Concept to reduce cotton bale packaging forces

Devices to reduce force requirements by, focusing compression at the eight locations [0.10 m(2) (160 in.(2))] where bale ties are applied were developed for cotton bale presses. Results of eight studies are reported. The devices reduced compression forces for a gin universal density, cotton bale by 20 to 35% depending on whether one or both of the platens were modified to use the devices. Additional studies determined the relationship between the force required to compress cotton with one standard flat platen compared to platens that had either six or eight compressive inserts to apply, focused compression. The inserts were either 2.54, 3.81, or 5.08 cm (1.0, 1.5, or 2.0 in.) wide across the width of the platen. The experimental platen inserts were installed on top of the standard bottom platen. Bales weighing about 226.80 kg (500 lb) each were ginned and compressed to about 640.72 kg/m(3) (40 lb/ft(3)) density,. Least square means for compressive forces (adjusted for bale weight and lint moisture) ranged from 3800 kN (854,021 lb) for the standard platen to 3049 kN (685,197 lb)for the 6-tie pattern with 3.81-cm (1.5-in.) compressive inserts. The 6-tie, 3.8-cm (1.5-in.) wide inserts installed on one of the two opposing platens required about 21% less force to achieve the same compression density, as the standard platen. The 3.8- cm (1.5-in.) wide inserts are suitable for use with the 1.90-cm (0.75-in.) wide traditional strapping that is used in the industry today,, and the 2.54-cm (1-in.) wide inserts are suitable for use with wire ties, which are also in use today. A special unitized platen consisting of eight focused compressive areas was constructed and tested. Compressive forces were reduced 18% when one unitized platen was used. Bales are about 1.12 cm (0.44 in.) larger at the hump when initially, released from the press but this difference disappears after a few days. A different version (of the unitized platen that bolted directly, to the existing platen was constructed and performed well infield tests at a commercial gin for the complete ginning season.