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 S3S -
ft tA^t U.S.D.A.
&£•£& United States
iLasJjj Department of
\sGiy Agriculture
Economic
Cotton Qua
Research
Service Evaluation
ERS-668

Testing Methods and Use

Edward H. Glade, Jr.

Keith J. Collins
Clarence D. Rogers
 COTTON QUALITY EVALUATION: TESTING METHODS AND USE, by Edward
H. Glade, Jr., Keith J. Collins, and Clarence D. Rogers,
National Economics Division, Economic Research Service, U.S.
Department of Agriculture. ERS-668.

ABSTRACT Cotton quality characteristics are increasingly measured by

instruments rather than manually. Increased competition in the
industry, consumer demand for a wider range of products, and
more stringent standards for product use have prompted more
intensive fiber quality examination. Over 92 percent of textile
firms surveyed own one or more fiber testing instruments. Ninety
percent own instruments for testing fineness and maturity, 70
percent for measuring length and length uniformity, and 60
percent for determining fiber strength. This report presents
information on the determination and use of cotton quality
measures, and the development of high volume instrument testing
systems.

Keywords: Cotton, quality measurement, fiber properties,

NOTE Use of company names in this publication is for identification

only and does not imply endorsement by the U.S. Department of
Agriculture.

Washington, D.C. 20250 November 1981

in
 Page

CONTENTS SUMMARY v

INTRODUCTION 1

DEVELOPMENT OF COTTON QUALITY TESTING 2

Changing Needs for Cotton Testing 2
USDA and Cotton Industry Testing Efforts 3
Quality Measures and Cotton Marketing 6

COTTON FIBER PROPERTIES AND PROCESSING PERFORMANCE... 8

Grade 8
Staple 9
Character 9

CURRENT TEXTILE INDUSTRY TESTING PRACTICES 11

Scope and Method of Analysis 11
Fiber Property Testing Methods 12
Ownership of Testing Instruments 13
Importance of Each Fiber Property 15
Use of Specific Fiber Properties 15
Relationship of Fiber Property Use to
Instrument Ownership 19
Confidence in Instrument Values Versus
Traditional Cotton Classing 20

INSTRUMENT TESTING SYSTEMS AND USDA COTTON CLASSING.. 20

Current HVI Testing 20
Implementation Considerations 22

REFERENCES 24

xv
SUMMARY Increased competitiveness in the textile industry has pushed
cotton quality measuring methods toward increased mechanization
and a more thorough examination of cotton quality
characteristics.

Technological advances in textile production and more stringent

standards for product quality have sharpened the importance of
the relationships between processing costs and fiber quality.
Along with traditional grade and staple information, the cotton
industry now uses measurements of fiber fineness and maturity,
length uniformity, strength, and nonlint content of the sample
to describe fiber quality. Cotton quality determination has now
progressed from human assessors to high volume instrument (HVI)
systems.

This report traces the development of cotton quality testing,

provides a description of the measurable fiber properties and
how they relate to processing performance, and presents the
results of a survey of textile mills to determine current use of
quality information and the extent of instrument testing for
determining cotton quality.

All textile industry firms surveyed in 1980 reported using fiber

property measures in some phase of their operation, and over 92
percent of those firms owned one or more fiber testing
instruments for making quality evaluations. The extent of
instrument ownership increased with firm size, triggering a
wider range of goods produced and the corresponding need for
additional fiber quality data.

Textile mills indicated that the fiber properties of length,

fineness, and maturity, and the elements of grade are the most
important properties.

Of the 40 textile firms surveyed, 90 percent reported owning

instruments for testing fibers for fineness and maturity, 70
percent for measuring both length and length uniformity, 60
percent for determining fiber strength, and 45 percent of the
firms owned instruments for measuring the nonlint content of
samples. A surprisingly high 67.5 percent of the respondents
indicated ownership of other instruments, primarily for
determining neps (tangled masses of fibers) in cotton samples,
and equipment for estimating sugar content.

Textile firms reported using fiber property values for mixing

and blending fiber, purchasing specifications, maintaining
quality control, and screening fibers for other mills in the
same firm. The mixing and blending of fibers is one of the most
critical operations in textile processing with nearly 93 percent
of the firms using fiber property measures for this purpose.
 Use of fiber property measurements in the other areas of
application included: purchasing, 80 percent; maintaining
quality control, 70 percent; and screening fibers, 42.5 percent.

VI
 Cotton Quality
Evaluation
Testing Methods and Use

Edward H. Glade, Jr.

Keith J. Collins
Clarence D. Rogers*

INTRODUCTION Knowledge of cotton quality is a necessary component of an

efficient marketing system. Because cotton exhibits such wide
variation in fiber properties among samples, effective
description and measurements of these properties are essential.

The use of quality information by textile mills enables

management to develop optimum blending levels which reflect the
best combination of fiber properties required for each end-use.
For cotton producers, premiums paid for qualities most in demand
and discounts for undesirable qualities provide an incentive to
growers to produce those qualities that have the highest values
to manufacturers and consumers of textile products.

Official USDA cotton quality classifications measure three

factors: grade, staple, and micronaire (10). 1/ Grade depends
on the color, trash content, and preparation (smoothness) of the
sample. Staple is the average length of the individual fibers.
Micronaire is a measure of fiber fineness and maturity.
However, other fiber properties are also recognized as being
important and are increasingly being measured by instrument
testing.

This report traces the development of cotton quality testing;

provides a description of the measurable fiber properties and
how they relate to processing performance; and presents the
results of a survey of textile mills to determine current use of
quality information and the extent of instrument testing of
cotton for quality determination.

*Glade and Collins are economists in the National Economics

Division, Economic Research Service. Rogers is an economist,
Cotton Division, Agricultural Marketing Service, Clemson, S.C.
1/ Underlined numbers in parentheses are cited in the
References section.
DEVELOPMENT OF Grade and staple have been factors in quality determination
COTTON QUALITY of cotton for a long time; micronaire became part of the
TESTING official classification system during the sixties. Other
factors, such as fiber strength and length uniformity, have also
been used to evaluate cotton quality. These other factors,
together with micronaire, determine the character of the cotton.

Changing Needs for Cotton has been used in textile manufacturing for thousands of
Cotton Testing years. Over time, manufacturers came to realize some qualities
of cotton behaved much differently from others during the
manufacturing process; disparities in performance ultimately led
to systems of describing cotton quality. Cotton grading
apparently began in Liverpool, England, about 1800 (_5)« The
grading system, which assigned names to grades, was used by
merchants and spinners. The system, however, only approximated
quality measurement because many differences existed in grade
perception as cotton passed through the marketing process, so
classed cotton often was not uniform in grade.

Early cotton classers could not grade consistently because of

many genetic differences of cotton fibers. Even for a given
cotton type, quality varies with climate and cultural practices,
such as chemical treatments, irrigation, degree of defoliation,
and exposure to the elements. At harvest, cottonpickers and
strippers can damage and contaminate fibers. Cleaning and
drying equipment at the gin, transportation and handling on the
way to the mill, and cleaning equipment at the mill all can
cause quality variability and deterioration.

The growth in more stringent standards for end-product quality,

as dictated by consumers, has been an important element in
establishing the relationships among classes of cotton, spinning
performance, and product quality. Technological advances in
textile production have sharpened the importance of the
relationships between processing costs and fiber quality. Poor
quality fiber results in higher waste levels, increased ends
down (interruptions in the yarn formation process), and more
seconds in finishing operations. Manufacturers must have
detailed fiber quality information to keep pace with
ever-increasing processing speeds and to assess elimination of
some intermediate processing steps.

Technological gains in textile production have been

significant. For example, in ring spinning, spindle speeds for
manufacturing a typical yarn have grown from fewer than 4,000
revolutions per minute in 1940 to more than 12,000. Weaving
gains have been just as dramatic. Loom speeds have surged from
fewer than 100 pics per minute (ppm) 20 years ago to 125 to 200
on the current shuttle looms. Speeds are near 300 ppm on rapier
 looms. Although they do not use cotton, the new water jet looms
indicate future technological developments of speeds of 700 to
1,000 ppm. Ends down and the product seconds that result from
fiber quality considerations have become more critical under
such technological advances.

Different end-use requirements, such as yarn strength and yarn

and fabric appearance, require different fiber qualities. The
ability of a fabric to hold dyes, as well as recently developed
finishes such as shrink resistance, flame retardance, and
durable press, depend on fiber qualities. For given product
requirements or spinning characteristics, a textile producer may
not be able to obtain all the raw fiber qualities needed when
buying a particular genetic cotton type from a given location.
Quality of a cotton variety can vary from farmer to farmer and
vary tremendously from year to year. In such instances, quality
—
measures become the basis for a recipe of sorts the textile
producer blends, or lays down, mixes of various types of cotton
to obtain a specific quantity of cotton with the requisite
quality measures.

Textile producers have not been alone in their interest in

cotton quality measurement. Cotton shippers and merchants also
use quality measures to fill textile mill orders with
even-running bales, or bales of the same grade and staple.
Farmers and ginners demand more and better quality measurement,
using such information to improve cotton quality with better
growing, harvesting, and ginning methods. Quality measures have
also become a marketing tool for the farmer, enabling farm
prices to better reflect fiber quantity characteristics and
product value.

Quality testing has also been important to researchers. For

example, geneticists use quality measures as guidelines for
developing improved cotton varieties. USDA and industry
researchers employ existing quality measures to develop new
measures and tests to establish relationships between fiber and
end-product qualities.

USDA and Cotton Grades for upland cotton were first established in 1909 with the
Industry Testing preparation of quality standards for nine white grades (11).
Efforts However, these grades were never widely used and were replaced
in 1914 by the U.S. Cotton Futures Act's Official Cotton
Standards. These standards were revised and became binding with
the U.S. Cotton Standards Act in 1923. Standards for staple
length and grade standards for American pima cotton were first
established in 1918 under authority of the Futures Act.
The 1923 Standards Act made the use of the official standards
mandatory in interstate and foreign commerce unless the cotton
was sold from actual samples or private types (purchasers buy
directly from farmers and conduct their own testing). The
standards were soon accepted by foreign countries and the name,
universal standards, was approved. Since the early twenties,
revisions of the standards have continued, with the last major
revision coming in 1962. The goal of the revisions was to
develop standards that are useful from a product perspective,
can be uniformly applied, and are related to stable and
measurable quality factors.

Quality testing traditionally has been based on human

inspection. With the introduction of the official standards,
visual quality determination was aided by the development of
practical forms. For grade determination, a practical form is a
number of boxes, each containing samples of the same grade. A
classer then grades by comparing cotton to be classed to the
practical forms. For staple length determination, a practical
form is 1 pound of cotton of a given staple length. A classer
may then compare cotton to be classed with some pulled from the
comparable staple length form, using both sight and touch.

The 1937 Smith-Doxey Amendment to the Cotton Statistics and

Estimates Act helped make USDA classing the most pervasive
quality testing procedure in the cotton industry. With passage
of this amendment, USDA began providing free classing services
to cotton growers at their request in an effort to motivate
growers to improve quality. The importance of this service is
reflected in more than 97 percent of the cotton crop being USDA
classed.

Research directed at refining standards, reducing human classing

errors, identifying exactly what factors describe a particular
cotton, and explaining why that cotton performs the way it does
has resulted in refinement of existing standards, creation of
new standards, and the invention of instruments that help
determine grade, staple, and character of cotton (6_).

One of the earliest instrument inventions, the Suter-Webb

Sorter, measured the relative quantities of different fiber
lengths and length uniformity contained in a sample of a
particular cotton. Growth in instrument invention and
refinement has surged since the twenties. Early Government and
private research indicated that fiber fineness and maturity were
closely related to product quality. This was reflected by
increased demand from mills for cotton having these properties
within a specified range. Fineness and maturity of individual
fibers are indicated by micronaire readings taken from airflow
instruments. The importance of the micronaire measure and the
 .

confidence in instruments to perform accurately was indicated by

addition of this fiber property measure to the official USDA
cotton classification system. liicronaire readings became part
of the Smith-Do xey service beginning with the 1966/67 season.

Instruments are the primary tool for assessing production

efficiency and product quality in both USDA and private
industry. USDA instruments are used to improve classer
accuracy, prepare standards, and provide measures, which are not
part of the official classification system, on a fee-for-service
basis. For private industry, instruments have been used to
grade, measure staple, ascertain character, provide a check on
quality of cotton delivered, and aid product manufacturing and
quality ( 1_)

Information on USDA research in the relationships between raw

fiber properties and product has been published annually since
1946 in the Agricultural Marketing Servicers (AMS) Summary of
Cotton Fiber and Processing Test Results .

Instrument evolution has reduced the cost of using instruments.

USDA and private industry have been cooperating to develop and
implement a high volume instrument (HVI) testing system. This
system represents a move from primary emphasis on humans in the
current USDA classification system to emphasis on instruments.

Test instruments were first demonstrated by USDA in Lubbock,

Tex., and Memphis, Tenn., in 1968, to evaluate their capacities
to perform high volume, or production line, testing under
several arrangements (7). By the seventies, the instrument
test line was able to provide measures of color, fiber length,
fiber fineness and maturity, length uniformity, and strength.
Trash content is visually determined, and a numerical trash
grade index is recorded with the other test line measures.

The Secretary of Agriculture created a National Cotton Marketing

Study Committee in 1974 to provide recommendations on various
cotton industry issues (4_). One recommendation, approved by the
Secretary, called for funding of a comprehensive field
evaluation of the instrument test line in a classing office
environment. The test began in 1976 in Lubbock, Tex. In
preparation for the test, USDA worked with the test line
producer, Motion Control Inc., Dallas, Tex., to refine the
line. Two test lines were installed, and almost 61,000 bales
were classed during the 1976 crop year.

During the 1976 to 1979 crop years, 50,000 to 70,000 bales were
classed on the HVI system each year in the Lubbock laboratory.
The instrument test line was accepted by USDA with the
establishment of an AMS office in Lamesa, Tex., in 1980. This
 office classed about 300,000 samples of 1980-crop cotton.
Manufacturing interest in test lines increased when the
instrument test line moved out of the laboratory and into the
classing offices and textile mills.

The move toward automated instrument test lines reflects, in

large part, increased economies of scale. For example, using
the Pressley strength tester, one operator can test 100 samples
in a workday employing two specimens per sample. The three
operators running an instrument test line can perform tests of
strength and other factors on 600 to 800 samples. Most measures
are now an average of the reading results on four specimens per
sample.

Economics is only a partial motivation for instrument use.

Providing additional quality measures such as strength and
length uniformity for the farmer, merchant, "and mill buyer
should assist their marketing decisions. For the cotton
industry, continued improvement in, and application of,
instruments will help in the search for uniform standards,
accurate and repeatable tests, and constant and measurable
factors on which to base quality standards. Reliance on
instruments, whether brought together in the form of a test line
or used independently for specific tests, is becoming common in
cotton classing.

Quality Measures The typical marketing sequence for cotton begins with
and Cotton transportation of harvested cotton to a local gin (2^9_)» At the
Marketing gin, the cotton is dried and cleaned, the seed is removed, and
the lint is packed into a 480-pound net weight bale. The cotton
usually goes from the gin to a local warehouse for storage,
compression, consolidation into even-running lots, and eventual
disposition to domestic and foreign outlets. Although farmers
sell some cotton to the gin, it is usually sold to merchants at
the gin or after entering the warehouse.

Most samples for quality are taken at the warehouse, the first
point for sampling. Some gins, mostly in California and Texas,
have mechanical samplers which collect samples during the
ginning process, but such samples constitute only a small
portion of samples classed. At the gin or warehouse, the bale
is tagged with identification and is cut on both sides
(mechanically or by hand). The two cuttings are combined to
form a minimum-6-ounce sample which is identified, packaged, and
sent to the bale owner or a designated place for
classification. The usual destination is one of 27 USDA
marketing services offices.

The marketing services office places the values for grade,

staple, and micronaire on the samplers classification or green
 card (fig. 1). The green card is returned to the gin, the
farmer, or designated person and is the basis for the first sale
of practically all cotton. The farmer uses green card values as
a check on production and harvesting methods. The values also
help determine relative quality so the farmer may expect
premiums or discounts, if applicable, for the marketed
quality. For the ginner, the green card measures may be useful
as a check on ginning methods. Green card and other quality
measures permit the merchant to assemble bales into even-running
lots and satisfy mill specifications.

Quality measures are used in forward contracts and on organized

exchanges, in addition to uses in the usual
farmer-to-merchant-to-mill marketing chain, and in direct
farmer-to-mill sales. Forward contracts, which are signed prior
to harvest, call for the farmer to place a quantity of cotton or
production from certain acreage under contract. A single price
may be set for all cotton meeting some minimum quality, a hog
round contract, or the price may depend on quality deviations
from a base quality, a grade and staple contract. Futures
contracts, such as those on the New York Cotton Exchange,
specify within narrow limits the quality acceptable for
delivery. TELCOT, an electronic spot market organized in
Lubbock, Tex., solicits bids by flashing quantity, quality, and
asking price across a computer network. Information on quality,
despite its addition to marketing cost, is essential for
efficient operation of all of these alternative marketing
arrangements.

Figure l~Classif ication green card

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WNITfO (TATCi DEPAftTMENI Of AOMICULTURf
AGRICULTURAL MARKITIKO MIIVICI
COTTON CLASSIFICATION MEMOtANOUM FORM 1 (HV|)

5
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!

MCSW-J03M HKM3M4
 ,

COTTON FIBER Some tests measure different facets of the same quality factors
PROPERTIES AND of grade, staple, and character. Many fiber properties have
PROCESSING PER- readily identifiable effects on textile processing and the
FORMANCE quality of the yarn and fabric that is produced:

Processing characteristic
Quality factor affected

Grade:

Color Dyeing, bleaching.

Trash Processing waste,
textile machinery contam-
ination, product
appearance
cotton dust levels.
Preparation Processing waste, product
appearance.

Staple Yarn and fabric fineness and

strength, nep formation
during processing.
Character:

Fineness and maturity Nep formation during proces-

sing, yarn and fabric strength,
product appearance, processing
waste, ends down.

Length uniformity Processing waste, ends down.

Strength Yarn and fabric strength,

ends down.

Some properties, such as trash or length uniformity also affect

cost of production, as well as spindle speed, end breakage, or
losses due to waste. Staple or fineness and maturity affect
yarn and fabric quality, such as appearance, strength, and
fabric feel, or hand.

Grade Grade, the earliest quality factor measured, is part of official

USDA classification, and is determined on the basis of color,
trash content, and preparation. There are 37 upland cotton
grades. A physical standard (practical form) composed of 12
 samples is available for each of 14 grades for visual grade
evaluation. Descriptive standards that refer to the physical
standards are used for the remaining 23 grades. Color, leaf
content, and the ginning process for pima cotton require
different grade standards.

Color. Cotton is normally white, but it can become spotted or

assume various shades of yellow and gray, deepening in color
with age and exposure to weather. Deviation from the normal
white color is considered grade deterioration. Color tests
evaluate brilliance, or reflectance and hue, with some chroma
differences being permitted within a grade.

Trash. Grade depends on trash, the quantity and appearance of

foreign matter remaining in cotton lint after ginning. Foreign
matter includes seed, stem, leaf, bract, dirt, grass, bark, and
particles introduced by harvesting equipment (oil, rubber) and
handling (bagging, rope). Differences in trash content can
determine color differences within a given grade.

Preparation . This is the effect ginning has on smoothness of

the cotton lint. Machine harvesting, excessive gin drying and
cleaning, and high gin production rates can lead to rougher
lint. Naps and neps contribute to roughness. Naps are large,
tangled masses of fibers that often result from ginning wet
cotton. Neps are smaller snarled clusters of fibers that look
like dots in the lint and are more difficult to remove.

Staple In most cotton, fibers range from less than 1/16 inch to more
than 1-3/4 inches. Staple refers to an average of the lengths
of the individual fibers, and value depends on the proportions
of the different lengths represented in the cotton sample.
Staple is critically important in determining product use.
Thirty-one official standards exist for U.S. cotton staple. The
standard intervals range from less than 13/16 inch to 1-3/4
inches, and are expressed in 1/32 inch. Staple usually refers
to the length determination of the classer, and length indicates
an instrument measure. The former is expressed in 1/32 inch and
the latter is measured in 1/100 inch.

Character The character of cotton is determined by identifying and

measuring a number of important fiber properties.

Fineness and Maturity . Two quality factors, fineness and

maturity, may be measured independently, but are grouped
together in this discussion because the airflow instrument most
commonly used to test them gives one value, the micronaire
reading, for their combined effect. A cotton fiber has a cross
—
section like a pipe hollow with inside and outside diameters.
For upland cotton, the outside diameter is approximately ttie
 same for all fibers, at 15 microns. Fineness and maturity,
then, relate to the inside diameter. Fineness is weight per
unit of length, and maturity is the extent of cell wall
development. Fineness is a characteristic of variety, so
different values for a given variety indicate maturity
differences. Similarly, fully mature fibers from different
varieties may differ in micronaire due to fineness differences.
Micronaire readings range from about 2.4 to 7.5, with each
cotton sample containing individual fibers carrying values
throughout this range. The overall micronaire reading depends
on the proportions of values represented in the sample. A
micronaire reading below 3.0 is considered very fine, and 5.0
and above is considered coarse; 3.5 to 4.9 is most desirable for
upland cotton varieties.

Strength. Fiber strength contributes to the yarn and fabric

strength, and is a measure of the force required to break a
sample of fibers. The measures are reported in 1,000 lbs. of
pull per square inch or in grams per tex. Increased speeds in
modern textile spinning and weaving machinery are placing
increased importance on fiber strength as a measure of cotton
quality.

Length uniformity. Although staple gives an indication of

average fiber length, it does not provide information on the
proportions of various fiber lengths constituting the cotton
sample. Measures of length uniformity describe the distribution
of the fiber lengths in the sample.

Elongation. Elongation is the extent to which a fiber may be

stretched, and is usually tested as part of a strength test
expressed in percentage terms. Fiber elongation is related to
yarn elongation which helps to withstand the stresses of the
weaving process without breakage.

Stickiness . Manufacturing problems may occur if cotton fibers

stick to equipment because of farm chemical sprays, oils, plant
and insect sugar (secretions from insects), or fiber
immaturity. One test used to indicate potential stickiness is a
measurement of the sugar content of the cotton sample.
Processing problems usually occur when the sugar content exceeds
0.3 percent.

Nep count Although neps may be considered part of preparation,

.

they are related to other fiber properties and have a separate

test. Nep formation during harvesting, ginning, and processing
increases as fiber length, fineness, and immaturity increase.
Neps are measured by processing a cotton sample into a web and
counting neps per unit of area.

10
 Moisture content . Moisture levels are frequently determined by
weighing the fiber before and after drying. Moisture is
reported as a percentage of the weight of the predried
specimen. Some instruments use a current flow method to
determine moisture content. Controlling moisture is also
important for accurately measuring other fiber properties.

CURRENT TEXTILE Numerous combinations of machines and machine speeds, settings,

INDUSTRY TESTING and drafts (force on the yarn) may be used in a textile mill.
PRACTICES All of these factors affect overall production efficiency and
manufacturing costs. These factors also determine cotton
qualities required for efficient operation, type of product, and
satisfactory product quality.

Mill management has recognized that cotton qualities other than

traditional grade and staple have a significant impact on
processing performance. While the measurement and use of other
factors is not new, increasing reliance is being placed on
instrument testing of cotton at textile mills.

Scope and Method Interviews with cotton buyers for textile firms were conducted
of Analysis during the fall of 1980 to determine the extent of fiber testing
activities by the textile industry. Initially, 52 firms were
—
contacted firms that were used in a 1974 study of textile mill
operations and covered the major textile producing areas of the
southeastern United States (8). Forty usable schedules were
obtained for the final sample analyzed. The remaining 12 firms
either went out of business, merged with other firms in the
intervening years, or did not respond. Every major category of
cotton fabric and every class of cotton yarn that is produced in
the United States are represented in responses to the survey.

Table 1 shows the distribution of the sample firms by the

quantity of cotton they annually consume. Five size categories
were used to group textile firms; they ranged from small
companies processing less than 15,000 bales to large users with
an annual consumption exceeding 150,000 bales. Since most of
the larger firms contacted operated more than one mill, data
contained in the survey represented each firnTs total cotton
consumption for textile manufacturing.

Over 3.2 million bales of cotton grown during the 1979/80 season
were consumed by the sample firms, representing nearly 50
percent of U.S. mill consumption during 1979/80. The eight
largest firms used an average of 236,000 bales, or a total of
—
nearly 1.9 million bales 30 percent of total domestic mill
consumption during 1979/80.

11
 c

Table 1 — Distribution of sample firms, by quantity of

cotton fibers consumed, 1979/80

:Combined Proportion
Firm size Firms Proportion: cotton consume of total
:

of sample: by firms U.S. mill

:

contacted use
:

Number Percent 1,000 bales Percent

Bales consumed:
Less than 15,000 11 27.5 119.4 1.8
15,000 to 25,000 : 5 12.5 106.7 1.6
25,001 to 50,000 7 17.5 240.5 3.7
50,001 to 150,000 : 9 22.5 861.8 13.2
Over 150,000 : 8 20.0 1,885.9 29.0
All firms 40 100.0 3,214.3 49.3

Firms provided information about their use of specific fiber

properties, use of instrument test values, their ownership and use
v
of cotton fiber testing instruments, and the firms confidence in
instrument values for staple compared with conventional human
classing values.

Fiber Property Many methods are used by USDA and private industry for measuring
Testing Methods fiber properties to determine cottoa quality. The methods include
sight and touch, and a variety of instruments:

Quality factor Measurement method

Grade:
Color Sight, colorimeter. Sight, Shirley
analyzer,
Trash Infrared fiber analyzer.
Preparation Sight, touch.

Staple Sight, touch, fibrograph, Suter-Webb

sorter, Motion control length/strength
analyzer.
Character:
Fineness and maturity Micronaire, fibronaire, arealometer,
causticaire maturity test, Shirley
fineness and maturity test, fibrograph
maturity test, sodium hydroxide test,
differential dyeing test.

Length uniformity Fibrograph, Suter-Uebb sorter,

Motion control L/S analyzer.
Strength Pressley, stelometer, Motion control
length/strength analyzer.
Other Nep count, sugar test, moisture test,
ultraviolet light.

12
 —

Ownership of The large number of instruments commercially available for

Testing Instru- measuring fiber properties suggests instrument ownership is
ments widespread in the textile industry. The survey results
confirmed such a pattern.

Over 92 percent of the surveyed textile firms reported owning at

least one cotton fiber testing instrument. Instruments for
measuring cotton fineness and maturity or micronaire were most
prevalent, owned by almost 73 percent of the small firms
(consuming less than 15,000 bales annually) and by nearly all of
the remaining firms (table 2). Seventy percent of the firms
owned instruments for testing length and length uniformity.
Since instruments that measure fiber length uniformity also
measure length, the percentage of firms owning equipment to test
for both length and length uniformity was identical for each
size category of textile firms.

The next factor for which instrument ownership was most

prevalent was fiber strength; 60 percent of the firms surveyed
owned such instruments. While most large firms, 87.5 percent,
had strength testing instruments, firms in the other size
groupings showed lower ownership percentages. However,
marketing practices may explain the relatively lower ownership
compared with that for other properties. Mill buyers usually
have knowledge of the annual strength characteristics of cotton

Table 2 — Textile firm ownership of fiber testing

instruments, 1979/80 1/

Firms owning instruments for testing

: Fine-
Firm size : ness and Length Nonlint
: maturity Length uniform- Strength Color content Other 2/
: ity

Percent
Bales consumed:
Less than 15,000 72.7 36.4 36.4 36.4 18.2 45.5
15,000 to 25,000 100.0 60.0 60.0 40.0 20.0 60.0
25,001 to 50,000 85.7 85.7 85.7 71.4 14.3 42.9 57.1
50,001 to 150,000 100.0 88.9 88.9 66.7 77.8 77.8
Over 150,000 100.0 87.5 87.5 87.5 62.5 100.0
All firms 90.0 70.0 70.0 60.0 2.5 45.0 67.5

1/ Reflects textile firms owning at least one testing instrument.

2/ Respondents indicated ownership of instruments for testing for neps and
stickiness only.

13
 grown in the various areas of the Cotton Belt. Therefore, a
heavy reliance is placed on purchasing cotton from areas of
known fiber strengths and specifying these requirements in
x
contracts with cotton merchants and shippers. USDA s annual
cotton quality determinations, which are frequently published,
v
are widely used by the textile industry s cotton buyers to
x
obtain strength data on each season s crop.

Instruments are available for measuring only the color and tras
components of grade. Only one firm reported ownership of
equipment for cotton color measurements. The textile industry
appears to have confidence in official USDA grade determination
as an indication of color. The color of a sample is probably
v
close enough to the classer s grade call for mill purposes to
justify not having a colorimeter.

Of growing importance to mills is the need to measure nonlint

content of cotton samples, including noncotton parts of the
cotton plant and other foreign material introduced in harvesting
and handling. Also, less opportunity exists for visual
inspection because of new and stricter regulations for the
opening rooms of textile mills in an effort to reduce cotton
dust. Automated bale opening systems are becoming more common.
Mills can do a better job of specifying the extent of lint
cleaning and estimating the approximate manufacturing waste loss
involved by using information on trash content. Instruments for
determining the nonlint content of cotton were owned by about
half the sample firms with ownership more prevalent among the
larger firms.

Other testing instruments owned by firms primarily included

equipment for determining neps in cotton samples, as well as
sugar content to measure the stickiness of individual fibers.
Over 67 percent of textile mills, including a significant number
of the smaller firms, reported owning at least one of these
instruments.

Fifty-seven percent of all firms contacted reported owning an

Uster Evenness Tester, although it is not considered a testing
instrument of fiber properties. All fiber properties (including
uniformity) are reflected in the quality of the yarn. The Uster
tester is used to measure the evenness of cotton yarn after
spinning, and it determines whether the yarn varies in thickness
from place to place. It is used as a product quality-control
device.

14
Importance of Textile firms were asked to rank their perceptions of the
Each Fiber importance of each fiber property measure used in
Property manufacturing. Rankings ranged from 1, indicating the least
important fiber property, through 6, indicating the most
important property. Results indicated that length, fineness and
maturity, and grade are the three most important properties,
respectively (table 3). These measures, of course, are those
provided by official USDA classifications and are listed on the
green card. The factor that emerged as most important, fiber
length, received a mean rank of 5.06 compared with a rank of
2.85 for length uniformity, a surprising outcome. Either the
importance of other fiber properties outweighed the importance
of uniformity, or uniformity was not frequently used in laying
down mixes. Apparently, length uniformity may be used mainly
for screening fibers to remove bales with extreme values. Also,
increased short fiber content can often result from ginning and
be reflected in lower staple length.

v
Nonlint content ranked lowest. Again, the cotton buyer s
knowledge of the classer grade designation and the area of
growth provide a good indication of the trash, or nonlint
content, of the bale, making separate instrument measures of
this property lower in importance. However, the need for more
attention to this area is reflected in instrument ownership
patterns and the increased use of open-end spinning which is
particularly sensitive to trash.

Use of Specific Table 4 shows the extent of specific fiber property usage by
Fiber Properties textile firms during all phases of their business operations.
These data show the proportion of firms using the fiber

—
Table 3 Ranking of importance of each cotton fiber
property measure used in manufacturing, 1979/80

Fiber property F irms assigning a rank of- -1/: Mean

6 : 5 : 4 : 3 : 2 : 1 rank

Number

Fineness and maturity 21.1 27.3 30.3 18.2 3.1 4.45

Length 48.4 30.3 6.1 9.1 6.1 5.06
Length uniformity : 6.1 6.1 9.1 27.3 48.4 3.C ) 2.85
Strength 6.1 21.2 12.1 36.4 21.2 3.C ) 3.45
Grade :18.2 15.1 42.4 9.1 15.2 4.12
Nonlint content 6.1 93. S) 1.06

1/ "6" equals most important value; 1 equals least

important.

15
 properties regardless of ownership of testing instruments. The
firms were simply asked which properties were used in
manufacturing.

All firms employed measures of fiber fineness and maturity in

their manufacturing operations, and 85 percent of the firms used
values for fiber length. The next most used measures, strength
and grade, were employed by 7 2.5 and 70 percent of the firms,
respectively.

As firm size becomes larger, a higher proportion of fiber

properties is used, because as size increases, the variety of
fabrics and products generally increases, making the use of
additional fiber properties necessary.

Both the importance and use of the specific fiber properties are
significantly influenced by the types of products
manufactured. For example, manufacturers of thread and fine

Table 4 — Use of specific fiber property measures by textile

firms during manufacturing, 1979/80 1/

Firms by size, bales consumed per year 2/

15,000 25,001 50,001
:

Fiber property Less than : to : to to Over

: All
measures : 15,000 . 25,000 50,000 150,000 150,000 firms

Percent

Fineness and
maturity : 100.0 100.0 100.0 100.0 100.0 100.0
Length 72.7 60.0 85.7 100.0 100.0 85.0
Length uniformity : 36.4 20.0 71.4 77.8 75.0 57.5
Strength 54.5 40.0 85.7 77.8 100.0 72.5
Grade 72.7 60.0 85.7 44.4 87.5 70.0
Noncotton
content : 9.0 42.9 44.4 50.0 30.0
Other 2/ 20.0 22.2 50.0 17.5

1_/ Proportion of textile firms sampled using fiber property measures in processing
regardless of ownership of testing instruments.
2/ Nep and stickiness measures.

16
 —

yarns are most concerned with staple length and strength, while
producers of denim are more interested in selecting fibers based
on grade and fineness and maturity. The results showed
industrywide use patterns of the specified fiber properties to
the extent that the sample firms still represented as broad a
cross section of manufacturers as originally projected when the
sample was designed.

Firms were also asked to state the most important operations

which required knowledge of fiber properties determined by
instruments. The four major areas in which the fiber properties
are used in manufacturing operations in textile mills are
quality control, fiber screening, laying down mixes, and
purchasing.

Quality control involves establishing that the specific quality

of cotton purchased was indeed received from merchants and
shippers, or from mill stocks at other locations. The screening
of fibers refers to sorting and assembling even-running lots at
a given mill, or for use at other mills owned by a given firm.
Laying down mixes refers to the textile mill opening room
operation of mixing and blending cotton fibers with differing
properties to achieve spinnable cotton having a desired set of
properties. Fiber property measures are used in purchasing to
obtain the quality characteristics needed for manufacturing and
for determining the alternative prices a firm is willing to pay
for differing qualities.

Over 92 percent of all firms contacted used fiber property

values for laying down mixes, by far the most important use
(table 5). All firms consuming over 25,000 bales used

Table 5 — Textile mill use of fiber property measures

in manufacturing operations, 1979/80

Firms using fiber properties for

Firm size Quality Screening : Laying down
control fibers : mixes : Purchasing

Percent
Bales consumed:
Less than 15,000 45.5 9.1 81.8 72.7
15,000 to 25,000 60.0 80.0 100.0
25,001 to 50,000 : 71.4 28.6 100.0 57.1
50,001 to 150,000 : 88.9 66.7 100.0 83.9
Over 150,000 87.5 100.0 100.0 87.5
All firms : 70.0 42.5 92.5 30.0

17
 instrument values of fiber properties in laying down mixes.
About 80 percent of the smaller f Lrms consuming less than 25,000
bales also used instrument values.

The second major area of application was the use of fiber

properties in purchasing cotton, where 80 percent of all firms
used instrument values for this purpose. Seventy percent of
all firms used test results for quality control purposes. About
42 percent reported use in screening fibers, primarily for other
mills in the same firm; as expected, this function is relatively
unimportant for small firms.

Because the mixing and blending of fibers is one of the most

critical operations in textile processing, mills were asked to
provide information on which fiber properties, as determined by
instrument, were used in laying down mixes. Every firm that
used fiber properties for mixing and blending used fineness and
maturity measures (table 6).

Fiber length was the next most important decision variable, used
by 70.3 percent of the firms. About 65 percent reported using
grade information. Length uniformity and strength measures were
employed by less than 25 percent of the firms contacted.

Each of the various fiber properties is not exclusively used in

laying down mixes, but is generally employed in combination with
other quality measures, depending on product, equipment, and

Table 6 — Textile firm use of specific fiber properties

for laying down mixes, 1979/80

F irms using- -1/

Firm size Fineness and : : Length
maturity : Length : uniform- Strength Grade
: ity
Percent
Bales consumed:
Less than 15,000 : 100.0 66.7 33.3 11.1 66.7
15,000 to 25,000 100.0 75.0 25.0 25.0 75.0
25,001 to 50,000 : 100.0 71.4 28.6 42.9 71.4
50,001 to 150,000 100.0 55.5 22.2 22.2 66.7
Over 150,000 100.0 87.5 25.0 50.0
All firms 100.0 70.3 21.6 24.3 64.9

\J This is the percentage of firms that reported using fiber properties for
laying
down mixes. No firms reported using nonlint content or other measures such as
nepiness or stickiness in laying down mixes.

18
 machinery settings. Textile firms clearly have made instrument
values essential for optimum blending of- various kinds of
cotton.

Relationship of A comparison of textile firm use of fiber property measurements

Fiber Property with information on ownership of the associated testing
Use to Instru- instruments is shown in table 7. These data provide a broad
ment Ownership indication of the potential demand for instrument test values as
an integral part of the official cotton classification system.
In most cases, the categories for smaller firms consuming fewer
than 25,000 bales, show a higher proportion of their members
using fiber property measures relative to their ownership of
related instruments. Comparisons for each of the five size
groupings of firms may be made by using data contained in tables
4 and 6.

—
Table 7 Textile mill use of fiber properties related to
ownership of associated fiber testing instruments,
1979/30 1/

Firms owning
Firms instruments to
Fiber property using property measure property

: Percent

Fineness and
maturity : 100.0 90.0
Length : 85.0 70.0
Length uniformity : 57.5 70.0
Strength : 72.5 60.0
Grade 2/ : 70.0 2.5
Noncotton
content : 30.0 45.0
Other : 17.5 67.5

1/ Represents the average for all firms surveyed.

2/ The only associated instruments reported are those
measuring color.

19
Confidence in Textile firms were asked to express their opinion on their
Instrument Values confidence in instrument test values for staple determinations
Versus Traditional versus values obtained through traditional human cotton classing
Cotton Classing operations. Of the 40 firms surveyed, 34 responses were
obtained. Overall, 26.5 percent reported more confidence in
instrument values, 32.4 percent reported the same level of
confidence, while 41.1 percent said they had less confidence in
instrument values then in conventional cotton classing (table
8). The distribution of responses by size of firms indicates
the smaller firms have considerable confidence in instrument
values. Less than 50 percent of the firms in the consumption
size category between 25,000 and 50,000 bales had reported that
they were at least as confident with instruments as traditional
methods.

INSTRUMENT TESTING The first section of this report indicated that USDA is
SYSTEMS AND USDA currently increasing its use of HVI systems. The HVI system
COTTON CLASSING provides those fiber property measures that the textile firms
require.

Current HVI HVI systems differ by number of operators, instruments included,

Testing and sequence of instruments used. A typical HVI system is
depicted in figure 2. A cotton sample passes through three test
stations: micronaire, beard preparation, and length/strength.
Three operators run the system, one at each station.

The micronaire station operator is the first to touch the cotton

sample. A micronaire determination, the same as that for

—
Table 8 Textile mill confidence in instrument test
values for staple versus traditional cotton
classing, 1979/80

Confi- : Favored
Favored : dent in : tradi-
Firm size instru- either : tional
ments method : classing

Percent
Bales consumed:
Less than 15,000 : 50.0 25.0 25.0
15,000 to 25,000 : 50.0 25.0 25.0
25,001 to 50,000 16.7 16.7 66.6
50,001 to 150,000 : 50.0 50.0
Over 150,000 : 25.0 37.5 37.5
All firms 6.5 32.4 41.1

20
Figure 2. High Volume Instrument System (without Conveyors)
10'

CO

Loose
Disposal
Length /Strength

CD Sample CO

^
Tray Micronaire

Color

Leaf
Keyboard
CO

\_
Operators
y

traditional classing, is made; the value is automatically

recorded. A visual determination of trash content and
preparation is also made and manually entered into the system by
keyboard. A refinement of this system now in the developmental
stage would have trash content measured by instrument and
automatically recorded.

The sample then passes to the beard preparation station where it

is tested for color. Yellowness and grayness (analagous to the
colorimeter measures of yellowness) and reflectance are
automatically recorded.

The sample is then used to make four small segments, or beards,

and placed in clamps for multiple readings on length and
strength. The length/strength station operator places the
clamped beards on the length and strength elevators for testing
and automatic recording. Beards and the remainder of the sample
are discarded at the beard preparation station and lose their
identity.

A fourth operator services several HVI systems, supplying each

system with its samples and collecting the loose waste.

21
 ,

The automatic recording of test measures is controlled by an

important component of HVI hardware, the microprocessor, which
provides sample identification, proper sequencing of the tests,
computes averages of multiple test readings, formats data, and
records the data on tape. The tape is then used on a computer,
with appropriate programs, to write reports. For example, a
report is sent to the gin indicating individual bale numbers,
quality data, and frequency distributions for quality factors on
all cotton processed by the gin. Quality information is also
transferred to the classification cards which are then sent to
the gin (see fig. 1).

Implementation Increasing use of HVI systems is related to both technical and

Considerations economic issues. The survey results in this report showed 41
percent of the respondents had less confidence in instrument
values than in traditional classing. Confidence in instrument
values is important for industry acceptance of HVI systems.

AMS has conducted numerous tests of HVI measures since the

system came into existence. The tests assess the accuracy and
precision of HVI fiber quality measures. For example, some of
the major tests have included:

. Assessment of the HVI systenTs ability to remain in

calibration over time,

Comparison of HVI with classer measures to determine the

frequency and extent to which the measures differ,

Repeated HVI testing of calibration cotton samples to

x
compare average HVI measures with the calibration cotton s
standard values,

Repeated HVI testing of samples to determine variablity

(repeatability)

Comparison of the way processing performance and yarn

quality are related to measures determined by HVI, classer,
and a set of individual laboratory instruments of the types
often used by textile firms, and

Determination of the extent to which measures from HVI,

classer, and various laboratory instruments are related.
Overall, the results of these tests show HVI measures are
very similar to both classer and individual laboratory
instrument measures in terms of accuracy and repeatability
(getting the same reading each time tested) and as
indicators of manufacturing performance (3,12).

22
A variety of economic issues are related to HVI classification.
The broad issue underlying Government grading and classing of
any commodity is benefits and costs of publicly supplied
services versus private sector monitoring. Given USDA
classification, benefit/cost issues relate to partial or all
crop HVI classing compared with traditional or alternative
instrument classing systems.

Much of the information developed in this report relates to

textile firm benefits of instrument testing. Textile firms
place a value on knowledge of fiber properties other than
traditional grade, staple, and micronaire. The value is derived
from a reduction in uncertainty over the quality of cotton
purchased and improved processing and final product. For most
firms, the apparent value of the additional instrument
information exceeds the cost of testing, based on this survey of
instrument use and ownership patterns of textile firms. For
firms not using instrument data, test costs may exceed use
value; however, use value may still be positive. A company
using only one type of cotton (high-strength, California cotton,
for example) may have little need for instrument testing.
However, companies that purchase several types can save by using
USDA test results, rather than buying expensive testing
equipment. HVI classing by USDA permits these latter firms to
employ this use value and allows other firms to increase theirs,
especially if USDA testing results in a reduction of their own
test efforts. The value of information is also a resource
allocation issue. More fiber quality information should permit
cotton and its production resources to be attracted to the
highest value end-uses. HVI testing would thus aid resource
allocation by enabling premiums and discounts of cotton, based
on its HVI quality measures, to be transmitted from textile
mills back to cotton farmers.

23
REFERENCES (1) Faver, William H. Use of Cotton Fiber Tests by United
States Cotton Mills . Southern Coop. Series Bull. No. 70.
Southern Regional Cotton Marketing Research Committee,
Dec. 1959.

(2) Glade, Edward H. Jr., and Joseph L. Ghetti.

, Marketing
U.S. Cotton to Domestic and Foreign Outlets in 1977/73:
Practices and Costs . ESCS-79. U.S. Dept. Agr. Econ.
,

Stat. Coop. Serv., Feb. 1980.

(3) Griffith, Samuel R. "Evaluation of Instrument Classing of

Cotton, Lubbock, Texas, Crop of 1976/' U.S. Dept. Agr.,
Agri. Mktng. Serv., Jan. 1978.

(4) National Cotton Marketing Study Committee. National Cotton

Marketing Study Committee Report U.S. Dept. Agr., Aug.
.

1975.

(5) Palmer, Arthur W. The Commercial Classification of American

Cotton Dept. Circ. 278.
. U.S. Dept. Agr., Jan. 1924.

(6) The Growth of Cotton Fiber Science in the

United States . Publication 4452. Smithsonian
Institution, 1961.

(7) Smith, Harvin R. "High Volume Testing Production and

Operation," Summary Proceedings. 1969 Cotton Quality and
Processing Conference. Paper presented at National Cotton
Council meeting, Memphis, Tenn. 1969, pp. 12-14.
,

(8) Rogers, CD., H.C. Spurlock, and D.E. Crawford. Trends in

Use of Cotton and Competing Fibers, 1973 .Bulletin 57 8.
South Carolina Agr. Exp. Sta., Clemson Univ., in
cooperation with the U.S. Dept. Agr., Nov. 1974.

(9) Sporleder, Thomas, James Haskell, Don Ethridge, and Robert

Firch. Who Will Market Your Cotton ? D-1054. Texas Agr.
Ext. Serv., Texas A & M Univ., College Station, Mar.
1973.

(10) U.S. Department of Agriculture, Consumer and Marketing

Service. Cotton Testing Service: Tests Available,
Equipment and Techniques, and Basis for Interpreting
Results. C&MS-82, May 1970.

(11) Agricultural Marketing Service. The

,

Classification of Cotton . AH-566. Apr. 1930.

(12) Agricultural Marketing Service.

, "Variations
in Cotton Classing Systems." Staff paper, July 23, 1980.

24

•U.S. GOVERNMENT PRINTING OFFICE: -0-360-932/ER5-229

UNITED STATES DEPARTMENT OF AGRICULTURE
POSTAGE ANO FEES PAID
WASHINGTON. DC. 20250 U.S.DEPARTMENT OF
AGRICULTURE
AGR 101
THIRD CLASS

Economic Research Service

The Economic Research Service carries out research on the production and marketing of major agricultural
commodities; foreign agriculture and trade; economic use, conservation, and development of natural resources;
trends in rural population, employment, and housing; rural economic adjustment problems; and performance
of the U.S. agricultural industry. ERS provides objective and timely economic information to farmers, farm
organization members, farm suppliers, marketers, processors, consumers, and others who make production,
marketing, and purchasing decisions, and to legislators and other public officials at the Federal, State, and local
government levels.