Ginning & Pressing Machinery

Continental Eagle Corporation turned a page in its long and storied history today when it was announced that the manufacture of cotton gins and related machinery in its Prattville, Alabama plant will be phased out over the next year, after more than 177 years of continuous operation in Prattville.

Roger Fermon, the President of Continental Eagle, made the announcement to the company employees today, stating that the manufacture of nearly the entire product line will be transferred from its historic Prattville facility to Nagpur, India. Nagpur, located in central India, is the home of Bajaj Steel Industries, Ltd., a well established and highly respected manufacturer of cotton ginning machinery. Mr. Fermon stated, “Like Continental Eagle Corporation, Bajaj is the leader in their segment of the industry and they are a natural fit as our partner to continue the tradition of producing the highest quality ginning machinery in the world.”

Earlier this year Continental contracted with Bajaj to manufacture a limited portion of the product line at their plant in India. “The transfer was very smooth and the quality was excellent”, said John Kolasky, Vice President of Engineering at Continental. “An independent contract engineer confirmed that the quality and capacity was every bit as good as the machines made here.” To assure that the quality is maintained, Continental will permanently assign a quality control engineer to oversee the manufacture in India and engineers from Continental will make regular visits. “To maintain and increase our customer base, we cannot compromise on quality. Our customers should expect no less,” says Kolasky.

The corporate headquarters in Prattville will retain some light manufacturing for repairs and for a small number of items such as gin saws. Continental has developed a reputation for supplying the best gin saws in the industry

Bajaj has begun construction of a new facility to handle the increased volume. They operate the most advanced computerized machinery in their factory. The skill level and work ethic of their engineers and factory personnel is exceptional. The Continental equipment will not be modified to metric measure. All machines and parts will continue to be built to US standards to maintain continuity of parts for the installed base and for future customers.

“Bajaj was not the only company in contention for this partnership, but they emerged as the obvious choice after our successful experience with them on the pilot program earlier this year. There is no language barrier and the technical communication between our engineers is very efficient,” says David Mrozinski, Vice President of International Sales. “Not just any company was considered. We have been acquainted with the Bajaj family for many years and we know them to be very professional, well organized and of the highest integrity. Their existing product line has, by far, the largest share of that segment of the market. They do not compete with Continental products. We will in fact, compliment and enhance their product offering in the Indian market.”

“We are excited about the new direction our company is taking,” continued Mrozinski. “We will supply our parts and machinery to the cotton industry more competitively, while maintaining the same quality that has always been expected of Continental Eagle products and services. It also allows us to penetrate markets that have been unapproachable in the past.”

Continental Eagle Corporation will continue to operate out of Prattville, but on a different level and with a revised business model. “We will operate primarily as a marketing and engineering firm, maintaining our expertise in machinery design and distribution of our products to the cotton industry,” says Fermon. “Our spare parts sales and after sale service as well as our research and development will remain here in Prattville. Our branch offices throughout the USA and in Australia will continue as they have in the past to service our customers.”

“The extended downturn in the cotton industry here in the United States and throughout the cotton growing regions of the world combined with significant raw material cost increases have caused us to review our corporate structure and the direction we will take the company,” said Mr. Fermon. “Orders of machinery and systems have declined over the past few years, but we did not see a reduction in market share. Our customers are cutting back and waiting for improvements in the industry and in the global economy. We have had to lay off many of our factory and office personnel to maintain the company during this low period, as have our competitors.

Fermon went on to say, “In order to respond to these new market developments, we had no choice but to increase our sales through an increase of our market share. To reach that goal we decided to combine our proven Research and Development talents with quality manufacturing, but at a lower cost. The most recent results of our Research and Development efforts were the very successful introduction this year of our new EagleMax 201 saw gin and the EagleMax 9120 feeder. Continental Eagle will be able to continue to provide the latest technology at a lower cost while still maintaining its recognized high standard of quality.”

Continental Eagle is an American owned, US corporation and will remain 100% controlled by the existing owner. All proprietary technology will be retained by Continental Eagle Corporation and Bajaj will function solely as a supplier under the supervision of Continental.

“These changes will free us to concentrate our efforts toward continuous improvement of supply and customer service without the pressures imposed by a widely fluctuating market and escalating material costs,” says Mr. Fermon. “By combining our design experience and our extensive knowledge of the cotton markets with the manufacturing capabilities of Bajaj, Continental Eagle will continue to provide the world class parts, machinery and systems for which we are recognized. We look forward to serving the cotton and oil mill industries for many years to come.”

Dust / Waste Handling Systems particularly applicable to the handling of cotton / lint  waste and associated trash created by machines in ginning plants. The system consists of a pneumatic  ducting circuit connecting a filteration unit  to all  factory locations where waste and dust is generated. A fan creates an air flow in the ducting circuit to carry waste and dust therealong. The fan  separates the air flow into major and minor portions and by centrifugal force transfers most of the waste and dust to the minor portion. The air in the major portion is directed back to the factory space via a filter  to remove any dust contained in the major portion.

A typical waste handling system we offer for removing waste and dust from a ginning factory  has been shown. The major components of the waste/ dust handling systems comprise of :

• Pneumatic ducting line with G.I. Pipes, bends and diverters.
• Centrifugal fans already attached to the systems in case of existing plants to draw dust / trash from the trash generating machineries.
• Primary filter to seperate fibrous material from the conveying air and allows micro dust to pass to the secondary filters.
• Secondary filter to seperate micro dust from conveying air.
• Ventilator to pull microdust air along with fibrous waste from primary filter to compactor and again supply the excess to primary filter after compaction.
• Secondary ventilator to pull microdust from secondary filters and pass it to cyclone seperator and dust compactor with fresh air exit to secondary filters.
• Cyclone separator and dust compactor to separate microdust taken from secondary filter and allow to fresh air back to secondary filter.

Salient Features :

• Better performance due to minimised pressure loss.
• Compact design and hence less space required.
• Waste is compacted and hence easy to handle.
• Optimum utilisation of fans ensures complete cleanliness.
• Cost effective.
• Can be incorporated in existing set ups.
• Easy to maintain, low maintenance costs.
• Sturdy gearbox design and high quality rotating parts and nozzles for longer life.

Bajaj offers pre fabricated steel trusses for any projecs new or existing. Steel trusses are non-combustile, easy to handle, strong and easily fabricated for any design. these trusses are pre-engineered and pre-fabricated by truss experts available with us

The seeding of success

Bajaj Group of Industries are starting a new ” Cotton Export Division” at Nagpur to widen their horizon in the field of Cotton Export, to serve buyers across the globe and thus making a mark in the cotton world.

We Endeavor to put in our hardest and best of efforts, to provide the best quality cotton to the world.

Dealing in all types of Raw Cotton ranging from short staple to extra long staple, according to the specifications & parameters of the buyers, at most affordable and attractive terms.

Bajaj DR gins give highest out turn of lint with better seed quality at lowest maintenance and per unit cost of production. Highest out Turn of Lint than other Ginning Systems. Cleaner Seeds with minimum Cotton Linter on it.

Application areas:

• Cotton industry

Features:

• Higher productivity
• High-quality output
• Less downtime
• Efficient removal of dust and trash
• Lowest cost of production per unit in the industry
• Lower power consumption per quintal of lint ginned
• Lower manpower required

Bajaj horizontal baling press with a 40 hp hydraulic power unit and a standard operating pressure of 2700 psi and a 7-inch bore industrial grade compression cylinder is a unique solution for baling of various items such as bio mass, textile waste and many other applications. the model has the advantage over other similar baling presses as compression force is higher by about 36%, which yields up to 40% heavier bales. bale tie required per bale is 25% lesser and hence 25% lower baling material cost. the other models for higher or lower pressure are also available on request.

Features & Benefits for high & medium capacity presses :

• Highest bale density of all similar machines.
• Largest feed hopper of all similar machines.
• Feed hopper door with inspection windows, dust seals and interlock.
• Heavy duty spring loaded retainer dogs.
• Level sensor at hopper for automatic operation of main ram.
• Warning for startup and full bale.
• Double tie slots in ram to prevent material buildup and also crossing of bale ties.
• Adjustable bale density switch.
• Robust body
• Simple operations
• Easy maintenance
• Highest bale density

Humidifiers with disel / gas / kerosene burner suitable for 1700  1700 cmh of hot humid air & 204 litres of peak evaporation capacity

• Instant humidification by easing out wax surface of the fibre and recuperation after humidification by cooling effect for retained moisture.
• Preserves fiber length, improves strength and uniformity and reduces short fiber content.
• Eliminates moisture condensation which is a general problem with all other moisturisation techniques.
• Increases the lint slide capacity and allows more cotton to enter the press box at each stroke of the tramper and hence higher density bale is obtained.
• Improves the capacity of the bale press whereas dry cotton requires higher compression forces and more time to charge and compact it into the press box.
• Achives better sliding of lint in the lint slide.
• Instant / online humidification
• Increases bale weight
• Reduces pressing force
• Reduces power per bale
• Improves lint grade & appearance
• High quality construction for longer life
• Improves fibre parameters

Hot air humidification applications:

• Hot humid air is inducted in the lint on a lint slide with a set of louvers at temperature around 45 to 50 degree celcius.
• The hot air eases out the surface tension of the fibre and humidity is transfered to inner stem while air passes out. the cooling down recuperates the fibre surface and maximum moisture contents are retained by fibre for a longer period.

Features & Benefits :

• Available in various sizes upto 450 mm diameter
• Helicoids of high quality carbon steel provides smooth surface with no sharp edges.
• All rotating parts are provided with precision bearing to reduce friction for optimum efficiency.
• All rotating parts are precision machined using advanced manufacturing process on CNC machines providing best finish and tolerances to enhance life of the machine & minimizes the down time.
• Mechanism requiring lower periodic maintenance & setting of the machine.
• Bearings are enclosed in bracket housing with dust proof covers thus enhancing the life.
• Troughs designed for optimum feeding and carrying of material to machine or for bagging.
• Reduces man power in the process largely.
• Robust Construction
• Long life
• Maintenance free
• Uniform and adequate feeding at all points
• Ease of use
• Protects fibre quality
• Made with superior technical know how