Some of the Grower's Problems

Early in the spring, the farm hands begin the work of getting the seed beds ready. Upland fields have to be terraced, ditched, and drained by an elaborate process before the work is well begun. Plowing and sub-soiling are the least of the planter's worries. He must often chop last year's stalks with a disc harrow or with a stalk cutter. The spike tooth or the disc harrow must work again after the plowing is finished. It is customary to plant cotton in a slightly raised bed, in order that thinning may be more easily done, and that the soil may be more quickly warmed. Much planting is still done by hand, one man dropping the seeds in the long straight furrow and another following close behind him with a hoe, covering them up; but of late years the one-horse planter and the two-horse combined lister and planter have come into vogue, and, now that the tractor is both cheap and serviceable, it is possible to plant two or more rows at a time.

The Long Season of Intensive Cultivation

When the tiny seedlings first appear above the fragrant mellow soil, the planter's work is well begun, but it is only begun, for then comes the season of cultivating and thinning out. As soon as there are two or three inches of growth, the first cultivation takes place. How many times the field is cultivated depends on the planter, the nature of the soil, the availability of labor and other factors. But the general rule is, the more cultivations, the more cotton. The first cultivation sc.r.a.pes away the soil from the plants, leaving them on a small ridge, where the thinning-out process can easily be done with a hoe. The stalks are left from fifteen to twenty inches apart in the hill, the rows being usually about three and a half feet apart. The next cultivation, usually with a sweep, pushes the soil back against the plants. Then begins the farmer's fight against the weeds, each of which seems st.u.r.dier and harder to eradicate than its predecessor. Usually cultivation must take place about every three weeks.

In June, on the average, the bell-shaped blossoms appear. On the first day they are cream colored or white; on the second day, they change to a beautiful wild-rose pink, deepening toward evening to a deeper magenta or carnation. On the third day they fade completely, and the development of the boll begins.

The Many Enemies of the Growing Boll

Of the plants upon which humanity depends, the various species of the genus Gossypium have probably more enemies, and more relentless enemies, than any other. Besides army worms, cut worms, locusts, green flies, leaf bugs, blister mites, and several others, nature has produced and rendered extremely prolific and hardy, these two particular pests, the boll weevil and the boll worm. It is said that the collective attacks of all the insects which feed upon cotton cost the country in the neighborhood of $60,000,000 every year at pre-war prices. The little gray beetle that the world knows as the cotton boll weevil is responsible for most of this.

The mother weevil lays her eggs in the bud. As the grubs from the eggs develop, the bud drops. If a weevil arrives on the scene after the bolls have begun to form, she lays her eggs in those with a fine indifference.

These bolls will not drop, but the grubs ruin the cotton they contain.

There have been numerous investigations and experiments made to develop a variety of cotton impervious to the weevil's attacks, as well as to find another insect willing to meet him in combat and overcome him. Guatamalan cotton is said to be immune and efforts are being made to transplant it to the United States. A small ant-like creature called a "kelep" has also been found, which attacks, kills and devours the weevil, but, unfortunately, the kelep prefers a warmer clime, and pines away and dies in even the mild winters of the cotton belt. The boll worm is very similar to the corn worm with which all housewives are familiar, and indeed corn is its favorite diet. But cotton will do in a pinch, and, next to the weevil, he ruins more cotton than any other pest. The boll weevil cost the country about $25,000,000 yearly, pre-war prices, and the boll worm about $12,500,000 yearly, enough to justify an even greater expenditure for investigation and eradication than has yet been made.

Despite the ravage of insects and diseases, when a well-tended field of cotton is ripening, one would think from the number of bolls per plant, that the owner's fortune was surely made. Unfortunately, the plants shed bolls as well as buds and flowers, in great numbers. It has frequently been noted that even well-fertilized plants upon good, carefully cultivated soil, will mature only fifteen to twenty per cent. of the bolls produced.

[Ill.u.s.tration: _Cotton blossoms and bolls at various stages of growth_]

The planter will tell you that he would be willing to stand the boll weevil, the dropped bolls, the extra cultivations, and all the remainder of it, if he could only be sure that cotton which did mature would be picked when it should be picked, and picked with rapidity and care.

Picking is the most laborious, as it is the most picturesque operation on the plantation. Many types of machine pickers have been introduced, but there are few planters who will admit that any of them suits his particular needs. Now, as a hundred years ago, the picking is done by hand. It is a simple operation, so simple that children ten years old can do it, and women excel in it. But the best pickers rarely average more than a hundred pounds a day, and most of them pull much less. Careless work plays its part, too, for cotton is easily dropped from the boll and soiled or lost altogether. Leaves and twigs as well as the sh.e.l.l of the boll frequently cling to the fiber, and are picked with it, and all these things tend to dirty and discolor it, and lessen its marketability. It requires about three pounds of cotton with the seed in it, as picked, to produce one pound of ginned or lint cotton.

There were in the United States, in 1917, a total of 24,272 ginneries, of which 3,921 were idle. Each active gin produced an average of 526 bales running bales of cotton. The number of gins shows a tendency to decrease every year, not rapidly, but surely, and this despite the opposite tendency of the crop. The Whitney gin of the old days has been improved beyond the dreams of its inventor. He boasted that one man could do as much with his machine as ten men without it. Today's gin averages about five bales a day--a quant.i.ty which the negro of old would find difficult to turn out in a year.

To the gin then, which is located either on the plantation or in the immediate neighborhood, the mule drawn wagons, driven by negroes as a rule, bring their loads of cotton.

[Ill.u.s.tration: _Gin bale and compress bale showing reduced bulk of latter_]

As the downy lint, pulled from the tenacious seeds, rolls into the receiving bin of the gin, the huge compressors are put to work. The coa.r.s.e jute bagging is on hand, and the steel straps spread out. The gin balers as a rule turn out a bale measuring approximately 28 by 56 by 42 inches, and weighing approximately 500 pounds including twenty pounds of bagging and straps. The cotton, in being separated from its seeds, has lost about two-thirds of its weight. But the first process in the long series that manufacturing entails has been completed, and the cotton is ready to begin its long journey to the mill. It is usually carted to the nearest railroad station, and from there shipped to the compressing point.

The small farmer almost always gets his money for the cotton as it leaves the gin. His interest in it, therefore, is ended when the buyer there pays him the current price. The cotton is a market commodity from that time forth.

The compress is a large and powerful hydraulic press, whose function is to force the loosely packed gin bale into a density that will make its handling by the railroads, ships, and warehouses more easy and economical. The compresses are frequently owned by the railroads.

Gin Bales and Compress Bales

Before being compressed, the bales are sorted according to grade, and are then compressed into a smaller sized bale, measuring approximately 28 by 56 by 18 inches, with a density of from twenty-eight to thirty pounds a square foot. It is this bale which is handled from that time forth, whether it be for export, for consumption in Northern or Southern mills, or whether, as sometimes happens, it is shipped from place to place as market conditions change, and the price offered makes reshipment profitable.

Movement for Improving the Bale

It is encouraging to note that the war brought about, under Government auspices, a very definite movement for the improvement of the bale. The proposal demands the installation of high pressure baling machines at the gin, capable of producing a bale with a density of thirty-five pounds a cubic foot. The trading unit in cotton is one hundred bales, and such a compression would mean that one hundred bales could be loaded into a single freight car, and shipped directly to the export point or warehouse. The present practice requires three cars to carry the ginnery bales to the compressor, and two cars to carry the compressed bales to the port, warehouse, or mill. The saving in freight and handling is obvious. It needs only a glance at the photograph of the two bales side by side to see the possible saving in waste and "city crop," or tare. The obstacles in the way of such an improvement are those which face any revolutionary change in commercial methods. Established practice, invested capital, and the natural conservatism of human nature militate against quick improvement.

CHAPTER VIII

In the Cotton Mill

The manufacture of cotton cloth may be divided into five departments:

1. Preparatory processes: Opening, carding, combing, and drawing.

2. Spinning.

3. Spooling, warping, sizing, slashing, entering or drawing-in.

4. Weaving.

5. Converting and finishing, including bleaching, mercerizing, dying, printing, and finishing.

Before the cotton fiber can be spun into the yarn from which the cloth is woven, the bales must be broken open, the impurities removed, and the fibers arranged so that they are parallel and contain no bunches or tangles. Care in these processes has become more and more necessary and important as the demand for a higher quality of cloth, possessing greater strength and evenness, has been developed. Hence, some of the most elaborate, complex, and admirable machinery in the mill is that devoted to these preparatory processes. The principle involved is always that of thoroughly cleaning the material, then opening it so that every fiber shall be thoroughly separated from its fellows, and then straightening out the fibers, no matter what types of machines may be used.

Conveying Fiber By Air Blast

The heavy laps of cotton are first thrown directly from the bale into the breaker, and the cotton is then usually blown through large pipes from the room in which the bales are broken to the room in which the openers are located.

The functions of the opener are two. The first is to clean from the cotton the dirt and bits of leaf, pod, and foreign substances, which may have clung to the fiber as it pa.s.sed through the gin back on the plantation. The second is to roll the cotton into a more or less regular "lap," as it is called.

The Energetic Opener At Work

As the cotton goes into the opener (see diagram on following page), dusty and dirty, it is seized by strong teeth fastened upon a large cylinder (A), revolving rapidly, and is flung by centrifugal force against an iron grid (B) time after time. Sometimes there is a strong current of air blowing through the tangled ma.s.s, helping to loosen the particles. The dirt comes out through the grid and is carried away, while the lint itself, after being carried around an indefinite number of times, gradually works its way along a channel, and finally out between two large rollers (C), which compress it once more, so that it is, in effect, a sheet of batting. This sheet, or lap, is rolled up in a large roll (G), which may be two or three feet in diameter, and is then ready for the first doubling or blending process. In mills where strength and evenness of yarn are at a premium, the sheets from three or four laps may be fed through another opener, usually called a "scutcher," which breaks them all apart again, mixes up the fibers, cleans out more of the dirt, and produces a more even lap.

The cotton, as it comes from the opener and the scutcher, is much cleaner and more attractive. It begins to look like the riches it contains.

[Ill.u.s.tration: _Cross-section diagram of opener_]

To convey the heavy opener-lap from the opener to the carding room, the more modern mills are doing away rapidly with hand-power, and carry the lap on a sort of travelling mono-rail conveyor.

The fibers of the lap which comes from the opening room are by no means parallel, but lie in all directions just as they happened to come from the grid of the opener. The function of the card is to straighten them, and at the same time to remove those which are knotted or immature and of a length below that required for the yarn to be spun, and to take out practically all of the impurities which may have escaped in the opening operations.

The principle of carding is one of the oldest of textile mechanical principles, and all the improvements that have been made have been in developments rather than in basic ideas. Hargreaves, inventor of the jenny, and Sir Richard Arkwright both expended their ingenuity upon it, the latter seeming to have been the first to provide a carding machine operated by other than hand-power. The basic principle involved is the straightening out of the fibers by combing or brushing them with wire brushes or cards.

[Ill.u.s.tration: _"Scutchers" at work_]

In the revolving flat card, which dominates the field today, there are, as a rule, three princ.i.p.al cylinders. The lap pa.s.ses first under the smallest of the three, called the taker-in, which is covered with very fine saw-teeth all in one long strip of steel, wound and fixed spirally in the surface of the cylinder. The taker-in receives the cotton from a feed-roller (C) that turns above a smooth iron plate (D) called the feed plate. The saw-teeth comb the fibers which are imbedded, so to speak, in the lap, and deliver the loose ones to the second cylinder, which is the largest of the group. This main cylinder is covered with wire teeth all bent at exactly the same angle. The cotton clings to them, and is carried around to the top of the cylinder, where it is engaged by teeth on the revolving-flat card which are bent in the opposite direction. This "card-clothing" arranged in strip, crosswise on a travelling lattice, moves in the same direction as the cylinder but moves very slowly, and so the fibers are carded between the two sets of wire points, the short and immature fibers remaining on the card wires of the lattice and the perfect and now almost entirely parallel ones being carried over from the main cylinder to the doffer cylinder, the third of the trio. From this they are removed by an oscillating comb (F), coming off in a light, fleecy lap, which is condensed through a funnel into a soft untwisted roping, or sliver, about the diameter of a man's thumb, and is then coiled into a can, usually about 45 inches high by 8 inches diameter.

[Ill.u.s.tration: _View of Modern Motor-Driven Opener Picker_]