Curriculum For Certificate in Cotton Ginning (6- Months) Code:VI87S002.1 (2013)

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1 Curriculum For Certificate in Cotton (6- Months) Code:VI87S002.1 (2013) i

2 Table of Contents Scheme of Studies Introduction Overview about the program Curriculum for (Certificate in Cotton ) Certificate in Cotton Curriculum Contents (Teaching and Guide)... 6 Module 1: Inspect from cotton fields... 6 Module 2: Check Process Machinery... 9 Module 3:Check Process Module 4:Check Process Maintenance Module 5: Title: Inspect The Material Module 6: Separation of Material into Lots Module 7: Monitor Conditioning Module 8: Plan Material Packing Assessment Template Module 1 (Inspect from cotton fields) Module 2 (Check process ry) Module 3 (Process Checking) Module 4 (Check process maintenance) Module 5 (Inspect the ) Module 6 (Separation of Material into lots) Module 7 (Monitor conditioning) Module 8 (Plan packing) Supportive Notes List of Tools, Machinery & Equipment List of Consumable Supplies Text Books Contributions for Development of This Curriculum ii

3 Scheme of Studies Duration: 6 months 20% Theory 80% Certificate in Cotton Sr. No. Modules Theory Hours Hours Total Hours 1 Module 1: Module 2: Module 3: Module 4: Module 5: Module 6: Module 7: Module 8: Total Hours

4 1. Introduction - Name of the Curriculum Certificate in Cotton - Overall objective of course To be able to monitor all the operations of fabric cotton ginning. - Competencies gained after completion of course o Trainees will be able to monitor cotton supplied from cotton fields for ginning process. o Trainees will be able to supervise all processes involved in. o Trainees will ensure that the settings of all s are according to the specifications and according to the instructions of ginning manager. o Trainee should be able to distinguish different types of cotton fibers (i.e. fibers from fields of different areas). o Trainee should be able to assess different types of impurities present in raw cotton. o Trainee should be able to segregate the cotton based on different quality parameters. - Job opportunities available immediately and in the future Textile ginning mills. Trainee entry level Matriculation - Minimum qualification of trainer BSc. Textile Engineer (preferably specialized in Spinning) - Medium of Instruction i.e. language of instruction Urdu - Sequence of the modules Trainees must complete all modules in the following given sequence. 1) Inspect from cotton fields 2) Check process ry 3) Check Process 4) Check process maintenance 2

5 5) Inspect the Material 6) Separation of Material into lots 7) Monitor conditioning 8) Plan packing - Timeframe of assessment (recommendation) Duration of course 6 months Total hours 800 Theory hours 160 hours 640 3

6 2. Overview about the program Curriculum for (Certificate in Cotton ) Module Title and Aim Units Theory 1 1. Inspect from cotton fields 2. Check process ry 1. Check the weight 2. Unload the 3. Placement of cotton 4. Sorting of cotton 5. Check of cotton from heap 6. Drying with dryer or sun 7. Identify cotton characteristics 1. Check working and settings of 2. Use hand tools 3. Check power tools held operations 4. Check type of s 3. Check Process 1. Check flow 2. Check humidity and temperature 3. Check feeding of 4. Check ginning rate 4. Check process maintenance 1. Check maintenance schedule 2. Repair when needed 3. Check working of parts of 4. Check the oiling 5. Inspect the Material 1. Check fiber length 2. Check trash 3. Check short fiber percentage 4. Check waste percentage, fiber strength, moisture content Workplace 2 20 hrs 80hrs 20 hrs 80 hrs 20 hrs 80 hrs 20 hrs 80 hrs 20 hrs 80 hrs Timeframe of modules Completing Module 1 Completing Module 1,2 Completing Module 1,2,3 Completing Module 1,2,3,4 4

7 6. Separation of Material into lots 1. Place different lot separately quality wise 2. Inspect the lots 3. Inspect staple length, waste, strength, and moisture of lots 7. Monitor conditioning 1. Check moisture content of 2. Control moisture in by showering water 3. Check humidity conditions w.r.t harvesting and ginning 8. Plan packing 1. Feed the to bale press 2. Press the into compact bales 3. Check use for packing 4. Check the weight of bales 5. Check the moisture of bales, and trash percentage in compressed bales 6. Check stalking of bales 20 hrs 80 hrs 20 hrs 80 hrs 20 hrs 80 hrs Completing Module 1,2,3,4,5 Completing Module 1,2,3,4,5,6 Completing Module 1,2,3,4,5,6,7 5

8 3. Certificate in Cotton Curriculum Contents (Teaching and Guide) Module 1: Inspect from cotton fields Objective of the Module: To study about inspection Duration:20 hours Theory:80 hours Practice: 100 hours Unit 1. Check the total weight of received Outcomes Trainee must know how to measure and check the weight Elements measuring standards (e.g. Kg, Lbs, tons, etc.) Duration TH+PR 2 12 Materials Required Place 2. Unload the handling make calculations and unit conversions loading and unloading means and methods (place must be clean, different based on must be unloaded separately) 3 11 Unloading (loader) mill, class room, and 3. Placement of cotton Placing the cotton depending on quality and place of growth make the process time efficient (by controlling the unloading workers) Segregation by checking: Yellow spot Trash Moisture Staple 3 11 Cotton mill, class room, and 6

9 length Shinning Seed quality 4. Inspection of cotton inspection methods and instruments (e.g. moisture meter, etc.) segregate by checking the quality parameters mentioned above tools and instruments (e.g. moisture meter, etc.) of inspection (e.g. ginner s turn out) 3 12 Different tools and instruments used for inspection mill, class room, and 5. Check of cotton from heaps 6. Drying with dryer or sun Trainee will have knowledge and skill of heap formation and feeding of to the s drying methods, processes, and inspect different properties of cotton, e.g. length, trash, moisture, etc. selection of for inspection and feeding of depending on moisture level proceed the process of ginning keeping the required level of moisture (i.e. about 9%) various types of s to be dried Cotton Dryer/ oven mill, class room, and mill, class room, and 7

10 7. Identify cotton characteristics conditions different properties of cotton (physical) assess the moisture content in the cotton s properties: length, mic, moisture, strength, UR, RD, color, shinning 3 12 Instruments used for characteristic analysis mill, class room, and identify above mentioned properties 8

11 Module 2: Check Process Machinery Objective of the Module: Know how about the ginning s Duration: 20 hours Theory:80 hours Practice: 100 hours Unit 1. Check working and settings of Outcomes Complete knowledge of saw gin Elements how to adjust rib in saw gin, how to adjust saw blade, how to adjust pulleys, how to adjust take up nozzle Duration TH+PR Materials Required Place mill, class room, and 2. Use hand tools Know how to use hand tools (moisture meter, screw driver, wrench, wooden stick, etc.) run and control the tools used for ginning (moisture meter, wooden stick, wrench, screw driver, etc.) Different hand tools mill, class room, and 3. Check power tools held operations power tools (blower, drill, grinder, welding plant, etc.) use hand tools using power tools and their operations (blower, drill, grinder, welding plant, etc.) Different power tools mill, class room, and 4. Check type of s different types of ginning s (separator, cleaning, saw gin, bale use power tools skillfully ginning ry types (Saw Gin 1, Saw Gin 2, Saw Gin 3, Saw Gin 4, Roller Gin, etc.) ry mill, class room, and 9

12 press, weight ) check the functions of different s Module 3:Check Process Objective of the Module: know about ginning process Duration: 20 hours Theory: 80 hours Practice: 100 hours Unit 1. Check flow Outcomes Trainee will be able to monitor the flow from to and within Elements passage through the and to, conveyer belt speed and quantity delivered Duration TH+PR Materials Required Cotton Place 2. Check humidity and temperature the atmospheric conditions (RH, temperature, etc.) check & analyze the speed, input and output measuring RH and temperature, different methods of calculations and devices used for measurement Devices/ instruments for measuring RH and humidity calculate RH and temperature 10

13 3. Check feeding of feeding process (suction feeding system is used) types and feeding systems (for saw ginning, suction feeding system is used with 3 to 4 laborers needed) Cotton 4. Check ginning rate ginning rate and its calculation carry the process efficiently ginning rate calculations and know how to change the rate of ginning, how to change the speed gears of s Cotton, ginning ry adjust the ginning rate at optimum required level 11

14 Module 4:Check Process Maintenance Objective of the Module: Skill for maintenance of ginning ry Duration: 20 hours Theory: 80 hours Practice: 100 hours Unit 1. Check maintenance schedule Outcomes maintenance and its importance Elements requirement of maintenance: check the blade, check the rib, check the mesh, check the general parts of (screw, nut, bolt, etc.) Duration TH+PR Materials Required Machinery and spare parts Place mill, class room, and 2. Repair when needed the conditions for maintenance perform maintenance heath of different parts: blade, rib, bearings, etc. Maintenance tools and equipment mill, class room, and 3. Check working of parts of different parts of and their working. Also know about settings. check and analyze conditions and the quality of maintenance done working, ginning rate, performance, condition and performance of different parts of Machinery mill, class room, and check, analyze and replace the 12

15 4. Check the oiling oiling status and oil application required parts using oil, types of oils, and need of oiling Oils, tools for oiling mill, class room, and estimate the need of oiling Module 5: Title: Inspect The Material Objective of the Module: Enalbe the learner to inspect the out put Duration: 20 hours Theory: 80 hours Practice: 100 hours Unit 1. Check fiber length Outcomes Able to estimate the fiber length Elements physical characteristics (fiber length, strength, mic. Trash, moisture, etc.) Duration TH+PR Materials Required Fibers, tools and equipment for measuring fiber parameters Place 2. Check trash trash content in raw estimate fiber parameters physical characteristics (fiber length, strength, mic. Trash, moisture, etc.) Tools and instruments used for trash analysis 3. Check short fiber percentage short fibers and their calculation in the raw estimate fiber parameters different methods of finding short fiber content in the raw Tools and equipment check 13

16 4. Check waste percentage, fiber strength, moisture content different cotton quality parameters the short fibers Knowledge to collect and analyze waste of ginning, estimate fiber strength, estimate moisture content Tools and equipment estimate and control the moisture, and other cotton quality parameters Module 6: Separation of Material into Lots Objective of the Module: Enable the learner to separate and stalk the into lots Duration: 20 hours Theory: 80 hours Practice: 100 hours Unit 1. Place different lot separately Outcomes Know how to segregate the Elements raw characteristics, allotting of numbers to specific lots Duration TH+PR 6 24 Materials Required Cotton Place 2. Inspect the lots Trainee must know the different quality parameters of cotton to be checked for inspection, and methods plan and place the in segregates/ groups lot s specifications: fiber strength, trash, color, growth area, cultivation quality 7 28 Cotton 14

17 3. Inspect length, waste, strength and moisture of lots used to inspect the Trainee must about fiber physical properties assess and analyze the collected data assessing fiber s physical properties: fiber strength, moisture, length 7 28 Cotton and testing instruments make tests for fiber s physical characteristics Module 7: Monitor Conditioning Objective of the Module: Enalbe the learner to maintain requiered atmospheric conditons Duration: 20 hours Theory: 80 hours Practice: 100 hours Unit 1. Check moisture content of Outcomes fiber moisture requirements and methods of fiber conditioning Elements fiber s moisture content and regain and methods to get optimum moisture content: spray method, showering, Air conditioning Duration TH+PR 7 28 Materials Required Conditioning devices Place 2. Control moisture in the know how to provide required moisture to the and assess required quantity of check the moisture content and perform conditioning various methods of conditioning: spray method, showering, Air conditioning 7 28 Moisture and temperature measurement devices 15

18 3. Check humidity conditions w.r.t harvesting and ginning moisture know about requirements of conditioning of raw depending on their source of growth and conditions of picking change the settings to change conditioning picking processes and different methods: time of picking (morning, noon, afternoon), preferable time is noon, and afternoon 6 24 Humidity checking tools assess raw cotton received from the field Module 8: Plan Material Packing Objective of the Module: Enalbe the learner to fully understand and carry out packing process Duration: 20 hours Theory:80 hours Practice:100 hours Unit 1. Feed the to bale press Outcomes Trainee will be able to supervise the continuous feeding of lint to bale press and control the feeding process Elements fiber feeding methods and process parameters: continuous air current feeding system, how to run the and control the process and knowledge of pressing mechanism, Feeding of packing (bags, Duration TH+PR 3 13 Materials Required Bale press Place 16

19 strips, etc.) to the pressing 2. Press the into compact bales Complete understanding of pressing mechanism control the labor and bale pressing process bale pressing process, feeding of, feeding of packing, pressing pressure, adjustment of bale weight output 3 14 Bale press 3. Check the used for packing Know the properties of packing Ability carry the process and make changes if necessary different types of packing s and their characteristics 3 13 Packing 4. Check the weight of bales Complete knowledge of weight measurement and size of bale Ability asses the packing weighing parameters and processes (methods), size of bale (160 kgto 170 kg), operations of weighing 4 14 Weighing balance control the pressing and 17

20 5. Check the moisture of bales, and trash percentage in compresse d bales Complete knowledge of moisture content, types of trash and assessing the trash percentage weighing process moisture content, moisture regain, assessing the moisture content, assessing the trash percentage 4 13 Process control devices 6. Check stalking of bales Complete knowledge of stalking the on the basis of quality parameters assess the different parameters of compressed bales and lint bale stalking techniques, segregation, tagging carry and control the stalking process of bales 3 13 Cotton 18

21 4. Assessment Template Module 1 (Inspect from cotton fields) Units Check the weight Unload the Placement of cotton Sorting of cotton Theory Days/hrs Workplace 8 min 34 min 8 min 34 min 9 min 34 min 9 min 35 min formative assessment Check the weight of given Solve the given numerical Describe different methods of loading and unloading Visit a ginning mill to study unloading process Discuss different methods for cotton placement Visit the ginning mill for practical observation How to sort different qualities of cotton Methodology Scheduled Dates Check of cotton from lots Drying with dryer or sun 9 min 35 min 8 min 34 min Sort the given samples of cotton Demonstrate methods for cotton testing from different lots Dry the given sample to cotton to get 9% moisture content identify cotton characteristics 9 min 34 min Explain different cotton drying methods Describe the need of testing the cotton 19

22 parameters/ characteristics Find out staple length, trash, strength of given cotton sample Module 2 (Check process ry) Units Check working and settings of Theory Workplace formative assessment Describe which settings must be checked before running Methodology Scheduled Dates Use hand tools Study the in detail and write down the existing settings Enlist hand tools used in ginning Check power tools held operations Check type of s Use hand tools to change given settings Enlist power tools used in ginning Use power tools to change settings or to carry given operation Enlist different types of s Visit a ginning factory to view various s 20

23 Module 3 (Process Checking) Units Check flow Theory Workplace formative assessment how to check flow Methodology Scheduled Dates Check humidity and temperature visit ginning factory to observe flow Describe the importance of humidity and temperature in ginning process Check feeding of Calculate RH and Temperature of ginning factory production hall Importance of proper feeding to Check ginning rate Calculate the feeding and output rate of Explain the term ginning rate Calculate ginning rate. How can you change the ginning rate Module 4 (Check process maintenance) Units Check maintenance schedule Theory Workplace formative assessment Explain importance of maintenance Methodology Scheduled Dates Observe maintenance 21

24 Repair when needed Check working of parts of Check the oiling When a needs repair Observe repairing of s in ginning factories Importance of various parts working Observe working of parts and their effect on production Importance of oiling Observe timing and methods of oiling Module 5 (Inspect the ) Units Check fiber length Theory Workplace formative assessment How to measure fiber length Methodology Scheduled Dates Check trash Assess/ calculate estimate staple length of given cotton sample How to estimate trash in cotton Check short fiber percentage Estimate the trash content in given cotton sample Effect of short fibers on ginning rate/ process Estimate the short fiber percentage in given cotton sample 22

25 Check waste percentage Effect of waste on ginning process Estimate the waste percentage in given sample Module 6 (Separation of Material into lots) Units Place different lots separately Theory Workplace 16 min 64 min formative assessment Explain Importance of placing the lots separately Methodology Scheduled Dates Inspect the lots Observe the placement of lots Describe different parameters of lots Inspect length, waste, strength and moisture of lots 16 min 64 min 16 min 64 min Visit the ginning factory and observe lot inspection Demonstrate different parameters of cotton Calculate length, and strength of given cotton sample 23

26 Module 7 (Monitor conditioning) Units Check moisture content of Control moisture in Theory Workplace 16 min 64 min formative assessment Illustrate importance of optimum moisture content in cotton Calculate the moisture content of given cotton sample Explain different methods to control moisture Methodology Scheduled Dates Check humidity conditions w.r.t harvesting and ginning 16 min 64 min 16 min 64 min Visit a ginning factory and observe the change in moisture content Demonstrate the importance of optimum RH Estimate the moisture in raw cotton given sample Module 8 (Plan packing) Units Feed the to bale press Theory Workplace 12 min 64 min formative assessment Illustrate continuous feeding to the Methodology Scheduled Dates Press the into 12 min 64 min Study/ observe feeding system Explain bale pressing 24

27 compact bales mechanism Check use for packing Check the weight of bales 12 min 64 min 12 min 64 min Study the bale pressing process in a ginning mill Describe some required properties of packing Observe the quality of packing in a ginning factory Describe the standard of pressed bale Check the moisture of bales, and trash percentage in compressed bales Check stalking of bales 12 min 64 min 12 min 64 min Check the weight of given bales Illustrate the effect of moisture, trash on ginning output Estimate the moisture and trash percentage of given samples of cotton Explain the process and methods of bales stalking Visit a ginning mill and observe bale stalking Supportive Notes This certificate will be assessed on the job. Critical aspects: 1. Setting of s 2. Types of waste s 3. Careful handling of equipment 4. Safety of oneself and others Assessment condition: 25

28 1. The learner will have access to all tools 2. The learner will be permitted to look at reference s 3. The learner will be required to communicate their answers to the assessor 4. The leaner will have to give presentation on the required topic Resources required for assessment: All s with respect to the relevant department, settings, tools, etc. 5. List of Tools, Machinery & Equipment Name of Trade Duration Certificate in Cotton 6 months Sr. Qty. Name of Item/ Equipment / Tools No. Equipment Cleaning module 1. Condenser Rock catcher Flat cleaner Inclined cleaner Stick Feeder extractor cleaner (FEC) Dust collector (Cyclone) Lint cleaner Fan / blowers Ducts Plate valves Dragon Suction Fan with all accessories 01 Module 14. Saw ginning (Gin stand) Gin saws Ribs (various sizes and designs) Roller ginning 01 Packing Module 18. Hydraulic press Hydraulic pump station 01 Baling unit 20. Weighting unit Over Head Crane 01 26

29 22. Fork Lifter Pillar Type Drill Machine Pedestal Grinder Power Saw Machine 01 Tools 26. Bearing Puller Tools box (steel) Steel rule Screw driver set Phillips screw driver set Combination pliers set Allen key set Open ended spanner set Ball peen hammer Gross peen hammer Mill file Square file Needle file set File brush Oil can ¼ Liters Hand vice Vernier caliper Adjustable wrench Round file Half round file Triangle file Counter sink Twist drill set Micrometer (mm) Micrometer (inch) Scribers Safety goggle Grinding wheel dresser with holder Bench vices Surface plate Work bench Hand shear Riveting gun Numbering Punch Sets Lettering punch set Portable hand disk grander Try square Combination set Steel divider Portable electric hand drill 01 27

30 66. Tap set Die set Hack saw Hacksaw blade Hacksaw blade Pressure dial gauge Pedestal grinder List of Consumable Supplies Name of Trade Duration Certificate in Cotton 6months Sr. No. Name of Consumable Supplies 1. Mobile oil 2. Grease 3. Nuts 4. Bolts 5. Dusting Cloth 7. Text Books 1) Cotton: An Entrepreneur's Story by A. L. Vandergriff 2) Bale o' Cotton: The Mechanical Art of Cotton by Karen Gerhardt Britton 3) Cotton (Textile Progress) by Indra Doraiswamy, ) The Cotton Gin (Inventions That Shaped the World)by Nancy Robinson Masters, ) Cotton ginner s handbook by W.S Anthony,

31 8. Contributions for Development of This Curriculum DACUM Working Group Muhammad Fahim, supervisor Almajeed cotton factory, Veharri Muhammd Ejaz, helper Nishat cotton, Chunnian Muhammad Younus, Quality officer, Shafi Texcel, Lahore Almas Anwar, ASM Gulshan Textile Mills, Samma Satta, Bahawalpur Qurbat Zahra, ASM Skytex, Lahore Bilal Rafiq, supervisor Shafi ginning, Lahore Shaukat Ali, Supervisor Shafi, Lahore Mr. Arif Mukhtar, DM (Tech)TEVTA, Pumjab Curriculum Developer Dr. Naveed Akhtar Faculty of UMT Lahore. Technical Expert Dr. Nabeel Amin Director, School of Textile and Design (STD), Lahore. National Curriculum Review Committee (NCRC) Members Mr. Muhammad Majid Mr. Abdul Rehman Foreman, Iqbal & Company, Peer Mahal, Selector, Toba Tek Singh Almajeed Cotton Ginner, Vehari Mr. Shahnawaz Ginner, Iqbal & Company Peer Mahal. Toba Tek Songh Mr. Shoaib Nisar Head our Iqbal & Company, Peer Mahal, Toba Tek Singh Mr. Kasif Iqbal Ginner, Iqbal & Company, Peer Mahal Toba Tek Singh Mr. Atif Iqbal Ginner, Iqbal & Company, Peer Mahal Toba Tek Singh Mr. Maqbool Ahmad Almajeed Cotton Ginner, Vehari Mr.Abdul Ghaffar Ginner, Shan Cotton Factory, Vehari Mr. Almas Anwar Lecturer University of Management & Technology,Lahore Mr.Muhammad Aslam Foreman, Sapphire Cotton Mill, Sheikhupura Road, Lahore DACUM Facilitator Ms. Sadia Abbasi Assistant Director, NAVTTC, Islamabad DACUM Coordinator Mr. Muhammad Nasir Khan Deputy Director, NAVTTC, Islamabad 29

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