Disclosure of the Invention The present invention overcomes the shortcomings of the prior art by providing a method of processing whole fuzzy cottonseed into animal feed pellets. The primary steps of replacing the lint of the cottonseed with a lesser grade cotton fiber, mincing the cottonseed until the hulls have been broken down and increasing the pressure before extruding so that the mixture achieves a mash-like consistency enables the forming of pellets.

These whole fuzzy cottonseed pellets have the same nutritional value as before the pellet process and can be handled by machinery used to process grain products. In addition to the handling capabilities, the pellets are a densified form of whole fuzzy cottonseed as opposed to unprocessed whole fuzzy cottonseed or coated whole fuzzy cottonseed.

Furthermore, because the whole fuzzy cottonseed is reduced to a blend the introduction of enrichments such as, vitamins, feed supplements and medications are able to be absorbed by the pellet and attain a consistency throughout the pellet which is not possible with coated seeds. Also, the use of rodent and insect repellants can be applied as a coating after pelletizing the whole fuzzy cottonseed.

In addition the introduction of binding agents for the cottonseed pigment gossypol would provide a feed of ad libitum intake.

Brief description of the Drawing Figures In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawing in which: FIGURE 1 is a diagrammatic view of a system used to perform the method of producing pelletized cottonseed of the present invention; FIGURE 2 is a diagrammatic view of a portion of system for performing the method of producing pelletized cottonseed of the present invention able to remove lint and add alternate cotton fibers to the cottonseed; FIGURE 3 is a flow diagram showing the method of producing pelletized whole fuzzy cottonseed of the present invention; FIGURE 4 is a flow diagram illustrating the steps involved in the method of producing pelletized whole fuzzy cottonseed of the present invention; and FIGURE 5 is a flow diagram illustrating the steps involved in the method of producing pelletized whole fuzzy cottonseed of the present invention which are enriched and/or coated.

The reference numerals utilized in the drawing figures are defined as follows: 10 System for accomplishing the method of producing pelletized cottonseed 12 holding bin 14 Saw delinter 16 conduit for passing cottonseed from holding bin to delinter 18 passageway 20 cotton fiber feeder 22 screening device 24 conveyor between screening device and screw extruder 26 screw extruder 28 conveyor for providing cottonseed from screw extruder to pelletizer 30 pelletizer 32 conveyor for providing cottonseed from pelletizer to cooler 34 cooler 36 finished pellet storage container Detailed description of the Preferred Embodiment Turning now descriptively to the drawings in which similar reference characters denote similar elements throughout the several views, Figures 1 through 4 illustrate the method of producing pelletized whole fuzzy cottonseed of the present invention. A system for performing the method of producing cottonseed is indicated generally by the numeral 10.

The system for performing the method of producing palletized cottonseed 10 is shown in Figure 1. Cottonseeds which have been ginned are provided to a holding bin 12 for storage until used for producing the pelletized cottonseed. Cottonseeds are the raw material used by the process of the present invention to produce pelletized foodstuffs. The cottonseeds within the holding bin 12 are cleaned and prepared for being put into palletized form by the method of the present invention. The cottonseeds are transported from the holding bin 12 at a predetermined volume to a Saw delinter 14 via a conduit 16. The Saw delinter 14 removes lint from the cottonseeds during passage therethrough. Cottonseeds from which the lint is removed are provided to a passageway 18. The passageway 18 leads past a cotton fiber feeder 20. The cotton fiber feeder 20 adds cotton fibers to the cottonseeds. The added cotton fibers are less valuable and thus less costly than the lint removed by the Saw delinter 14. The cotton fibers added to the cottonseeds are at least any one of gin waste, textile waste or any type of low grade cotton fiber. The lint removed from the cottonseed may be used in the production of cellulose based products. The alternate cotton fibers replacing the lint in the cottonseeds cannot be used in the processes for producing cellulose based products. Preferably, anywhere between 0-240 pounds of lint can be removed from the cottonseeds by the method of the present invention.

The cottonseed including the added cotton fiber is conveyed at a predetermined volume through the passageway 18 to a screening device 22. The screening device 22 removes foreign materials from the cottonseeds. The screened cottonseeds are conveyed via a conveyor 24 to a screw extruder 26. The screw extruder 26 has an input port having a predetermined diameter and an output port having a diameter smaller than the diameter of the input port. The screw extruder 26 gradually decreases in diameter along its length from the input port to the output port. Within the screw extruder 26 is a blade, the blade having a diameter which decreases along its length for placement within the screw extruder 26 and between the input and output ports. The blade of the screw exteruder 26 minces the whole fuzzy cottonseeds within the screw extruder 26, thereby increasing the atmospheric pressure as the minced cottonseeds progress towards the output port. The minced mixture under increasing atmospheric pressure crushes the mixture into a whole fuzzy cottonseed mash which has an elevated temperature and is under increasing pressure.

The whole fuzzy cottonseed mash is extruded onto a conveyor 28 for delivery to a pelletizer 30. The pelletizer 30 forms the cottonseed mash into pellets of predetermined sizes. The pellets formed in the pelletizer 30 are then conveyed along a subsequent conveyor 32 to a cooler 34 for reducing the temperature of the pellets.

After sufficient temperature reduction, the pellets are provided to a finished pellet storage container 36 where they are stored for future use as feed for animals such as cattle.

Figure 2 shows a portion of the method for producing palletized cottonseeds in which the lint is removed from the cottonseeds and replaced with alternate cotton fibers. At this time along the process, the cottonseeds are passed from the holding bin 12 to the Saw delinter 14 via the conduit 16. The Saw delinter 14 removes the lint from the cottonseeds during passage therethrough. Cottonseeds from which the lint is removed are provided to a passageway 18. The passageway 18 leads past a cotton fiber feeder 20. The cotton fiber feeder 20 adds cotton fibers to the cottonseeds. The added cotton fibers are less valuable and thus less costly than the lint removed by the Saw delinter 14. The cotton fibers added to the cottonseeds are at least any one of gin waste, textile waste or any type of low grade cotton fiber. The lint removed from the cottonseeds may be used in the production of cellulose based products. The alternate cotton fibers replacing the lint in the cottonseeds cannot be used in the processes for producing cellulose based products. Preferably, anywhere between 0-240 pounds of lint can be removed from the cottonseeds by the method of the present invention.

The method of producing palletized cottonseeds will now be described with reference to the figures and specifically Figures 3-5. Referring to the flow diagram shown in Figure 3, the method of turning whole fuzzy cottonseeds into animal feed pellets is described. The cottonseeds which have been ginned include a hull having residual fibers attached thereto. The ginning of cotton results in the removal of all seed material. The seeds can be further processed to cull the most desirable seeds from the seed aggregate for next crop planting. The remainder of the seed aggregate is selected for use in the method of the present invention for producing animal feed. The cottonseeds can not be handled by normal grain handling equipment with the hull attached fibers. These fibers have a tendency to bind with other seed hull fibers and thereby clump together and clog the machinery. The remainder of the seed aggregate having the hull attached is selected and placed within the holding bin 12 as stated in step S2 wherein the cottonseeds are cleaned.

The selected cottonseeds are provided to the delinter 14 wherein lint from the cottonseeds is removed as discussed in step S4. The lint removed from the cottonseeds may be used in the production of cellulose based products. The delinted cottonseeds are provided to the passageway 18 wherein the cottonseeds pass by the cotton fiber feeder 20. The cotton fiber feeder 20 adds lesser grade cotton fibers such as gin waste, textile waste and any other type of low grade cotton fiber as described in step S6. The cottonseeds including the added cotton fiber is conveyed at a predetermined volume through the passageway 18 to a screening device 22. The screening device 22 removes foreign materials from the cottonseed mixture. The screened cottonseed is conveyed via a conveyor 24 to a screw extruder 26.

The screened cottonseeds having the lint replaced with a low grade cotton fiber are metered to the screw extruder 26 as stated in step S8. The metered seeds are minced by a bladed screw in the screw extruder 26 until the seeds and attached fibers have been reduced to a smaller seed particle aggregate as discussed in step S10. The mincing of the cottonseeds by the screw extruder 26 reduces the cottonseeds to a predetermined particle size. As the bladed screw moves the material toward the output port of the screw extruder, the minced seed aggregate is compressed under increasing atmospheric pressure. The increasing atmospheric pressure crushes the seed particle aggregate into a hot whole fuzzy cottonseed mash mixture. The cottonseed mash is then advanced by the screw within the screw extruder 26 to the output port and extruded by the screw extruder 26 as described in step S12. Under ever increasing atmospheric pressure the mixture is compressed causing rupturing. Furthermore, the temperature is caused to increase within the resulting in an extruded mash 40 having an elevated temperature and pressure. The hot oatmeal-like mixture is then conveyed to the pellet forming mechanism 30 as stated in step S14. The pellet forming mechanism 30 forms pellets having a predetermined size from the mixture as discussed in step S16.

The hot pellets formed by the pellet forming mechanism 30 are conveyed to the cooler 34 wherein the temperature of the pellets is reduced to a predetermined level as described in steps S18 and 20. The cooler 48 reduces the temperature of the pellets before conveying 50 the pelletized fuzzy cottonseed to the storage container 36 as stated in step S22. The palletized cottonseeds remain in the storage container until they are desired for use.

While the aforementioned method will turn whole fuzzy cottonseed into densified pellets that can be handled in similar fashion as other grain product, it would normally be desirable to enhance the nutritional content of the pellets and to protect the pellets from insects and rodents as will be described hereinafter.

While it has been determined that whole fuzzy cottonseed is a desirable animal feed, the fibers attached to the seeds have prevented their common use as an animal feed. There are products presently available that either coat the seed in a gelatinous starch or subject the seed aggregate to an acid wash to remove the cotton fibers from the seed hulls. Both of these methods increase the processing costs in providing a whole cottonseed feed. The present invention overcomes these undesirable seed aggregate characteristics in a new, novel and cost effective manner.

Mainly the seed aggregate is comprised of hulled seeds having cotton fibers attached thereto. Normal grain handling equipment gets clogged by these fibrous seeds requiring special handling or treatment of the seeds, such as acid baths to remove the fibers. While these methods have been successful for their intended purposes, the present invention provides a natural solution by mincing the seeds and attached fibers into smaller particle matter that is further compressed under pressure to produce a whole fuzzy cottonseed mash that can be formed into pellets.

Referring to Figure 4, the method for producing palletized cottonseed of the present invention is illustrated. Figure 5 illustrates the method including additional steps for enhancing the pellets by adding feed supplements, vitamins and medicines as well as coating the pellets to protect against insect and vermin infestation. The method of producing palletized cottonseeds is initiated by selecting seeds that have been ginned as stated in step S100. The ginning of cotton results in the removal of all seed material.

The seeds can be further processed to cull the most desirable seeds from the seed aggregate for next crop planting. The remainder of the seed aggregate can be used as animal feed.

The selected cottonseeds are provided to the delinter 14 wherein lint from the cottonseeds is removed as discussed in step S12. The lint removed from the cottonseeds may be used in the production of cellulose based products. The delinted cottonseeds are provided to the passageway 18 wherein the cottonseeds pass by the cotton fiber feeder 20. The cotton fiber feeder 20 adds lesser grade cotton fibers such as gin waste, textile waste and any other type of low grade cotton fiber as described in step S104. The cottonseeds including the added cotton fiber is conveyed at a predetermined volume through the passageway 18 to a screening device 22. The screening device 22 removes foreign materials from the cottonseed mixture. The screened cottonseed mixture is conveyed via a conveyor 24 to a screw extruder 26.

The screened cottonseeds having the lint replaced with a low grade cotton fiber are metered at a specific rate to the screw extruder 26 as stated in step S106. The metered seeds are minced by a bladed screw in the screw extruder 26 until the seeds and attached fibers have been reduced to a smaller seed particle aggregate as discussed in step S108. The mincing of the cottonseeds by the screw extruder 26 reduces the cottonseeds to a predetermined particle size. As the bladed screw moves the material toward the output port of the screw extruder, the minced seed aggregate is compressed under increasing atmospheric pressure. The increasing atmospheric pressure crushes the seed particle aggregate into a hot whole fuzzy cottonseed mash as described in step S110. The minced cottonseeds are then advanced by the screw within the screw extruder 26 to the output port and extruded by the screw extruder 26 as described in step S112. Under ever increasing atmospheric pressure the mixture is compressed causing rupturing. Furthermore, the temperature is caused to increase within the mixture resulting in an extruded mash 40 having an elevated temperature and pressure.

The hot oatmeal-like mixture is then conveyed to the pellet forming mechanism 30. The pellet forming mechanism 30 forms pellets having a predetermined size from the mixture as discussed in step S114. The hot pellets formed by the pellet forming mechanism 30 are conveyed to the cooler 34 wherein the temperature of the pellets is reduced to a predetermined level as described in step S116. The cooler 48 reduces the temperature of the pellets before conveying 50 the pelletized fuzzy cottonseed to the storage container 36. The palletized cottonseeds remain in the storage container until they are desired for use.

As shown in figure 5, the enriching of the cottonseed by the introduction of feed supplements, vitamins, and medicines can occur at one or more selected point depending on the properties that are to be attained. The enriching step S118 may be accomplished at any time after steps S106, S108, S110 and S112, e. g. the enriching can be performed at any time before palletizing. The infusion of additives and preservatives has an added advantage over coating in that the additives will permeate through the pellet. Because these additives are not subjected to atmospheric conditions such as UV rays, they may have a longer shelf life. Also the introduction of greater quantities of additives is possible that is not possible with coatings due to the fact that there is a finite surface area on a seed. The thicker the coating the greater chance of chipping and separation of the coating from the seed.

Furthermore, the pellets can be coated as a final process to protect the pellets from rodents and insects as discussed in step S120. This final coating would have little effect on the feed supplements, vitamins, and medicines that to a large extent are contained within the pellet. The step of coating, S120, occurs at any point after the cottonseeds are formed into pellets.

From the above description it can be seen that the method of producing palletized cottonseed of the present invention is able to overcome the shortcomings of prior art devices by providing a method of producing palletized cottonseed wherein at least a portion of the lint is removed from the whole cottonseed prior to extruding and replaced by a lesser grade of cotton fiber, the removed lint being preferably used in the production of cellulose based products. The method measures and controls the flow rate at which cottonseed moves from a storage device to a screw extruder and the screw extruder includes an input port for introducing a predetermined measured amount of cottonseed, an output port for extruding a predetermined measured amount of cottonseed, a bore having a diameter which decreases in size from the input port to the output portand a helical blade having a diameter which decreases in size from the input port to the output port for grinding the cottonseed into a blend mixture. The cottonseed blend temperature increases during passage from the input port to the output port of the screw extruder and the free cottonseed oil pigment gossypol binds with constituent cottonseed elements thereby reducing the amount of free gossypol. A pellet forming mechanism forms pellets from the cottonseed blend and includes an input port for introduction of the cottonseed blend and an output port for delivery of a palletized form of the cottonseed blend. The method may introduce nutritional ingredients into the blend creation process, the nutritional ingredients permeating throughout the blend pellet and/or apply coatings to cover the palletized cottonseed blend for protect the cottonseed against insect and vermin and extending the shelf life of the pellets.

Furthermore, the method of producing palletized cottonseed of the present invention is simple and easy to use and economical in cost to manufacture.

It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above.

While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.

Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.