USTER® HVI Testing in the Cotton Supply · PDF fileUSTER® HVI Testing in the Cotton...
Transcript of USTER® HVI Testing in the Cotton Supply · PDF fileUSTER® HVI Testing in the Cotton...
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Joe Yankey
USTER® HVI Testing in the Cotton Supply Chain
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Since 2002: New Organization
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USTER® Fiber Testing Products in the Cotton Supply Chain
For gin process
controlling...fiber
testing...yarn
testing...yarn
clearing ......for fabric inspection !
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Cotton Production AreasIn over 50 countries worldwide:Million Metric Tons Million Metric Tons 20022002 20032003 2004*2004* 2005*2005*
• China 4.916 4.870 6.30 6.19
• U.S.A. 3.747 3.975 4.63 3.80
• India 2.312 3.009 3.23 2.97
• Pakistan 1.736 1.734 2.07 1.90
• Brazil 0.848 1.273 1.30 1.42
• Uzbekistan 1.022 0.893 1.07 0.99
• Others 4.718 4.858 5.53 5.42
• TOTAL 19.298 20.610 24.14 22.69* Projected
Source: “The Outlook For Cotton Supply in 2004/ 05,
ICAC International Cotton Advisory Committee, November 2004
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Cotton Production Areas (%)
5-yr. Worldwide Cotton
Production Estimates:
(million metric tons)
2001 21.473
2002 19.298
2003 Est. 20.610
2004 Proj. 24.14
2005 Proj. 22.69
www.icac.org2004 Distribution of Worldwide Cotton
Production
27%
19%13%
9%
5%
4%
23%
China USAIndia PakistanBrazil UzbekistanOthers
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Worldwide Cotton Quality
Fiber Property Ranges
(excluding Pima)
• Micronaire 2.7 - 5.9
• Length 15/16 - 1 3/8 (32s)
0.94 - 1.37 (inch)
23.8 - 34.9 (mm)
• Strength 23.0 - 35.5 HVI g/tex
Source: Cotton Varieties by Origin, Bremen Cotton Exchange
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USTER® HVI Installations Worldwide – 2004
Total ~ 1580 units in 74 countries
NAFTA 23%
S.America 9%
Europe 16%
Africa & Middle East
13%
Asia & Australia
39%
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USTER® HVI Installations- Turkey
USTER® HVI SPECTRUM 40 units (30%)
USTER® HVI 900 SA 90 units (70%)
Total USTER® HVI Instruments: 130 units
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Cotton Quality Measurements
RESEARCH
Institutes
Industry
BreedingPrograms
MachineryManufacturers
Gins
Classing Laboratories
TextileMills
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GINS
On-LineProcess Control
On-Line Classing:Color, Leaf
Off-Line Classing:Micronaire,
Length, Strength
CLASSINGLABORATORIES
Warehousing
Marketing
TEXTILE MILLS
Procurement
Warehousing
MixSelection
Off-line Process Control
Cotton Quality Measurements –Industry
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Based on:
• Grade: Visual classification of color and trash content
• Staple: Manual determination of fiber length
• Disadvantage: Highly dependent on human (= highly variable) Cotton Classer
• Disadvantage: No information on strength, uniformity, micronaire,
Manual Cotton Classing
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Edgar Degas: Edgar Degas: ““Portraits in a New Orleans Cotton OfficePortraits in a New Orleans Cotton Office””, 1873, 1873
Manual Cotton Classification
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• 100% HVI™ test results: Micronaire, UHML, Uniformity, Strength, and color (Rd, +b)
• Short Fiber Index, a direct measurement from HVI™ fiber length distribution
• Leaf Grade is the only quality parameter still assigned by a USDA Cotton Classer
• Advantage:
• Improved Accuracy of Cotton Classification• Provides “common language”in international
cotton transactions
USTER® HVI Cotton Classification
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USTERUSTER®® HVI HVI Cotton ClassificationCotton Classification
• USDA – since 1991: 100% USTER® HVICotton Classification
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USTERUSTER®® HVIHVI Cotton ClassificationCotton Classification• 12 USDA Classing Offices throughout the
Cotton Belt; total of 230 USTER® HVI units
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5
20
5
6
35
23
230
# of HVI™ installations
GovernmentChina
PrivateZimbabwe
GovernmentIndia (Maharastra)
PrivateAustralia
PrivateBrazil (SGS)
PrivateBrazil (BOLSA)
GovernmentUzbekistan
GovernmentUSDA (USA)
OwnershipClassing Organization
USTERUSTER®® HVI HVI Cotton Classing:Cotton Classing:Over 300 units worldwideOver 300 units worldwide
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GINS
On-LineProcess Control
On-Line Classing:Color, Leaf
Off-Line Classing:Micronaire,
Length, Strength
CLASSINGLABORATORIES
Warehousing
Marketing
TEXTILE MILLS
Procurement
Warehousing
MixSelection
Off-line Process Control
Cotton Quality Measurements –Applied
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USTER® HVI – Textile Mill ApplicationsResults Affecting Your Bottom Line
• Standard Cotton Classification – worldwide
• Common language for the seller and buyer of cotton
• Verifies cotton quality and ensures the buyer receives what they paid for
• Cotton warehousing based fiber quality
• Uniform and optimized lay-downs ensures uniform spinning performance and desired end quality of yarn
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USTER® HVI – Application Example
Fabric Barré
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Causes of Fabric Barré %Contribution
• Raw Material Variation (Fiber) 70%
• Yarn Count Variation 10%
• Yarn Twist Variation 10%
• Yarn Hairiness Variation 10%
?? Variation in raw material (cotton lay-downs) is the major cause of fabric barré
USTER® HVI – Application Example
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Cotton Fiber DevelopmentCotton Fiber Development
closed boll
open boll
Dead Fiber
ImmatureFiber
NormalFiber
• In 16-18 days, the fibers grow in their perimeter (diameter) and length
•For the next 22-50 days, cellulose is deposited inside the hollow fibers
•When the deposit of cellulose stops, the boll dries up and cracks open
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Fabric Barré: Acceptable variation of Micronaire
between bales within 1 lay-down:
3.6
3.7
3.8
3.9
4.0
4.2
4.3
4.4
4.5
4.6
4.7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Bale Number
Micronaire
Avg. 4.1 CV 17.7%
Recommended CV < 10%Recommended CV < 10%
USTER® HVI – Application Example
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Fabric Barré: Acceptable change in average Micronaire
From lay-down to lay-down
3.8
3.9
4.0
4.1
4.2
4.3
4.4
4.5
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Lay-down number
Micronaire
Maximum ± 0.1
USTER® HVI – Application Example
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Raw Material Control –
Single lot = 100 bales = 100%
Micronaire Distribution = normal
Maturity Distribution = normal
LOT #7
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
3.3 3.5 3.7 3.9 4.1 4.3 4.5 4.7 4.9 5.1 5.3 5.5 5.7
Micronaire
LOT #7
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
82 83 84 85 86 87 88 89 90 91 92 93
Maturity
USTER® HVI – Application Example
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Raw Material Control –
Single lot = 100 bales = 100%
Micronaire Distribution = OutlierOutlier
Maturity Distribution = SkewedSkewed
LOT #1
0.0%
5.0%
10.0%
15.0%
20.0%
3.3 3.5 3.7 3.9 4.1 4.3 4.5 4.7 4.9 5.1 5.3 5.5 5.7
Micronaire
LOT #1
0.0%5.0%
10.0%15.0%20.0%25.0%30.0%35.0%40.0%
82 83 84 85 86 87 88 89 90 91 92 93
Maturity
USTER® HVI – Application Example
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ALL LOTs
0%
2%4%
6%8%
10%12%
14%
3.3 3.5 3.7 3.9 4.1 4.3 4.5 4.7 4.9 5.1 5.3 5.5 5.7
Micronaire
5% Mature5% Mature= GOOD= GOOD
2% Immature2% Immature
= BAD= BAD
Fabric Barré – Prevention:
• Use new Maturity Index to detect outliers!
• Not all bales with a Micronaire below 4.0 are immature fibers
• Not all bales with a Micronaire between 4.0 and 4.4 are mature fibers
USTER® HVI – Application Example
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• Do not exceed a change in average Micronaire from mix to mix more than +/- 0.1 Micronaire
• Maintain low variation of Micronaire within mix (CV below 10%)
• Do not place groups of bales with same Micronaire side by side in lay-down
• Additional Maturity Index information helps eliminate outlier bales in the lay-down
Fabric Barré – Prevention:
USTER® HVI – Application Example
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• Additional customer value provided by unique algorithms:
• Expected waste levels indicated by the amount of short fibers (SFI – Short Fiber Index) in the cotton bale
• SFI also indicates how aggressive the cotton was ginned
• Micronaire alone does not prevent fabric barré if cottons from different growth areas are used
• Maturity Index allows for better evaluation of such cottons
USTER® HVI Unique Algorithms
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USTER® HVI Patented Moisture Probe
• Moisture content of cotton at the time of testing influences test results
• Essential for data comparison with international standards
• Allows reducing standard conditioning times considerably
• Increases sample turnaround time in the laboratory
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USTER® HVI Patented Xenon Flash Colorimeter
• HVI™ color = an essential criteria in the cotton purchasing process
• Improves accuracy and precision of HVI™ color measurement
• Reduces maintenance and calibration during cotton season to a minimum
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• Test results within internationally accepted ASTM standard tolerances for accuracy and precision
USTER® HVI Test results
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USTER® HVI The Cotton Classification System
• Patented Moisture Probe
• Patented Xenon Flash Colorimeter
• Improved module integration:
• Nep Module• UV Module
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USTER® HVI Product Illustration
• Standard Measurements include:• Length (UHML), Uniformity (UI), Short Fiber Index (SFI),
Strength, Elongation, Micronaire, Maturity Index, Color (Rd, +b,Color Grade), Trash (%Area, Count, Leaf Grade), Spinning Consistency Index (SCI), Moisture Content
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Web site information:
www.uster.com
USTER® FIBER TESTING