An Ultrasonic Phased Array System for Detection of Plastic Contaminants in Cotton

Cotton, a globally significant crop grown in over 100 countries, sustains a $40 billion market and provides employment for over 350 million people worldwide. However, plastic contamination remains a persistent challenge within the industry, degrading cotton fiber quality and disrupting ginning. Manual inspection and optical machine-vision systems struggle when plastic fragments are concealed by fibers or lack sufficient color contrast. To address these challenges, we developed an ultrasonic phased-array imaging system operating at 40 kHz under field-programmable gate array (FPGA) control. Transmitter elements emit pulsed ultrasound along radial paths, separate reflection receivers record echo amplitudes to form acoustic images, and a set of transmission receivers captures signal attenuation, which is overlaid onto the reflection-based image to highlight potential contaminants. In preliminary laboratory-based tests on both seed cotton and lint samples, the system successfully detected visually obscured plastic fragments as small as 2cm×2cm with an angular resolution limit of ±3°. Distinct reflection peaks and corresponding attenuation overlays were produced across the field of view, validating the system’s detection capabilities. These results demonstrate the feasibility of using ultrasonic imaging to reveal concealed plastics in cotton processing. Integrating this approach with existing optical methods could enhance contaminant-removal workflows and improve overall fiber quality and processing efficiency.