration
Plant at GTC,
Nagpur
Particle Boards
produced atDemonstration
Plant
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ICAC
Particle Board Demonstration Plant at GTC, Nagpur
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Material Balance for the Preparation of Particle Boards
from Cotton Plant Stalks
Cotton Stalk chips (10 % moisture) (1 tonne)
Rechipped Material (950 kg) 10% moisture
Dried Material (884 kg) 3 % moisture
Particle Separation Loss (813 kg) 3 % moisture
Finished Boards (674 kg) 6 % moisture
ICAC
Furnish Material (959 kg) 12 % moisture
Mat Formation (911 kg)
Pressing of Board (856 kg) 6 % moisture
Trimming & Sanding loss 20 %
Resin + Wax Addition
5 % loss
7 % loss
8 % loss
5 % loss
6 % loss
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• One tonne of cleaned cotton stalk chips
with 10% moisture yields 0.7 tonne of plain boards with 6% moisture
• To prepare 1 tonne of plain boards
with 6% moisture, about 1.4 tonnes of cleaned cotton stalk chips with 10 %
moisture are required
ICAC
ICAC
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Properties of Particle Boards Made in Pilot Plant
Parameters Urea Formaldehyde
Bonded Cotton Stalk
Boards *
BIS Specification
Thickness (mm) 18 18
Density (kg/m3) 671 500-900
Bending Strength (MOR)
(N/mm2)
14.64 11.00
Internal Bond Strength
(N/mm2)
0.6 0.3
Screw Nail Withdrawal
(Face - Newton)
2118 1250
Water Absorption (%)
2 h
24 hSurface Absorption (%)
28
313
40
809
ICAC
ICACM/s Eco-board Industries Ltd
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ICACM/s Eco-board Industries Ltd
Velapur, Maharashtra, India
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Properties of Particle Boards prepared at
Ecoboard Industries Ltd., Velapur
Parameters Urea Formaldehyde
Bonded Cotton Stalk
Boards
BIS Specification
Thickness (mm) 18* 18** 18
Density (kg/m3) 699
12.0
0.5
1610
28
31
2.5
731 500-900
Bending Strength
(MOR) (N/mm2
)
13.0 11.00
Internal Bond Strength
(N/mm2)
0.5 0.3
Screw Nail Withdrawal
(Face - Newton)
1250 1250
Water Absorption (%)
2 h
24 h
Surface Absorption (%)
36
80
2.8
40
80
9
* Drum chipper **Chaff cutter
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Room Paneled with Particle Board from cotton stalks
ICAC
False Ceiling
Shuttering
Partitioning
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Uses of particle boards manufactured from cotton stalks
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Dignitaries and Entrepreneurs in the Demonstration Plant
Training hall paneled with
particle boards manufactured
from cotton stalks
Entrepreneurs visit to particle
board demonstration plant at
Ginning Training Centre of CIRCOT Nagpur
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Awareness & co-ordination among stake holders isnecessary to popularize this technology
Cotton Farmers IndustryCIRCOT
ConclusionsICAC
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Conclusions
Collection and transportation of cotton stalks by farmersfrom the field to the chipping center, chipping and
subsequent transportation to the factory by local
entrepreneur is found to be economically viable Cleaning of cotton stalks has a direct bearing on the
quality of boards
Boards manufactured from Cotton Plant Stalks Conform toBIS Specification
Boards can be laminated with different surface finishes
Suitable for wall paneling, false ceiling and different
furniture items Assured additional income to the cotton farmers
Additional raw material to the Board Industry
Generation of rural employment and saving of forestresources
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Acknowledgement
We gratefully acknowledge the financial support and
guidance from CFC, Netherlands, ICAC, Washington &ICAR, New Delhi.
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THANK YOU