A specially designed device is used to heat several hundred pounds of cotton at temperatures previously shown to reduce endotoxin content during small-scale treatment of cotton lint. Dust from heated and unheated (control) cotton is captured during processing in a pilot plant textile mill. The endotoxin content of fibers, bulk dust, and fine dust is reduced by the heating, compared to the unheated bale. The effect of heat treatment on fiber physical properties and processability is monitored to provide an assessment of the effect of heating on the market value of the cotton.Results from dust from heated fibers distributed to other researchers for in vivo and in vitro evaluation of physiological activity are discussed.Long-term exposure of textile mill workers to cotton dust released during opening and processing of baled cotton may result in acute or chronic pulmonary dysfunctions, including byssinosis. The initial proposal for reducing byssinogenic potential of cotton dust suggested washing with water [ 41 ] . Subsequent research showed that washed cotton released lower levels of respirable dust during processing with decreased physiological activity [ 25 ] . Further studies of washed cotton, as cited by Wakelyn [43], led to exemption of thoroughly washed cotton from the 1978 OSHA Cotton Dust Standard [ 18 ] . Cotton washed under the severe conditions requited for exemption was much more difficult to process by ring spinning than unwashed cotton [6, 10, 31]. Milder wash conditions by continuous process on either a rayon rinse system or a continuous batt system were exempted (except for medical surveillance every two years) in 1985 [ 19 ] .Perkins showed that commercially acceptable yams can be produced by open-end spinning from cotton given a wash and bleach treatment by a continuous batt process, with application of a finish in the final rinse [ 29 ] . Industrial production of washed, scoured, and bleached cotton is customarily done by batch washing. Batch washing of cotton at 600C at a 40:1 I liquor: fiber ratio produces washed lint and airborne dust that is chemically and microbiologically comparable to cotton washed according to the 1985 standard by the continuous batt treatment or on the rayon rinse line [ 30 ], but batch-washed cotton has not yet been exempted under the Cotton Dust Standard. Southern Regional Research Center ( SRRC ) initiated research in the late 1980s to develop nonaqueous processes for reducing the pulmonary dysfunctions associated with exposure to cotton dust by reducing the endotoxin content of bulk cotton 6ber. Endotoxins (Iipopolysaccharides, LPS, produced by gram-negative bacteria that colonize cotton plants in the field) are carried on harvested cotton bolls. When ginned cotton fiber is opened and processed in textile mills, these endotoxins are released into the air, contributing to the pulmonary dysfunctions associated with cotton processing [ 38,39 ] . Correlations exist between the endotoxin content of cotton dust and decreases in pulmonary function in volunteers exposed to co...