USTER® HVI 1000

Best Operating Practices

For Lab Technicians/ Operators

HIGH VOLUME FIBER TEST SYSTEM

September 2008
Contents
USTER ® HVI ............................................................................................... 1

1 HVI Best Operating Practices ................................................... 2

1.1 General Laboratory Recommendations ....................................... 2
1.2 Overall Test Sequence................................................................. 4

2 HVI Test Results......................................................................... 5

2.1 Micronaire (Mic) ........................................................................... 6
2.1.1 Micronaire Sample Preparation.................................................... 6
2.1.2 Micronaire Calibration .................................................................. 7
2.1.3 Micronaire Troubleshooting.......................................................... 7
2.1.4 Maturity Index (Mat) ..................................................................... 8
2.1.5 Maturity Sample Preparation........................................................ 8
2.1.6 Maturity Calibration/ Troubleshooting .......................................... 8
2.2 Length .......................................................................................... 8
2.2.1 Upper Half Mean Length (UHML)................................................. 8
2.2.2 Uniformity Index (UI) .................................................................. 10
2.2.3 Short Fiber Index (SFI)............................................................... 10
2.3 Strength (Str).............................................................................. 11
2.3.1 Elongation (Elg).......................................................................... 11
2.3.2 Length/ Strength Sample Preparation ........................................ 11
2.3.3 Length/ Strength Calibration ...................................................... 12
2.3.4 Length/ Strength Troubleshooting.............................................. 13
2.4 Color........................................................................................... 14
2.4.1 Reflectance (Rd) ........................................................................ 14
2.4.2 Yellowness (+b).......................................................................... 14
2.4.3 Color Grade (C Grade)............................................................... 14
2.5 Trash .......................................................................................... 15
2.5.1 Trash Count (Tr Cnt) .................................................................. 15
2.5.2 Trash Area (Tr Area) .................................................................. 16
2.5.3 Trash Grade (Tr ID).................................................................... 16
2.5.4 Color/ Trash Sample Preparation............................................... 16
2.5.5 Color/ Trash Calibration ............................................................. 17
2.5.6 Color/ Trash Troubleshooting..................................................... 17

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1 HVI Best Operating Practices

The following information is provided as a guide to help the laboratory technicians
obtain the best possible results from the HVI instrument. The Instruction Manual
should be read thoroughly and fully understood on details as how to operate the HVI.
If there are any differences in the information in this document and the Instruction
Manual, the Instruction Manual should be accepted as correct.

1.1 General Laboratory Recommendations

A few best practices help improving data quality in any laboratory:

The laboratory has to be conditioned to ASTM standard conditions 24 hours a day, 7

days a week during cotton classing season. The air conditioning system has to be
checked regularly in different locations within the laboratory for accuracy and
consistency. Care should be taken to ensure the ASTM temperature and relative
humidity standards are met uniformly throughout the laboratory.

There should be no draft in any place in the laboratory due to the air conditioning
system, especially not anywhere close to the HVI instrument. The micronaire balance
is susceptive to air draft, which is the reason it is already protected by a plastic shield.

Samples must be stored openly in the conditioned laboratory, not in paper or plastic
bags. Open-wire shelves are preferred for sample conditioning since the air needs to
be able to penetrate the samples from all sides. Plastic mesh baskets can also be
used for sample storage as long as they are stored in mesh wire racks. Again, it is
important that the conditioned air can penetrate the cotton sample from all sides (see
figure 1 – 3 below).

Figure 1: Wire basket Figure 2: Plastic-mesh basket

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Figure 3 Sample storage in plastic-mesh baskets in open-wire shelves

Calibration cottons must be stored within the same laboratory under the same
conditions as the test samples and where they will be tested (= where the HVI
instrument is installed). Just take one of the two calibration cottons at a time to the
instrument when you calibrate the HVI. This helps avoiding mixing the calibration
cottons accidentally.

Calibration cottons must be replaced when there is any chance that they have been
mixed up or are otherwise contaminated! This happens even in the best
laboratories!! It is essential to discard mixed or contaminated calibration cottons
immediately to avoid any problems with the calibration.

Calibration cottons also need to be replaced when they have been used very
frequently. This is especially true for the USDA Micronaire calibration cottons that
become easily “clumpy” due to frequent use. It is recommended that the Micronaire
calibration cotton sample not be reused more than three times.

There is an expiration date on the new USDA calibration cottons for length and
strength. Calibration cottons should be discarded after this expiration date.

Cotton testing involves a lot of dust and dirt. Read and follow the maintenance
instructions in the Instruction Manual thoroughly. Excessive dirt accumulation will
affect the data reliability of the instrument, and will eventually reduce the
instrument’s lifetime.

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1.2 Overall Test Sequence

In order to obtain maximum efficiency in operating an HVI, it is necessary to properly

organize the sample handling for testing. It is recommended that sample trays be
used for organizing cotton lots. Either metal wire or plastic open mesh trays may be
used (see comment above). The bale samples in a lot should be placed in as many
trays as required to contain them. These trays then provide a convenient container in
which the samples are conditioned. When testing is started, the first tray should be
placed to the right of the HVI and an empty tray to the left to receive the samples as
they are tested. Usually, the following test set-up is selected for classing Upland-type
cottons:

Micronaire 1 repetition per sample

Length/ Strength 2 repetitions per sample
Color/ Trash 2 repetitions per sample

The different tests performed by the HVI may be done in different sequences.
However, performing the tests in the same sequence each time will minimize errors
and maximize throughput. The most efficient sequence may vary for different
operators but the suggested sequence is the following:

1. Pick up the bale sample from the right hand tray and
remove the bale tag.

2. Either scan the bale tag or enter it manually via the

keyboard.

3. Place approximately 10 grams on the balance for the

Micronaire measurement.

4. Place two samples with a thickness greater than 2 inch

(app. 5 cm) in the center of the color/ trash trays and press
the color/ trash start button.

5. Remove two 8 – 12 grams samples for the length/ strength

measurement. Place length / strength samples in the
sample drums and press the length / strength start button.

6. This will have allowed the balance time to stabilize. If the

balance mass is not within the allowed range, adjust the
mass of the cotton on the balance.

7. Check that the mass on the balance agrees with the mass
displayed on the HVI monitor.

8. Insert all the cotton on the balance completely into the

Micronaire chamber and close the Micronaire door.

9. When all tests are completed and no limits are

encountered, collect the cotton from each module, fold the

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sample around the bale tag, and place the sample in the
completed sample tray to the left.

2 HVI Test Results

USTER® HVI test results are explained in this section. Data ranges are given, with
the objective of providing users with basic information for what to expect in their test
results.

Table 2.1 below lists the different test results that can be obtained with the USTER®
HVI. It also shows the type of format being used (the number of decimals displayed),
and the abbreviations used in the printout.

Test Result Format Abbreviation

1.Micronaire X.XX Mic
2.Maturity Index X.XX Mat
(in) X.XXX
3.Upper Half Mean Length UHML
(mm) XX.XX
4.Uniformity Index XX.X UI
5.Short Fiber Index XX.X SFI
6.Strength XX.X Str
7.Elongation XX.X Elg
8. Reflectance XX.X Rd
9. Yellowness XX.X +b
10. Color Grade XX-X C Grade
11. Trash Count XXX Tr Cnt
12. Trash Area XX.XX Tr Area Tab. 2.1 HVI Test
Results, Format &
13. Trash Grade XX Tr ID Abbreviations

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2.1 Micronaire (Mic)

Micronaire is a description of the cotton fiber fineness, but it does not relate directly
to linear density. A fiber sample of known weight is measured by passing air through
the fibers and measuring the drop in pressure. The micronaire scale has been
established empirically with a standard set of cottons and is not linear. Other factors
such as fineness and maturity have an influence on micronaire results.

Micronaire is determined by the cotton variety. For example, a fine cotton variety
such as Pima will usually have lower Micronaire values than Upland type cottons.

Micronaire is strongly influenced by the growth conditions during the cotton

development. Thus cotton of the same variety can have different Micronaire values
from one season to another and from one growth area to another.

Below, please find some common ranges of Micronaire values for Upland cottons:

Micronaire Description
Less than 3.0 Very fine
3.0 to 3.6 Fine
3.7 to 4.7 Medium
4.8 to 5.4 Coarse Tab. 2.2 Micronaire
Ranges for Upland
5.5 and higher Very coarse Cottons

2.1.1 Micronaire Sample Preparation

Micronaire is also influenced by the degree of openness of the sample. The sample
should be slightly opened manually after it has been weighed, but care must be
taken not to lose any of the weighed material. The measured Micronaire value will be
wrong if the actual weight of the sample in the measurement chamber and the
sample weight recorded in the software are different.

The sample should then be inserted into the measurement chamber using your
fingers of both hands. Do not “poke” a finger through the middle of the sample in
order to insert the sample. This can skew the measurement results. The sample
density should be as uniform as possible.

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2.1.2 Micronaire Calibration

Follow the instructions described in the Instruction Manual. Do NOT re-use the same
sample calibration cottons after usage. Take the calibration cotton and open the
sample back up before putting it back into the respective storage bin. Again, do not
use the same calibration cotton sample over and over again. Replace the calibration
cotton once it is too “clumpy” to ensure proper air flow measurement. The Micronaire
calibration cotton sample not be reused more than three times.

Calibration cottons have been selected due to their more evenly distributed fiber
properties compared to regular cottons from the gin. Regular cottons from the gin will
have higher variations in the cottons. Saw ginning produces more evenly distributed
fiber properties than roller ginning.

So: Roller ginned cottons show higher variation in their test results compared to saw
ginned cottons. Saw ginned cottons show higher variations than cottons used for
calibration.

2.1.3 Micronaire Troubleshooting

The following actions can resolve frequently observed operation

problems:

Problem Action
Bad Start button for mic. • Wait until the HVI is ready for the Micronaire
Controller waiting for HVI ready. sample button. In general, the sample ID
must be entered first.
No valid Mass. • The HVI requires some time to ensure that
the mass is stable and within the allowed
mass range. Wait until the display on the
balance agrees with the HVI monitor and the
Micronaire air turns on.
Consistent lot limits • Lot limits must be assigned to match the
cotton being tested. Verify that the limits are
consistent with the lot.
High variability • Check the sample weight. Ensure that it is
stable on the balance and that the display on
the balance agrees with the HVI monitor.
Ensure the entire sample mass is entered in
the Micronaire chamber.
• Use both hands to insert the sample. Do not
poke the sample in with a single finger.
Door not closed • Check that part of the sample is not fully
inserted into the chamber and is holding the
door open.
• Very large sample mass near 11.5 grams
may push the door open. Use a smaller
mass.

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2.1.4 Maturity Index (Mat)

The maturity index is a relative value that is calculated using a sophisticated

algorithm including other HVI measurements, such as micronaire, strength and
elongation. It indicates the degree of cell wall thickness within a cotton sample. The
HVI Maturity Index correlates very well to the AFIS Maturity Ratio and the reference
method of microscopy (cross-sectional analysis).

Maturity is solely influenced by the growth conditions during the cotton development.
It will be different within the same cotton plant, and between different plants, and
from one season to another.

Below, please find some common ranges of Maturity values for Upland cottons:

Maturity Index Description

Below 0.75 Uncommon
0.75 to 0.85 Immature
0.86 to 0.95 Mature
Tab. 2.3 Maturity
Above 0.95 Very mature Ranges

2.1.5 Maturity Sample Preparation

Maturity is not directly influenced by sample preparation since it is

estimated using other HVI measurements along with Micronaire. As
long as good operating practices are applied for the major
measurements, maturity results will fall in place.

2.1.6 Maturity Calibration/ Troubleshooting

Maturity does not require a separate calibration for the same reasons as mentioned
above, since it is derived from a measurement algorithm. There are also no special
troubleshooting rules that are used for maturity.

2.2 Length

2.2.1 Upper Half Mean Length (UHML)

The by-weight measurement of the Upper Half Mean Length (UHML) is calculated
from the fibrogram. A fiber beard of randomly clamped fibers is scanned optically
across its length and the fibrogram is derived from it. The Upper Half Mean Length
corresponds to the classer’s staple length as well as to the USTER® AFIS Upper
Quartile Length by weight.

Please note that a length range is assigned in inches for each length staple or code.
The ranges calculated in millimeters do not line up exactly due to the conversion

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calculation. However, inches or 32nds are mainly used for staple length
determination in the international cotton trade, and are therefore binding.

Below, please find the length conversion list commonly used for Upland cottons:

UHML USDA Length

Inches UHML [mm]
[inches] Code (32nds)

<13/16 <0.79 <20.1 24

13/16 0.80 – 0.85 20.1 – 21.6 26
7/8 0.86 – 0.89 21.8 – 22.6 28
29/32 0.90 – 0.92 22.9 – 23.4 29
15/16 0.93 – 0.95 23.6 – 24.1 30

31/32 0.96 – 0.98 24.4 – 24.9 31

1 0.99 – 1.01 25.1 – 25.8 32
1 1/32 1.02 – 1.04 25.9 – 26.4 33
1 1/16 1.05 – 1.07 26.7 – 27.2 34
1 3/32 1.08 – 1.10 27.4 – 27.9 35

1 1/8 1.11 – 1.13 28.2 – 28.7 36

1 5/32 1.14 – 1.17 29.0 – 29.7 37
1 3/16 1.18 – 1.20 30.0 – 30.5 38
1 7/32 1.21 – 1.23 30.7 – 31.2 39
1 1/4 1.24 – 1.26 31.5 – 32.0 40

1 9/32 1.27 – 1.29 32.3 – 32.8 41

1 5/16 1.30 – 1.32 33.0 – 33.5 42 Table 2.4 Staple
1 11/32 1.33 – 1.35 33.8 – 34.3 43 Length Ranges and
Conversions – Upland
1 3/8 >1.36 >34.5 44 Cotton

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2.2.2 Uniformity Index (UI)

The Uniformity Index expresses the ratio of the Mean Length to the Upper Half Mean
Length. It is an indication of the distribution of fiber length within the fibrogram:
Uniformity Index (%) = 100 x (Mean Length / Upper Half Mean Length). Below,
please find some common ranges of Uniformity values for Upland cottons:

Uniformity Index (%) Description

Below 77 Very low
77 to 80 Low
81 to 84 Medium
85 to 87 High
Tab. 2.5 Uniformity
87 and higher Very high Ranges

2.2.3 Short Fiber Index (SFI)

The Short Fiber Index is a value that is calculated using a sophisticated algorithm. The
fibrogram is mathematically converted to a length distribution curve. The SFI is an
indication of the amount of fibers (%) that are below a certain length (either less than
0.50 inches/ 12.7 mm or less than 0.65 inches/ 16.5 mm). It correlates very well to the
USTER® AFIS Short Fiber Content by weight SFC (w).

Below, please find some common ranges of SFI values for Upland cottons:

Short Fiber Index (%) Short Fiber Index (%)

Description
< 0.50 in < 16.5 mm
Below 6 Below 11 Very low
6 to 9 11 to 17 Low
10 to 13 18 to 23 Medium
14 to 17 24 to 30 High
Tab. 2.6 Short Fiber
18 and higher 31 and higher Very high Index Ranges

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2.3 Strength (Str)

The bundle strength is the breaking strength of the cotton fibers in grams per tex.
The fineness is calculated from the micronaire value. The fiber beard is broken at a
continuous deformation rate (CRE = Constant Rate of Extension) and with a 1/8-inch
distance between the clamps.

Below, please find some common ranges of Strength values for Upland cottons:

Strength (grams/tex) Description

Less than 21 Very weak
22 to 25 Weak
26 to 28 Medium
29 to 31 Strong Tab. 2.7 Strength
Ranges for Upland
32 and higher Very strong Cottons

2.3.1 Elongation (Elg)

Elongation is a measurement of the elastic behavior of the fibers in the bundle. The
fibers are clamped in the bundle with a 1/8th-inch distance between the clamps. The
first pair of clamps is stationary, and the back pair of clamps is pulled away at a
constant rate. The distance the fibers extend before they break is recorded and
expressed as a percent elongation for the 1/8th inch gauge length. For example, if
you were to measure 50% elongation, the fibers would have extended 1/16th of an
inch before breaking.
Below, please find some common ranges of Elongation values for Upland cottons:

Elongation (%) Description

Less than 5.0 Very low
5.0 to 5.8 Low
5.0 to 6.7 Medium
6.8 to 7.6 High
Tab. 2.8 Elongation
7.7 and higher Very high Ranges

2.3.2 Length/ Strength Sample Preparation

The following are suggestions to improve the quality of the length / strength data:

A minimum of two combs should be tested for saw ginned upland cottons. A
minimum of four combs should be tested for either pima cottons or roller ginned
cottons.

Approximately 8 – 12 grams of cotton should be used for each sample drum to

provide samples with the proper amount. In general, a greater amount of sample

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should be used for short cotton samples and less sample for long cotton samples.
The ginning process (roller vs. saw-ginned) will also influence the proper amount of
cotton to use.

The length / strength sample should be pulled from the main sample and placed in
the sample drum with the pulled “open” surface down. Avoid placing either cut
surfaces or layered surfaces down, so that the cut edges will not be sampled (see
Figure 4 below). The sample should be placed so that it is evenly spread over the
width of the sample drum. Avoid lumps or holes across the width of the sample
drum.

Figure 4 Good sample side

2.3.3 Length/ Strength Calibration

Follow the instructions described in the Instruction Manual. Carefully follow the
instructions on the screen on when to pull and turn the calibration cotton during
calibration. Do NOT re-use the same sample surface of the calibration cottons after
usage. Take the calibration cotton and open the sample back up before putting it
back into the respective storage bin. Again, do not use the same calibration cotton
sample over and over again.

Use the recommended pairs of calibration cottons for length strength calibration:
• USDA Universal HVI Calibration Cotton Standards (Upland, blue boxes)
short-weak and long-strong when the average UHML length tested is
consistently lower than 1.22 (or 31.0 mm) inches.
• USDA Universal HVI Calibration Cotton Standards (Upland, blue box) short-
weak and USDA ELS (Extra Long Staple) HVI Calibration Cotton Standards
(Pima, red box) long-strong when the average UHML length tested is
consistently longer than 1.22 (or 31.0 mm) inches.

Do not use USDA ELS (Extra Long Staple) HVI Calibration Cotton Standards (Pima,
red box) short-weak and long-strong for Length/ Strength calibration! The spread of the
standard values of this pair is too narrow to provide a good measurement over a wide
range of cottons.

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Only use the USDA Universal HVI Calibration Cotton Standards (Upland, blue
boxes) short-weak and long-strong for calibrating the Short Fiber Index!

Calibration cottons have been selected due to their more evenly distributed fiber
properties compared to regular cottons from the gin. Regular cottons from the gin will
have higher variations in the cottons. Saw ginning produces more evenly distributed
fiber properties than roller ginning.

Note that the USDA ELS (Extra Long Staple) HVI Calibration Cotton Standards
(Pima, red box) are saw-ginned to achieve better uniformity of the fiber properties for
calibration purposes. However, this is an exception. Pima and other long and extra-
long staple cottons are usually roller ginned.

Upland and other short staple cottons are usually saw ginned. Roller ginned cottons
show higher variation in their test results compared to saw ginned cottons. Saw
ginned cottons show higher variations than cottons used for calibration.

2.3.4 Length/ Strength Troubleshooting

Learn to watch the data. Sudden changes in the data may warn of problems with the
HVI. The following actions can resolve frequently observed operation problems:
Problem
Consistent High Amounts
Consistent Low Amounts
L/S Button Error
Consistent lot limits
Unusually high (low) test results
High variability
Action
• The sample may be located deeper into the
sample drum so that it covers fewer holes in
the sample plate. The other option is to
remove part of the sample from the drum.
• Add some sample to the sample drum.
Another option is to pull the sample and place
it further up the sample plate in the sample
drum so that it covers more holes in the
sample plate. Finally, the sample can be
manually opened more.
• Wait until the HVI is ready for the L/S sample
button. In general, the sample ID must be
entered first. The green LED will indicate that
the HVI is ready.
• Lot limits must be assigned to match the
cotton being tested. Verify that the limits are
consistent with the lot.
• Test 4 combs of the each calibration cotton to
verify calibration.
• Observe uniformity of fiber beard. Adjust
sample placement if necessary (see high and
low amounts above).
• Verify that the comb is cleaning correctly.
• Check 10 combs in module testing from
extreme locations in the sample, to see if this is
variability is due to the natural variation within
the cotton.

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2.4 Color

2.4.1 Reflectance (Rd)

This value expresses the whiteness of the light that is reflected by the cotton fibers.
It corresponds to the reflectance (Rd) represented in the Nickerson/Hunter color
chart. It is used in conjunction with the yellowness (+b) to determine the instrument-
measured color grade of the cotton.

2.4.2 Yellowness (+b)

This value expresses the yellowness of the light that is reflected by the cotton fibers.
It corresponds to the +b value represented in the Nickerson/Hunter color chart. The
yellowness is used in conjunction with the reflectance (Rd) value to determine the
instrument-measured color grade of the cotton.

2.4.3 Color Grade (C Grade)

The color grade of a cotton sample is determined by measuring the Rd and +b

values of a sample. This objective method was developed by Nickerson and Hunter
in the early 1940’s to check the USDA cotton grade standards.
Today, the HVI color measurement is being used more than the subjective visual
grade determined by the cotton classer.

The following page shows the USDA color chart for Upland cottons:

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Fig. 2.1 USDA Color Grade

Chart for Upland
Cottons, 1999

2.5 Trash

2.5.1 Trash Count (Tr Cnt)

Trash is measured on the same glass window as the color measurement. The
sample is illuminated from underneath the glass window, and a monochromatic CCD
camera analyzes the information. A trash particle is counted if it exceeds the
grayness threshold set in the camera. All particles or pieces of trash that are
exposed to the glass window are counted one by one, and the results are expressed
in trash particle counts per surface area.

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2.5.2 Trash Area (Tr Area)

The area that is covered by a trash particle is measured at the same time the particle
is counted. The area that is covered by a single particle is summed up with all areas
of the other particles counted on the surface of the glass window. The result is
expressed in relation to the entire measuring area of the glass window and is
expressed as “% Area”.

For example, a small number of trash counts can result in a high % Area values if
the particles are large. On the contrary, a high number of particle counts with a small
% Area value indicates the trash is smaller in size (pepper trash, for example).

2.5.3 Trash Grade (Tr ID)

This is the trash grade that is determined by calibrating the HVI with known samples
(i.e., trash standards). These samples are usually numbered from 1 to 7 with
increasing amounts of trash as the number gets larger. The standards used for
calibration can be supplied by the USDA or established by the official cotton
standards agency in any cotton producing country.

2.5.4 Color/ Trash Sample Preparation

The following two areas are extremely important in order to ensure proper color and
trash measurement:

Cover the entire window of the color/ trash measurement module thoroughly! Repeat
the measurement, if you see a flash emerging from the color/ trash window.

Use a uniform sample thickness in the region under the sample hand for measuring
color and trash (greater than 2 inches or 5 cm in thickness) for different samples.
Different or uneven sample thickness can increase variation in color and trash
measurement results.

Repeatable color and trash results require that the sample hand presses the cotton
with the same density against the measurement window. The sample hand should
not come to an abrupt stop in the down position, but should come to a “cushioned”
halt (well cushioned by the cotton sample). It is therefore important that enough
sample material is placed under the color hand.

Do not measure the same sample surface twice to get the recommended 2
repetitions per sample: Turn the samples over for repeated measurement, providing
different sample surfaces to the measurement window.

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2.5.5 Color/ Trash Calibration

29B

Follow the instructions described in the Instruction Manual. Pay special attention to
the handling of the color tiles. Do NOT touch the front of the color and trash tile by
hand. Color and trash tiles must be clean to ensure proper instrument calibration.
Read and follow maintenance instructions in the Instruction Manual thoroughly.

2.5.6 Color/ Trash Troubleshooting

30B

The following actions can resolve frequently observed operation problems:

Problem Action
High trash readings • Ensure that the entire sample window is
covered and that the window is clean.
Color Button Error • Wait until the HVI is ready for the color
sample button. In general, the sample ID
must be entered first. The green LED will
indicate that the HVI is ready.
Consistent lot limits • Lot limits must be assigned to match the
cotton being tested. Verify that the limits are
consistent with the lot.
High variability • Check the thickness of the sample. Ensure
that it is greater than 2 inches or 5 cm thick
and uniform in thickness.

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