Moisture Products - Samuel Jackson, Inc.

Moisture Products - Samuel Jackson, Inc.
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Introduction to Moisture Restoration
Adding moisture can add efficiency and value.
We talk a lot about cotton moisture. But just to add variety to the same old fiber moisture
explanation, let’s take a look at another favorite ag product – chocolate!
When cocoa beans are harvested, their first step in becoming chocolate is to undergo a
fermenting process where their moisture content is around 60%. If done incorrectly, the
classic chocolate flavor will not develop.
Next the beans must be dried down to a moisture content of about 7%. If it’s too low, the
beans are too brittle and break. Too high and they will mold in storage. Now the beans are
ready to be shipped to the factory, where they will be dried further with roasting. Other
processes follow, including milling, pressing, refining, tempering and molding. Each of
these processes require a certain moisture range to produce desired results. Sound familiar?
Cotton, like chocolate and virtually every other ag product, requires the control of moisture
to maximize its value. In the previous section of this handbook, we discussed the needs and
benefits of drying. But the benefits of moisture control do not stop after the drying and precleaning stage of the gin.
There are two critical points in the gin where restoring moisture can yield
efficiency gains for the gin and higher bale values for the growers.
In the following pages you’ll see the products we offer that are designed to deliver these
benefits. If you are interested in obtaining the full advantages of moisture restoration in your
gin, give us a call and we will work with you to find the best solutions for your operation.
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Moisture restoration requires a
Humidaire Unit and an applicator.
Humidaire Units
Humidaire Units are used to safely and
effectively restore moisture to cotton.
They create moist or humidified air by
heating ambient air; allowing it to absorb
large amounts of moisture. Humidaire
Units are often generically called moist air
generators, humidifiers or simply moisture
units. Each system usually requires a single
Humidaire, but larger gins are reaching
capacities where multiple units would
actually be better in certain applications.
There are several models of Humidaire
Units with different levels of performance
and control for your gin’s specific needs.
Moist Air Applicators
Once the moist air has been generated
by the Humidaire Unit, you need a moist
air applicator. Applicators are separated
into two groups: those used to restore
moisture to seed cotton and those used
The King Mesa Humidaire Unit.
to restore moisture to lint. The two types
of applicators differ by their location in the gin and more importantly their function as it
relates to gin production, efficiency and fiber quality. Example applicators are shown below.
A Conditioning Hopper for seed
cotton moisture restoration
A Lint Slide Grid for economical
lint moisture restoration
A Steamroller for powerful and
efficient lint moisture restoration
Main Line: 806-795-5218
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Introduction to Moisture Restoration
Benefit from moisture at
your gin stand feeders...
A typical Conditioning Hopper System
Seed Cotton Conditioning Systems
Samuel Jackson Seed Cotton Conditioning
Systems apply humid air to seed cotton
between the conveyor distributor and
each gin stand using an applicator called
a Conditioning Hopper. Although each
system will have a single Hopper above every
stand, typically only one Humidaire Unit is
required for the entire system. Seed Cotton
Conditioning is used to prepare seed cotton
for ginning. When the moisture level of seed
cotton is raised before ginning, certain aspects
of fiber quality are preserved. Seed Cotton
Conditioning used alone has little effect on
bale moisture content and is not a substitute
for Lint Conditioning.
Lint Conditioning Systems
Samuel Jackson Lint Conditioning Systems
are found between the battery condenser and
the tramper on a press. Some gins, due to a
combination of capacity and lint slide space,
require compression of the lint batt. Other
gins have lint slides capable of handling their
capacity without compression. A Steamroller
is used when batt compression is needed. A
Lint Slide Grid is an economical alternative
when compression is not needed. The
purpose of restoring moisture to lint from a
gin’s perspective is to reduce the hydraulic
pressures on the press. Conditioned lint
presses easier, can improve press capacity
and adds consistency to bale weights. Samuel
Jackson Lint Conditioning Systems have no
positive or negative effect on fiber quality.
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... and at your press
A Steamroller 2 Lint Conditioning System
www.SamJackson.com
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Humidaire Operation in 4 Easy Steps
4
3
1
2
Understanding the principles of operation of a
Humidaire Unit is easiest when you break it down into
the following four steps:
Step 1: Ambient air is pulled
in through the air inlet of the
Humidaire Unit. Note: The air
inlet screen has been removed for
picture clarity.
Step 2: The air passes through the burner head which raises the
temperature of the air. Heated air will carry much more moisture than
cool or ambient air.
Step 3: The heated air enters the spray chamber where it mixes with a
torrent of water that is circulated through the unit and sprayed out of
nozzles. The air absorbs the moisture to become humidified air.
Step 4: The moist air leaves the Humidaire Unit through a pipe
connected to the top of the spray chamber and goes to the application
point. The picture shows humidified air being exhausted from our
Humidaire Test Stand as an example of the volume of moisture
generated. In a gin, the humidified air would go to a seed cotton or
lint moist air applicator.
Main Line: 806-795-5218
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Introduction to Moisture Restoration
Traditional Humidaire Control
Step 2:
Step 1:
The operator sets the
water temperature. This
controls the water valve.
The water valve adjusts
the amount of water
flowing through the
nozzles. Adjusting the
water temperature
closer to the air
temperature
creates more
moist air
output.
The operator sets the
air temperature. This
controls the fuel valve.
Hotter air absorbs more
moisture, so a higher
air temperature will
allow the Humidaire
to generate more
moisture output.
Step 3:
By balancing the air
and water temperatures,
the operator controls
the amount of moisture
the Humidaire Unit
generates.
Note: This picture shows an example of the volume of moist
air generated by a Humidaire Unit. In a gin, the moist air
would be carried by pipe to an application point.
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Humidaire Features Explained
Moisture Direct Control makes it easier
than ever to control Humidaire output
Our Humidaires have a strong reputation
for performance and dependability. But
controlling their output has always been a
skill that required specialized instructions,
experience in a variety of conditions and a
knowledgeable touch – until now!
Moisture Direct Control makes getting just
the right amount of moisture from your
Humidaire Unit easier than ever. Traditional
Humidaires measure temperature in the
water tank and adjust moisture output by
changing the amount of water being exposed
to the hot air stream. Moisture Direct simplifies the control process by adjusting the moisture
from the touch screen based on desired moisture output. Adjust the output percentage
higher for more moisture or lower for less. It’s that easy!
In addition to making moisture control easier to use, Moisture Direct also gives Humidaire
Units more precise output, a larger operating range and faster response.
The key to successful Moisture Direct operation is a complex algorithm that is specially
calibrated and unique to each Humidaire Unit. Every unit is carefully calibrated on our
factory test stand prior to shipping. Should your unit ever need recalibrating, the complete
procedure can be performed with the touch of a button and is completely automatic!
We tend to agree with the old saying, “It’s easy to make something complicated, what’s hard
is keeping it simple.” Our design team has done the hard work in making Humidaire control
easy for all of your operators to get great results.
Moisture Direct is a standard feature on all units
with the 1600 Series Operating System.
Main Line: 806-795-5218
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Humidaire Features Explained
The 1600 Series Operating System
After designing and manufacturing moisture equipment for over 50 years, we’ve seen a
number of machines that “look” like genuine Humidaire Units. While proven thermodynamic
design is critical, experienced ginners will tell you a very important part of any moisture
unit’s performance is the operating system or “controls”.
The King Mesa and Sahara Storm Humidaires closely resemble their popular predecessors,
the Southwest Lite and Sahara Lite. That said, don’t be quick to judge this book by its cover.
The 1600 Series Operating system is the most significant change in Humidaire controls
technology in over 20 years. Moisture output is easier to adjust, faster to respond and more
stable than ever! This Operating System was specifically designed for the King Mesa and
Sahara Storm Humidaires to support a number of features including:
•
•
•
•
•
Moisture Direct Control
Moisture Mirror X remote compatibility
Analog Water Pressure Monitoring
Analog Fuel Pressure Monitoring*
Improved Automatic Purge System
• Water Pump and Flame Settings for Gin
Idle
• Output for Moist Air Fan VFD
• Advanced Real-Time Error Logging
• And more!
The 1600 Series Operating System organizes all of these features on the Humidaire’s local
color touch screen so they are easy to find and use. Your operators will enjoy the simple and
intuitive controls compared to previous moisture units.
In addition to the King Mesa and
Sahara Storm, the larger, extreme-duty
Southwest and Sahara Humidaires also
features the 1600 Series Operating
System on all new units. Consult the
factory for control upgrade options
available.
* Currently available on the Sahara and
Sahara Storm models only.
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1600 Series Features You Don’t Want to Miss
The 1600 Series operating system is loaded with great features. We can’t cover them all here,
but we wanted to highlight a few of them that you won’t want to miss.
Moisture Direct Control
More analog inputs for advanced
control and performance
Detailed error reports and log
Auto calibration procedure
Flame idling
Moist air fan VFD control
Main Line: 806-795-5218
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Humidaire Features Explained
Moisture Tunnel Technology
Thermodynamically Speaking...It Sizzles!
You can see the Moisture Tunnel in action as the fire and water interact inside the spray chamber.
We’ve all had our share of hamburgers. Cooked in a pan or a griddle they can be satisfying, but
when you’re really craving a good, make-your-mouth water burger, there is no substitute for flamegrilled. Letting that flame come in direct contact with the patty as it cooks does something special.
Now you may be wondering what that has to do with Humidaires (other than this being written at
lunch time). Well the ‘classic’ Humidaire configuration uses ‘griddle’ thermodynamics. The flame
and the water are separated by a physical barrier and the water is heated indirectly.
Humidaire models equipped with Moisture Tunnel Technology use ‘flame-grilled’
thermodynamics, forcing the water into direct contact with the flame from a fuel-efficient,
premium burner head. The results sizzle in more ways than one. As an example, the Humidaire
Southwest is equipped with Moisture Tunnel Technology and can evaporate 100% more moist air
using 10% less fuel than traditional moisture units.
Moisture Tunnel Technology is available on the Humidaire
Southwest, Humidaire King Mesa, Humidaire Sahara and
Sahara Storm models. The Zephyr can be upgraded to the
Sahara Storm.
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Hydrocyclone Cleaning Option
Clean Water Makes For Happy Humidaires and Humidaire Owners
If you or one of your employees get stress relief from cleaning
the mud and muck out of your Humidaire tank and pipes,
then the hydro-cyclone may not interest you. But if you’d
like a device that helps do that work for you, read on!
Keeping the water circulating in your Humidaire clean
helps it perform better, extends time between cleaning,
makes cleaning the unit easier and adds life to your unit.
The hydro-cyclone option makes achieving cleaner water
and its benefits possible.
Similar in principle to the cyclones in your air systems,
dirty water is swirled through the hydrocyclone. The dirt,
sediment, lint and other junk entrained
in the water gets separated out and exits
the bottom of the cone. The cleaned
water exits the top and is recirculated
back into the bottom of the tank, where
it sweeps the bottom of the tank clean,
too.
The Hydrocyclone is standard on all
Humidaire Southwest and Sahara models
and is available as a factory option or field
retrofit on the King Mesa and Sahara Storm
Humidaires. Compatible models come
equipped with software controls that make
it easy to setup and customize cleaning
parameters.
Ask your Sam Jackson rep for more
information on how this option will work for
you and improve your system.
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Humidaire Features Explained
Moisture Mirror Remote Control
The Moisture Mirror 2X, 3X and 4X offer remote control of
1400, 1500 and 1600 Series Humidaires from your console.
How would you like to take back a little
real estate on your console? The Moisture
Mirror 2X, 3X and 4X can remotely
control up to four Humidaires and up to
eight Heaters from a single touch screen.
The Mirror allows you to start and stop
the unit, change temperatures and even
view performance statistics such as
gallons evaporated per minute. If there
is a problem at the unit, the Moisture
Mirror will notify you at the console and
offer possible solutions. You’re not going
to miss your old digital controllers!
Mirror X Home Screens (2X shown) show the
status of all connected Humidaires
Connecting 1400, 1500
and 1600 Series products
to the Moisture Mirror is
easy. It only requires a
single
Ethernet
cable from the
Mirror to each
product. If there’s
a communication
problem, there is only
one cable to check making
troubleshooting a snap!
Each Humidaire has its own screen complete with start
and stop buttons and operation statistics.
Moisture Mirror Remote Compatibility is not available
for the Static Zapper or Zephyr Humidaire Unit models.
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Water Watch
Don’t guess about Humidaire performance, watch for yourself.
The relationship between temperature settings
and Humidaire output can sometimes be difficult
to understand. Water Watch makes it easier by
displaying Humidaire performance as Fresh, Purge
and Evaporated water in gallons per minute. By
comparing the fresh water entering the unit with
the purge water being removed, the amount of water
evaporated is calculated as a running 30-minute
average. Fresh and Purge totals are kept over the
lifetime of the unit and resettable totals can be
zeroed at the start of each gin season.
Water Watch meters are housed in the lower
cabinet and help measure the ROI of moisture
restoration at your gin.
Water Watch information is graphed
over a 24-hour period. The graphing
window displays a 30-minute time frame
and defaults to the latest 30-minute
interval. Graphing history is viewed by
pressing the on-screen forward and back
arrows. The Water Graph is especially
helpful in identifying trends. Trends can
be used to compare moisture system
performance over time and highlight
problems with Humidaire performance
early. A malfunctioning water valve or
float valve is easy to see when you look at
the color-keyed graph.
The Water Graph clearly defines a problem such as the
malfunctioning purge valve in the example above.
Water Watch comes standard on 1600 Series Humidaire Units.
Main Line: 806-795-5218
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The Static Zapper
A Special Purpose Moisture Unit
Many don’t realize that the Humidaire was originally invented for the purpose of killing static.
Success at that led to its use in other applications, giving benefits to press efficiency, ginning speed
and protecting quality at the gin stand.
With that history and the known power
of moisture restoration, it’s not surprising
that interest in new applications for
moist air continues to grow. Not all of
those applications are suited for our
traditional sized Humidaires.
The Static Zapper offers an economical,
easy-to-use moist air generator that
is ideally sized for lower volume
applications. Simple and straightforward to install, this unit is suited
for special applications such as small
capacity gins, industrial processes, spot
conditioning, prototype testing and
research trials.
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•
•
•
•
Operates on natural gas or propane
2 HP water pump
500 - 1,000 CFM
1-million Btu/hr rating
Stainless steel water tank and spray
chamber
• PLC controls
• Water flow controlled by VFD
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• Output for fan speed control for constant
air volume
• Evaporation rates of 60 gallons per hour
• Fast warm-up time
• Output is adjustable in 1% increments
• Easy installation
• Great alternative to boiler systems
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Gas-Fired Humidaire Comparison
Which model fits your needs?
Model #
Max. Evaporation
Heating
Efficiency
Maximum
Air Volume
Water Pump Motor
Stainless Steel Pump
Burner
Moisture Tunnel
Technology
Two side water tank access
Access doors to tunnel
1600 Series Operating
System
Combustion Controls
Air Temperature Control
Water Temperature
Control
Operator Interface
Ethernet Communications
Moisture Mirror Remote
Control
Mirror Compatible for
Target Bale Moisture
Error/Alarm Interface
Water Watch Diagnostics
Purge System
Hydrocyclone Cleaner
Suggested Use
King Mesa
Southwest
HU-80-1635/1625*
3.5 gallons/minute
1,530 Btu per pound
of water evaporated
HU-SOUTHWEST-1680/1675*
4.2 gallons/minute
1,530 Btu per pound
of water evaporated
4,000 CFM
5,000 CFM
5 HP
No
Samuel Jackson
7.5 HP
Yes
Samuel Jackson
Yes
Yes
No
1
Yes
3
Yes
Yes
PLC/ AS 3814-2009*
User Set-Point PID
Controlled by PLC
PLC/ AS 3814-2009*
User Set-Point PID
Controlled by PLC
Moisture Direct
Moisture Direct
Touch Screen
Yes
Touch Screen
Yes
Mirror 2X and higher
Mirror 2X and higher
Yes; Ethernet
Yes; Ethernet
Touch Screen
Yes
Automatic
Optional
Conditioning Hoppers, Moisture
Condensers and Steamrollers
Touch Screen
Yes
Automatic
Yes
Conditioning Hoppers, Moisture
Condensers and Steamrollers
* Australian Humidaire Models
Main Line: 806-795-5218
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Gas-Fired: The Humidaire King Mesa
The Humidaire King Mesa has powerful moisture
output, fuel efficient operation and user-friendly
controls in one impressive package.
Meet the King Mesa. It can evaporate 75%
more moisture using less fuel compared
with traditional moist air units. It is a
powerful enough unit for larger gins, but
has great turndown for almost all moist
air needs. Its performance and efficiency
are by-products of Moisture Tunnel
Technology. The King Mesa was also the
first Humidaire model to include Moisture
Direct Control. Moisture Direct is the most
stable and user-friendly Humidaire control
system ever designed for a Humidaire
Unit. More information on both Moisture
Direct and the Moisture Tunnel can be
found earlier in this section.
The Humidaire King Mesa.
The Humidaire King Mesa comes standard
with several impressive features such as:
• A local color touchscreen for simple
control and advanced diagnostics
• Automatic heavy-duty purge system
to reduce cleaning needs
• Target Bale Moisture Control
with any Mirror X and a Tex-Max
• Remote control from any Mirror X
• Remote monitoring with an iPhone
or iPad using the Mobile Mirror App
• Easy access to the water tank during
operation
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The King Mesa utilizes a local color touch screen that
gives the operator in-depth performance statistics
directly on the home screen.
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6-inch color
touch screen
operator
interface
The King Mesa can
handle 4,000 CFM
of air
PLC controls
inside cabinet
Spray chamber
window
Water Watch
meters and
Dungs gas train
Improved
heavy-duty
purge valve
The Humidaire King Mesa is equipped with the
1600 Series Operating System!
Moisture Tunnel
technology using
the Samuel Jackson
burner head
HU-80
thermodynamic
design
Moisture Direct
technology
controls the water
valve
Analog switches
for advanced
diagnostics
Water tank
access door
High efficiency
5 HP motor and
water pump
Main Line: 806-795-5218
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Gas-Fired: The Humidaire Southwest
An extreme-duty machine for top performance
in the most demanding conditions.
The Southwest is powerful, rugged, fuelefficient, easy to clean and operator-friendly.
Introduced in 2004, the Southwest was the
first of the “super” Humidaires doubling the
moist air output of all previous models. This
model is especially popular in Australia
and the Western U.S. where extremely dry
conditions demand it. While maintaining
it’s maximum evaporation capacity of over 4
gallons per minute, the Southwest enjoyed a
major upgrade in recent years when the 1600
Series Operating System became standard.
To put in racing terms, the Southwest had a
supercharged engine (Moisture Tunnel), but
the 1600 Series OS gives it superb handling
with racing tires, responsive steering and
GPS navigation.
The Humidaire Southwest.
The Southwest comes standard with a 7.5
HP motor and a stainless steel water pump.
Stainless water pumps define heave-duty!
These components generate robust water
pressure with some of the most challenging
water sources in the world. The unusual
looking blue device in the picture on the
right is a hydrocyclone sand separator. If
you’ve got tough water, it can handle it.
The hydrocyclone is optional on some
Humidaire models, but it comes standard
on the Southwest. These features coupled
with an almost entirely stainless steel body
and touch screen controls make this one
amazing Humidaire.
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The Hydrocyclone Sand Separator comes standard
on the extreme-duty Humidaire Southwest.
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Southwest can
handle 5,000
CFM of air
6-inch color
touch screen
operator
interface
PLC controls
inside cabinet
Three access
doors with
windows to the
spray chamber
Water Watch
meters and
Dungs gas train
The Humidaire Southwest is equipped with
the 1600 Series Operating System!
Moisture Tunnel
technology using the
Samuel Jackson
burner head
HU- 80
thermodynamic
design
Analog switches
for advanced
diagnostics
Moisture Direct
technology controls
the water valve
7.5 HP stainless steel
water pump
Hydrocyclone
water filter
Main Line: 806-795-5218
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Automatic Bale Moisture Control
Oil or Gas-fired, Humidaire users are enjoying the
tightest automatic bale moisture control to date.
Every press has “moisture sweet spot” where it runs best. When moisture reaches that sweet
spot, the ram moves smoothly, bale weights are consistent and the strapper doesn’t miss.
Maintaining bale moisture consistently through day and night ginning, changes in varieties,
modules moisture and weather conditions is tough. The Mirror X can make it easy.
Finding your moisture sweet
spot is easier than ever!
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Oil-Fired Humidaire Comparison
Model #
Max. Evaporation
Heating
Efficiency
Maximum Air Volume
Water Pump Motor
Stainless Steel Pump
Burner
Moisture Tunnel
Technology
1600 Controls
Combustion Controls
Air Temperature
Control
Water Temperature
Control
Operator Interface
Ethernet
Communications
Moisture Mirror
Remote Control
Mirror Compatible for
Target Bale Moisture
Alarm/Error Interface
Fuel Watch
Diagnostics
Water Watch
Diagnostics
Purge System
Hydrocyclone Cleaner
Upgradable
Suggested Use
Zephyr
Sahara Storm
Sahara
HU-80-ZEPHYR
1.5 US gpm
1,230 Btu/lb
of water evaporated
2,500 CFM
5 HP
No
Beckett 2-Stage Burner
HU-80-1645
3.5 US gpm
1,170 Btu/lb
of water evaporated
4,000 CFM
5 HP
No
Maxon
HU-SAHARA-1690
4.8 US gpm
1,160 Btu/lb
of water evaporated
5,000 CFM
7.5 HP
Yes
Maxon
No
Yes
Yes
No
Honeywell/
Relay-Based
2 - Stage Burner High
and Low
Manual or
Optional User Set-Point
Selector Switches
Yes
Yes
PLC
PLC
User Set-Point PID
controlled by PLC
User Set-Point PID
controlled by PLC
NEW! Moisture Direct
NEW! Moisture Direct
Touch Screen
Touch Screen
No
Yes
Yes
No
Mirror 2X and higher
Mirror 2X and higher
Yes; Analog
Yes; Ethernet
Yes; Ethernet
None
Touch Screen
Touch Screen
No
Yes
Yes
No
Yes
Yes
Manual
No
Yes; to a Sahara Storm
Automatic
Optional
No
Conditioning Hoppers,
Moisture Condenser and
Steamrollers
Automatic
Yes
No
Conditioning Hoppers,
Moisture Condenser and
Steamrollers
Conditioning Hoppers
and Lint Slide Grid
Main Line: 806-795-5218
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Oil-Fired: The Zephyr Humidaire
A balance of power and simplicity.
The Zephyr is a Humidaire hybrid with
selector switch controls similar to the Static
Zapper and the HU-80 frame of the more
powerful Sahara Storm. This feature-mix
creates a unit that’s powerful and userfriendly for the novice operator. The HU80 frame allows the unit to be upgraded to a
Sahara Storm as the gin’s needs for powerful
moist air output and sophisticated controls
grow.
A Zephyr Humidaire Unit.
Key Features of the Zephyr:
• The Zephyr uses an oil-fired commercial grade
burner that burns either kerosene or diesel.
• The burner can change from high fire to low fire
with the flip of a switch.
• Moist air output is adjusted with the water valve
that’s located on the back side of the unit.
• With the selector switch interface, operators will
have little trouble learning how to make changes
based on climate and condition of the cotton.
The Zephyr’s Selector Switch Controls
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Selector switch
operator interface
The Zephyr can handle
2,500 CFM of air
Water tank
access door
Beckett
2-stage oilfired burner
assembly
Zephyr can be
upgraded to a
Sahara Storm
using existing
frame
HU-80
thermodynamic
design
5 HP Motor and
water pump
Manually adjusted
water valve on the
backside of the unit
Main Line: 806-795-5218
Header pipe
flush valve
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Oil-Fired: The Humidaire Sahara Storm
Our most popular oil-fired model.
Meet the Sahara Storm. It can evaporate
75% more moisture using less fuel
compared with traditional moist air units.
It is a powerful enough unit for larger
gins, but has great turndown for almost
all moist air needs. Its performance and
efficiency are by-products of Moisture
Tunnel Technology. The Sahara Storm
was also the first Humidaire model to
include Moisture Direct Control. Moisture
Direct is the most stable and user-friendly
Humidaire control system ever designed
for a Humidaire Unit. More information
on both Moisture Direct and the Moisture
Tunnel can be found earlier in this section.
A Sahara Storm Humidaire Unit.
The Humidaire Sahara Storm comes standard
with several impressive features such as:
• A local color touchscreen for simple
control and advanced diagnostics
• Fuel meter and consumption statistics
• Automatic heavy-duty purge system to
reduce cleaning needs
• Target Bale Moisture Control
with any Mirror X and a Tex-Max
• Remote control from any Mirror X
• Remote monitoring with an iPhone
or iPad using the Mobile Mirror App
• Easy access to the water tank during
operation
• Plate for addition of Hot Air Mix Valve
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The Sahara Storm utilizes the Premium Touch
Screen Interface that gives the operator instant
access to run times and real-time water statistics.
(French language option shown)
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The Sahara Storm
can handle 4,000
CFM of air
6-inch color touch
screen operator
interface
PLC controls
inside cabinet
Spray chamber
window
Water Watch
meters and
Dungs gas train
Improved
heavy-duty
purge valve
The Humidaire Sahara Storm is equipped with the
1600 Series Operating System!
Moisture Tunnel
Technology using
a premium Maxon
burner head
HU-80
thermodynamic
design
Moisture Direct
technology
controls the water
valve
Analog switches
for advanced
diagnostics
Water tank
access door
High efficiency
5 HP motor and
water pump
Main Line: 806-795-5218
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Oil-Fired: The Humidaire Sahara
The most powerful Humidaire in the world.
Seeking to design an oil-fired Humidaire
model with the same performance,
durability and user-friendly features
of the Humidaire Southwest, Samuel
Jackson engineers created the Humidaire
Sahara. Instead of getting a comparable
unit, surprisingly, the Sahara is more
powerful and efficient than its gas-fired
counterpart. Sahara users will find no job
too tough for this extreme duty unit.
The Humidaire Sahara.
The Sahara comes standard with all the
features you would expect from the best
Samuel Jackson has to offer:
• An onboard color touchscreen for
diagnostics and troubleshooting
• Moisture Mirror X remote control
capability
• Target Bale Moisture Auto Control
with any Mirror X and a Tex-Max
• Auto purge system to reduce cleaning
• Stainless steel water train and pump
• A Sand Separator to handle the
harshest water conditions
• Water tank access during operation
• Dual access to the spray chamber
and an additional door to the mist
eliminator for easy maintenance
• Wave-less float chamber to ensure
optimum water level
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The Sahara utilizes the Premium Touch Screen
Interface that gives the operator instant access to
operation parameters.
www.SamJackson.com
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Sahara can
handle 5,000
CFM of air
6-inch color
touch screen
operator
interface
PLC controls
inside cabinet
Three access
doors with
windows to the
spray chamber
Water Watch
meters and
Dungs gas train
The Humidaire Sahara is equipped with
the 1600 Series Operating System!
Moisture Tunnel
technology using a
premium Maxon
burner head
HU- 80
thermodynamic
design
Analog switches
for advanced
diagnostics
Moisture Direct
technology controls
the water valve
7.5 HP stainless steel
water pump
Hydrocyclone
water filter
Main Line: 806-795-5218
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Conditioning Hoppers
Everyone agrees gin stand moisture is important.
Conditioning Hoppers provide the best solution to
maintain optimum ginning moisture.
Conditioning Hoppers in operation at a gin running at over 60 bales per hour.
Over 50 years ago, Mr. Sam Jackson invented the first Humidaire Unit. At that time, the unit
was used to reduce static electricity problems in dry seed cotton through an applicator similar
to modern Conditioning Hoppers. Through later research, it was discovered that in addition to
eliminating static electricity, restoring moisture to seed cotton before ginning also preserves fiber
quality during fiber-seed separation. Within practical limits, increasing the moisture in seed cotton
before ginning has a positive correlation to fiber quality characteristics such as length, strength,
uniformity and lower short fiber content. Today, Hoppers are used in gins all over the world to
combat problems with static electricity and fiber damage due to dry ginning conditions.
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Original Hopper patent
The role of moisture in preserving fiber
quality at the gin has been studied for
many years. Below, you’ll find excerpts
gathered from that research that are
very impressive. You’ll see that raising the
moisture level of seed cotton before
ginning can significantly impact fiber qua
lity. If you’re not using seed cotton
conditioning in your gin, you are missing out
on some great benefits!
- Cotton with a 3% moisture content going
through two lint cleaners will have
40% MORE SHORT FIBER than cotton
at 5% moisture content.1
- Raising moisture content from 4% to 6%
before ginning resulted in a 1/32nd
INCREASE in STAPLE and a 2% decrea
se in SFC.2
- Results from a USDA - ARS study sho
wed consistent INCREASE in
UNIFORMITY and STRENGTH as moistu
re increased from 4.1% to 8.4%. 3
- FIBER LENGTH INCREASES almost
ONE FULL STAPLE length with
each 1% increase in moisture content. 4
- Moisture contents below 5% are especia
lly DAMAGING TO COTTON fiber.5
- FIBER LENGTH IS REDUCED fro
m a 37 staple to a 35 staple when
MOISTURE WAS REDUCED from 7.4
% to 3.4%. 5
- SHORT FIBER CONTENT INCREA
SED from 4.6% to 8.7% when
MOISTURE DECREASED from 8.4%
to 4.1%. 5
Mangialardi and Griffin (1966)
Impact Of Ginning On Fiber Quality: The Best Ginning Practices,
International Cotton Advisory Committee’s Expert Panel on Ginning Methods
3
USDA-ARS Cotton Ginning Research Unit website
4
Rick K. Byler. Moisture Restoration for Seed Cotton, Two Approaches.
5
W. Stanley Anthony. Moisture Management Practices at Gins.
1
2
Main Line: 806-795-5218
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Conditioning Hoppers
Conditioning Hoppers moisturize dry, brittle fiber
making it stronger and more valuable.
An End-Entry Conditioning Hopper.
Conditioning Hoppers are available in
two styles: Classic-Entry and End-Entry.
Alternative styles offer installation flexibility,
but neither has been shown to differ in
performance.
On both styles, the moist air enters through
two stainless steel valves that stop the flow
of humid air when the feeder stops. These
valves can also open and close automatically
based on incoming moisture when used with
a Moisture Mirror. This allows the humid air
to be quickly diverted if incoming seed cotton
moisture gets too high.
A diagram of a Classic Entry Hopper.
64
The humid air fills an internal chamber before
passing through the galvanized injection
plates and entering the seed cotton. This
feature creates uniform moisture distribution
along the entire width of the Hopper. The
moisturized seed cotton is strengthened,
giving it more protection from damage as it
enters the gin stand for the rigorous fiberseed separation process.
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Lint Slide Grid
An economical and effective moisture restoration
solution for capacities up to 30 bales per hour.
This picture shows a typical Lint Slide Grid installation. It is taken from inside the lint
slide looking up at the battery condenser. No hood or cover is used for clarity.
Originally introduced in the 1970s, gins around the world continue to use the Lint Slide Grid
as a simple and effective tool for lint moisture restoration. A Grid consists of overlapping
stainless- steel slats mounted in the bottom of the lint slide to create a 4-inch false bottom.
Moist air travels in the false bottom and evenly escapes through each slat, moistening the
batt as it passes down the lint slide.
The Lint Slide Grid can be both a forgiving and economical applicator that serves a broad
spectrum of gins from small to large. Considerations when using a grid include gin capacity,
permissible length of the lint slide, and roof height.
Main Line: 806-795-5218
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Traditional Lint Slide Grid
Easy to install, operate and maintain.
We offer a variety of Lint Slide Grid configurations that can be used to retrofit an existing
lint slide. A Grid moisturizes the batt after it leaves the battery condenser and enters the
slide.
While there are a number of factors to consider, well-executed Grids typically restore and
average of 1.5% moisture per bale and reduce hydraulic pressures by 30%. Be aware that
bale moisture is affected by several variables and can fluctuate. Any unused moist air can
be piped back into the lint flue or exhausted outside.
Insulation along with a dedicated exhaust fan are highly recommended. Your Samuel
Jackson representative can help make other recommendations specific to your gin to help
you achieve more consistent performance from a traditional Lint Slide Grid.
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The Super Grid
Today’s new powerful Humidaires don’t play around.
Neither does the Super Grid.
As Sam Jackson Humidaires have grown more powerful, the demands of a more forgiving
yet high performing Grid System has grown, too. The Super Grid design incorporates our
best Grid enhancements into a package that is...well...Super!
Key elements include a high output Humidaire Unit and a hot air jacketed lint slide paired
with a 1-Million Btu Heater. These systems can protect the condenser from moist air and
the lint charger from condensate while minimizing cleaning requirements for optimum
performance. For the harshest ginning environments nothing less will do and even in more
forgiving locations you’ll want nothing less.
Investing a little more in a custom Super Grid in the beginning will pay big dividends for
many years to come. Find out if it’s the right solution for your gin.
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Steamroller Overview
Overview of Steamroller Technology
Condensation. If you had to pick one word that inspired the
development of the Steamroller, condensation might be the
second best choice. Everyone sees condensation so often that
most folks don’t give it much thought. But then most folks
aren’t cotton ginners.
On a cold glass of iced tea, water condenses from the air
around it and forms water droplets. The more humid the air,
the more droplets.
In a gin, restoring moisture requires very humid air and
when the weather is cold, condensation can become a big
problem. Lint sticks to water droplets that form on parts of
a basic lint slide grid system or in a moisture condenser and
once that starts happening, you are well on your way toward a choke.
Auxiliary heaters and insulation can help, but with both grid systems and moisture
condensers the humid air is interacting with a much larger volume of cold air and eventually
the cold air wins out. Frustrated by haired over condenser screens and being forced to run
Humidaires at lower outputs, ginners were searching for a better way. These frustrations
grew bigger as gins grew in speed and the demands on their presses grew greater.
From this frustration, the Steamroller was born. The resulting design isolated the humid
air from directly interacting with large volumes of cold air and protected key points
from condensation with auxiliary heat to keep those surfaces warm. But if you think the
Steamroller’s advantages are just in the cold weather, you’d be wrong.
The Steamroller 1 and 2’s design makes them capable of restoring more moisture than any
other applicator, making it easier for you to achieve the desired moisture in all conditions.
This top performance is achieved using a lower humid air volume than other methods,
meaning you’ll save fuel costs. Easier to maintain target moisture, lower operating costs,
faster press performance and less wear and tear on your press all add up to the best one
word description behind the Steamroller: Efficiency.
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Steamroller Comparison
Comparison of Steamroller 1 and 2
Sam Jackson manufactures and supports both the Steamroller 1 and 2. Both models share core
technologies and offer a similar level of efficiency and capability in the amount of moisture they
can restore. However, there are some key differences in the two, which have led us to the decision to
continue offering both models. This allows users to pick the model that offers them the advantages
most important to them. The purpose of this page is to highlight those differences.
The Steamroller 1 was introduced fifteen years ago and since then has
conditioned over 70 million bales and improved the performance and
life of 90 presses. Advantages of the Steamroller 1 include:
• Lower initial cost
• Can be bypassed
• Better for short lint slides
• Eligible for upgrade program
• Suitable for wide range of • Factory refurbished units may
ginning speeds
be available
The Steamroller 2 was introduced in 2008 equipped with features
compiled from the wish lists of users of the original Steamroller.
The result is a more forgiving, easier to maintain design.
• Reduced cleaning demands
• No plenum to accumulate pin trash
• More aggressive feeding reduces choke
potential from large wads
• Easier to install
• Better suited for higher capacity gins
• Overshot drum provides more surface
area for applying moisture
• The lint batt
compressed
only at exit
• Simple and easy to replace flashings
• Drum wiper brush cleans the drum
• Handles uneven batts better
• Better choice for gins handling rough,
trashier cotton
Main Line: 806-795-5218
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Steamroller 1
How the Steamroller 1 Works
The lint conditioning process starts as the batt feeds into the Steamroller from the battery
condenser. Unlike moisture-type condensers, the Steamroller is a separate piece of equipment
from the battery condenser. This means that the moist air used by the Steamroller isn’t diluted
by outside air which reduces efficiency and causes condensation and hairing problems. The batt
passes under a rotating drum where moist air enters from underneath. The Steamroller is under
slightly negative pressure pulling the moist air completely through the batt for uniform moisture
application through the fiber. Excess air is exhausted by a dedicated fan piped into the lint flue.
The conditioned batt is compressed by the feed-out roller as it exits the Steamroller and continues
down the lint slide into the tramper.
Typical Steamroller 1 Lint Conditioning System layout.
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Steamroller 2
How the Steamroller 2 Works
Like the original design, the Steamroller 2 isn’t diluted by outside air, which reduces efficiency
and causes condensation and hairing problems. But unlike the original, the batt passes on top of
a rotating drum in an overshot fashion. The moist air enters from above, where it is pulled down
through the lint. Because there is no plenum, there is no place for pin trash to accumulate and
most of it is carried away in the exhaust air. Users report cleaning takes less than half the time of
the original.
The updated design also features aggressive doffing and compression rollers that do a superb job
of handling wads, avoiding chokes and keeping the cotton flowing.
Loaded with other design touches, the Steamroller 2 delivers the highest levels of performance
with easier than ever maintenance.
Typical Steamroller 2 Lint Conditioning System layout.
Main Line: 806-795-5218
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Moist Air Applicator Chart
How much does it cost you to restore moisture?
Lint Slide Grid
Low cost applicator
No batt compression
Moisture Condenser
Dual-purpose applicator/condenser
Good batt compression
Steamroller 1 & 2
Most efficient applicator
Best batt compression
Typical Moist Air
Volume (CFM)
Typical Maximum
Moisture Restoration
Capability (pounds of
moisture per bale)
Typical Energy
Consumed in a 40
BPH Gin (Btu per
pound of moisture)
2,000
8
3,125
(1.7 cents/lb)*
3,500
10
5,000
(2.8 cents/lb)*
2,400
20
1,625
(0.09 cents/lb)*
*Using natural gas at a cost of $0.55/therm. 1 therm = 1CCF
Every day a moisture condenser
uses this much MORE fuel...
72
AND misses out on this
much moisture...
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1501 Gas-Fired Auxiliary Heater
A One-Million BTU/hr Heater in
One Compact and Well-Designed Package
Perfect for providing just enough heat to tame or avoid condensation issues on moist air
applications, the HG-1-1501 Gas-Fired Heater can be the difference between achieving great
results or battling chronic chokes.
Without a dependable source of hot dry air at a consistent temperature, your moisture restoration
system will either be crippled by the need to run at lower than ideal outputs or you will be at risk
of condensation problems and the resulting chokes.
The HG-1-1501 has an integrated fan, burner body, gas train and control panel mounted on a
skid. Installation can be as simple as connecting pipe, three-phase power, a thermocouple and gas
supply.
Looking for something more sophisticated and able to provide
more convenient operation? The control panel can connect to
compatible Moisture Mirrors, providing remote functions such
as start and stop commands, temperature set point control and
error/alarm monitoring. You can even set up the HG-1-1501 to
automatically start and stop when your Humidaire does, ensuring
it’s ready when you need it.
Whether you do a basic install or take advantage of the more
advanced features, your HG-1-1501 will help your moisture
restoration system perform at its best. So take the advice of one
of our favorite ginning friends who counsels, “You either need a
good auxiliary heater or you need some stout ginners with big pipe
wrenches. The problem with the last one is those aren’t the kind of
guys you want to make mad by having them clearing chokes a few
times everyday.”
For our Australian friends, we offer a 1-Million Btu Auxiliary
Heater with similar features to the 1501, but designed to meet
AS 3814-2009. Ask your representative for details.
Main Line: 806-795-5218
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Water Softener Treatment
If you have scale buildup, it is costing you money.
What is “hard water”?
Hardness is composed primarily of calcium and
magnesium minerals and is broken down into
two categories.
1) Temporary hardness (carbonate)
When heat is applied, they create a soft scale or
sludge. This is the soft scale typically formed
around the spray headers that you can easily
break off with your fingers.
2) Permanent hardness (non-carbonate)
This comes out of solution as the temperature
rises to form hard scale, which is difficult to
remove. The thin layers of scale that appear to
be permanently bonded to the stainless are good
examples of this.
Do you have hard water? Water analysis is free!
Just fill a water bottle from the supply for your
Humidaire Unit and send it in or give it to your
Samuel Jackson Representative.
Hard Facts about Hard Water:
The average price of basic
reconditioning is $10,000-$12,000.
Humidaire
The average Humidaire performance reduction
from scale is 30% when untreated.
A nozzle plugged with scale that appeared to
be completely clean.
74
The average maintenance time spent cleaning
Humidaire Unit scale during a gin season is
20 hours with untreated water and requires
hazardous materials.
28453_rh 99_SamuelJackson 75 2_20_2015
Enjoy a cleaner Humidaire for about $5 per day.
What does a water softener do?
A water softener removes the hard calcium
and magnesium elements from the water by
substituting soft sodium and flushing the hard
elements to the waste system. Water softening
uses sodium chloride salt pellets for this efficient
process. 90% of all cotton gins require only water
softening to control scale. For the remaining
10% who need reverse osmosis treatment, water
softening is recommended for the membrane
inlet feed. A water softener should always be
your first line of defense in a water heater or
boiler application.
How much does it cost to operate?
Among gins surveyed, salt costs amounted to less
than $5.50 per day and additional water usage of
10% - 35% depending on water quality.
Why KINETICO Water Softeners?
Non-Electric: Moving water powers these systems, not electricity, so operation is
simple and reliable. There are no timers or computers to set, adjust, repair or replace.
Works on Demand: Systems regenerate based on actual usage. You won’t waste water
or salt, yet you’ll always have clean, soft water whenever you need it.
SmartDisk™: Set to accommodate your specific water conditions.
Soft Water, Countercurrent Regeneration: You’ll enjoy the benefits of improved
system efficiency and water quality thanks to Kinetico’s superior regeneration process
Twin Tank System: One tank is always in service, even during regeneration, for an
unlimited supply of clean, soft water.
Efficient Hardness Removal: Get the water you want in your Humidaire Unit
without sacrificing savings and convenience.
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Tex-Max Microwave Bale Moisture Sensor
Missing the mark on moisture could cost you a lot.
The Tex-Max allows you to monitor every bale.
A Tex-Max Bale Moisture Sensor.
Automatic bale moisture - simple and effective.
The Tex-Max is an online microwave moisture sensor built by Samuel Jackson using Vomax
Microwave Technology. It scans each bale leaving your gin thousands of times and provides a single
reading reflecting the average of those scans. The Mirror X models even display the previous 15
average bale moisture readings to help you closely monitor your automatic control. The Tex-Max
is highly repeatable as found in numerous studies including a 2008 Beltwide Cotton Conference
paper on Vomax Technology.
All current models of Moisture Mirrors and most Samuel Jackson Humidaire Units allow you to
enter a Target Bale Moisture for Automatic Control.
Do Not Use With
Water Spray Devices
76
A Tex-Max cannot protect you against problems from bales that have
been subjected to water spray systems. Because water spray systems
apply moisture unevenly, extreme wet spots can and do exist within a
bale that has an average moisture of less than 7.5%. Problems from
these wet spots can arise before the moisture can equilibrate throughout
the bale. Samuel Jackson reserves the right to refuse sale of a Tex-Max
to any gin using a water spray device.
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Moisture and Your Press
A Good Moisture Restoration System
Can Be Your Press’ Best Friend
Your press is the most expensive piece of equipment in your gin. Protecting it not only helps
preserve your original investment, it also pays big dividends by positively impacting production.
These points are so important, we added this page to further explain how proper bale moisture
restoration is critical to your press performance.
Makes Your Press Faster
For many gins, the press is a bottle neck.
Adding moisture makes the lint so much
easier to press that the faster vaneaxial
pumps can do more of the work. In some
cases, the piston pumps don’t have to kick
in at all.
Less Wear & Tear
Reductions in ram pressures of 3050% mean less strain on your press
components, decreasing downtime and
increasing lifespan.
Better Tramping & Turning
Dry cotton is fluffier making tramping
more difficult. Without proper moisture,
some presses struggle to pack a full bale
of cotton in the box without lint springing
out and hanging as the boxes turn.
Greater Lint Slide Storage
Lint slide storage capacity gives a greater
buffer for fluctuations and improves
production rates by limiting disruptions
to the gin stands. Applicators that offer
compression can increase this storage
capacity.
Help Your Strapper
Many modern gins use strapping systems
to tie bales. Strappers are great labor
savings devices and can help overall
speed, but the key to making them work
is providing them with a consistent platen
shut height, which requires consistent
bale moisture.
Improved Bale Tying
Properly moisturized bales exert less force
on bale ties. This results in fewer broken
ties and allows some gins to save money
with a 6-tie pattern over an 8-tie pattern.
Give your press a real boost with the many benefits
of a good moisture restoration system
Main Line: 806-795-5218
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A Common Sense Guide to Moisture Restoration
Restoring moisture to lint cotton is probably the most debated and most misunderstood ginning
practice. Abuses in recent years have made the industry even more fractured on this matter and
spawned even more misinformation.
The following facts are educational and practical as good ginning guidelines to follow in your
own operation. We hope you find them helpful...
• During storage, a bale will move toward and attain an equilibrium moisture content (EMC)
in the warehouse in which it’s stored.
• Without any moisture restoration at the gin, the typical moisture content of the lint is well
below the EMC a bale will reach in storage. Simply put, the fiber after lint cleaning is very
dry.
• There are significant benefits to a gin if they can raise the moisture in the lint prior to the
press. In fact, for efficiently operating at modern ginning capacities, the ability to restore
moisture is a necessity, not a luxury.
•
78
Bale moisture sensors are intended to offer a useful
display of lint moisture for a ginner skilled in evaluation
and handling of cotton bales. It is recommended
that an operator pay close attention to bale moisture
conditions at all times and validate readings against
oven moisture tests if they appear questionable. Always
gin your cotton with wisdom and prudence.
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28453_rh 99_SamuelJackson 79 2_20_2015
• Lint moisture restoration systems do not improve fiber quality. When considering this point,
it’s important not to confuse lint moisture restoration with seed cotton moisture restoration
(seed cotton conditioning), which can preserve fiber quality.
• Done properly, lint moisture restoration does not harm
fiber quality. This requires the moisture to be applied
uniformly and in moderation.
• Water spray systems do not apply moisture evenly
throughout the bale.
• A mill buying a bale based on the receiving dock weight is
paying for the moisture in that bale whether it was gained
by the lint at the gin or in the warehouse.
• A mill can derive benefits from bales that were properly
moisturized by the gin, including: bales opening to a
uniform and more manageable height, fewer broken bale
ties making handling easier, reduced tie forces making
opening the bales safer, faster conditioning times in the
mill’s opening room (because proper fiber moisture is
important for mill operating efficiency, too).
Taking the above points into consideration, it’s clear that there is some common ground
on this issue. If a gin restores moisture to lint using a safe method and reasonable level,
it can be mutually beneficial for both gins and mills. Growers benefit by having some
of the weight lost during harvesting or gin drying restored to the bale.
What is the best target bale moisture?
This is not only a good question, it’s also one of the most common asked. To answer it we first
have to know the answer to two questions that are specific to your gin:
1. What bale moisture provides the best performance for your press (and strapper)?
2. How much weight would the bale regain in storage if it were ginned without the
benefits of moisture conditioning?
Those factors are used to determine the ideal target bale moisture for your gin. This target will
help you gin faster and more efficiently, and it will help your growers get paid for the weight
gain that would otherwise go to a middleman.
Give us a call. We’d love to help you determine and achieve your ideal bale moisture.
Main Line: 806-795-5218
79
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