METHODS OF TREATING TEXTILES WITH FOAM AND RELATED PROCESSES

Abstract

The present invention offers a new approach to the treatment of garments, including novel compositions and related methods using foam as a carrier of chemical products that are used during the industrial treatment of textiles. Another aspect of the invention relates to methods for reducing total water content necessary in industrial treatment of garments. Another aspect of the present invention relates to processes and methods of forming a foam that can be used for textile treatment.

Claims

1. A method for treating a garment comprising introducing a foam composition to the garment, wherein the foam composition comprises at least one active ingredient necessary to treat the garment.

2. The method of claim 1 wherein the at least one active ingredient is a dyestuff or fixing agent.

3. A module for creating a foam treatment for garments comprising: a T-junction comprising a first inlet, a second inlet, and an outlet; a first inlet line fluidly connected to the first inlet and comprising a vessel containing a solution fluidly connected to a pump; a second inlet line fluidly connected to the second inlet and comprising an air compressor and a flow regulator; and an outlet line having a first end fluidly connected to the outlet, a second end opposite the first end, and a cartridge between the first and second ends and having an amount of stainless steel sponge.

4. The module of claim 3, wherein the air compressor is configured to compress air to about 6 bar.

5. The module of claim 3, wherein the pump is a peristaltic pump.

6. The module of claim 3, wherein the flow regulator has a nominal pressure of about 6 bar.

7. The module of claim 3, wherein the cartridge is about 32 cm long.

8. The module of claim 3, wherein the cartridge is about 4.5 cm internal diameter.

9. The module of claim 3, wherein the solution comprises an amount of water, and amount of foaming agent, and an amount of treatment chemicals.

10. The module of claim 3, wherein the cartridge is PVC.

11. The module of claim 3, wherein the second end of the cartridge is disposed within a drum of a washing machine.

12. A method of creating foam for textile treatment, comprising the steps of: pumping a treatment solution into a first inlet of a T-junction; compressing air and urging the compressed air to a second inlet of the T-junction; combining the treatment solution and the compressed air in the T-junction; and creating a treatment foam by urging the combination of treatment solution and compressed air through an amount of stainless steel sponge contained within a cartridge.

13. The method of claim 12, further comprising the step of delivering the treatment foam to a washing machine drum.

14. The method of claim 12, wherein the pumping step is accomplished by a peristaltic pump.

15. The method of claim 12, wherein the compressing air step compresses air to 6 bar.

16. The method of claim 12, wherein the treatment solution comprises an amount of water, an amount of foaming agent, and an amount of treatment chemicals.

17. The method of any of claims 12-16, in any combination.

18. The elements and methods of claims 1-17, in any combination.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

[0026] FIG. 1 depicts a schematic representation of a foaming generator module.

[0027] FIGS. 2-3 depict the foam application and ease of visual inspection during the dyeing process of a garment.

[0028] FIGS. 4-10 depict the appearance of the garment following treatment.

[0029] FIGS. 11-12 depict one embodiment of the foaming generator module.

DETAILED DESCRIPTION

[0030] For purposes of description herein, it is to be understood that the disclosure may assume various alternative embodiments, except where expressly specified to the contrary. It is also to be understood that the novel compositions and related methods disclosed and described below are simply exemplary embodiments. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0031] The present invention relates to the treatment of textiles or garments, including novel compositions and related methods using foam as a carrier of chemical products. For instance, these chemical products may include softeners, finishing agents, enzymes for stone wash or for discolorations, bleaching agents, and others readily known by those in the industrial treatment of garments. Another aspect of the present invention relates to a module and related processes for generating these foam treatments for textiles or garments, as generally depicted in FIG. 1.

[0032] There are numerous advantages to using these novel compositions to treat textiles or garments, including but not limited to those summarized in Table 1.

TABLE-US-00001 TABLE 1 Comparison of Methods Designed to Conserve Water and Energy Methods based on Method based on foam as aerosols or spraying a carrier of chemical devices products Water savings on traditional 30% to 95% 30% to 95% cycles Water savings on rinses none none Modification of existing Yes, structural Minimal (small aperture washing machines required (sealing is required) on the door or in the Specific machines needed. chassis) Energy savings (heating of 30% to 95% 30% to 95% water) Potential issues arising from Yes No inhalation of chemicals Versatility (non-homogeneous Minimal Yes application on garments) Versatility (real-time checks No (opening the door is Yes on garments as in traditional not advisable due to washing processes) danger of aerosol inhalation) Versatility (application of non- No (nozzle occlusion) Yes soluble particles such as pigments or coated enzymes) Productivity Low (long dead time due High (reduced time to to slow injection time) load chemicals)

[0033] As summarized in Table 1, there are numerous advantages of the present invention compared to existing, known methodologies which have the shared goal of conserving energy and water, as well as reducing carbon dioxide emissions.

[0034] According to at least one embodiment, the present invention comprises at least one foaming agent that is used as a carrier of other chemicals used during the treatment of garments. As described in greater detail in Table 2, depending on the desired treatment, certain foaming agents may be more desirable than others. Persons of ordinary skill in the art would understand that a variety of foaming agents would be suitable and fall within the scope of the present invention. According to at least one embodiment, the foaming agent is present in an amount of at least 1 g/L per kilogram of garment. For instance, according to at least one embodiment, the foaming agent is present in an amount ranging from about 6 to 100 g/L per kilogram of garment. Depending on the treatment or application, more than one foaming agent may be used.

TABLE-US-00002 TABLE 2 Foaming Agents Substance description Ionic FOAMING AGENT and CAS Number charge Applications FOAMING AGENT #1 Tween 20: Non- Tween 20 or Tween 80 can Composition: CAS 9005-64-5 Sorbitan ionic be used as “general Tween 20: 15% w/w; monolaurate, ethoxylated purpose” foaming agents. Tween 80: 15% w/w; 20 EO They may represent the Water: 70% w/w Tween 80: “first choice” carrier due to CAS 9005-65-6 Sorbitan their favorable monooleate, ethoxylated toxicological profile and 80 EO due to their compatibility with cellulase enzyme formulations. FOAMING AGENT #2 N,N- Non- Amine Oxide can be used Composition: dimethyltetradecylamine ionic to produce foam with Amine Oxide: 25% w/w; N-oxide: strong oxidizing agents, Water: 75% w/w CAS 3332-27-2 such as NaOCl FOAMING AGENT #3 Sodium lauryl ether Anionic Blends of SLES and Composition: sulfate: Cocamide DEA may be Sodium lauryl ether sulfate CAS 15826-16-1 used as foaming agents. (SLES): 12% w/w; Cocamide DEA: Foam produced by SLES Ethanolamine (DEA), 3 CAS 68603-42-9 and Cocamide DEA may be % w/w; used as carrier for Water: 85% w/w chemicals having anionic or non-ionic charge, (i.e. detergents, aqueous dispersions of several polymers) FOAMING AGENT #4 Dimethyl benzyl Cationic BAC may be used to Composition: ammonium chloride: produce foam that may act Benzalkonium chloride CAS 8001-54-5 as a carrier for cationic (BAC): 50% w/w; dispersions of cationizing Water: 50% w/w. agents for dyeing processes.

[0035] According to at least one embodiment, the composition of the present invention further comprises at least one booster, which can be used to enhance the chemicals present in the composition and/or provide other benefits to the overall treatment process, for instance by shortening the treatment time.

[0036] Another aspect of the present invention relates to a foam composition that can be safely used to treat garments, where industrial laundry personnel can visually inspect the garment during the dyeing process without posing the safety issues present in known spraying applications. According to at least one embodiment of the present invention, the foam composition allows for the door of the washing machine to be opened at any time during the process for inspections and to check on the garments. (See FIG. 2, 3). Similar inspections are not feasible on systems based on aerosols, where personnel could be exposed to toxic chemicals through inhalation of small droplets of water contaminated with the chemical agents.

[0037] Another advantage of the present invention is the versatility it affords in terms of possible treatments on garments. The examples described in greater detail below are understood to be exemplary and are provided to emphasize the variety of images and treatments achievable using the present method.

EXAMPLES

[0038] The present invention provides versatility in terms of possible treatments on garments. The examples described in greater detail below are understood to be exemplary and are provided to emphasize the variety of images and treatments achievable using the present method.

Example 1: Stonewashed Denim

[0039] Materials and Methods:

[0040] Table 3 contains the materials used throughout the experiment.

TABLE-US-00003 TABLE 3 Materials used Material Supplier Model Lot # Laser equipment Sei Laser, Italy Flexi denim — Foam generating module Kemin Textiles s.r.l., San Marino Prototype (See FIG. 1) — Washing Machine OMI, Italy LCF 16 ST — Denim garment (co 67%; poly Advance Denim, China QA149L5-5 Deep — 22%; vis 9.5%; ly 1.5%) blue L ATB 710 Kemin Textiles s.r.l., San Marino — 1901117806 Fortres GSL Kemin Textiles s.r.l., San Marino — 1807109646 Citric Acid Anhydrous Kemin Textiles s.r.l., San Marino — 1812111252 Foaming Agent #1 Kemin Textiles s.r.l., San Marino — — Tween 20 Industria Chimica Panzeri, Italy 8693 Tween 80 Industria Chimica Panzeri, Italy 37061 Special White LT Kemin Textiles s.r.l., San Marino — 1901118677 Hydrogen Peroxide 30% Garmon, San Marino — 1904083

[0041] Denim garments, five garment samples at 700 grams each, were treated with laser equipment (mode 01hs, resolution: 150.000 dpi on X-axis; 9.000 dpi on Y-axis) to mimic visual effects, such as strikes and lines on the denim. In order to achieve stonewashing with foam and cellulase, the garments were treated in the washing machine with an aqueous solution comprising: ATB 710 (liquid cellulase formulation able to perform abrasion at room temperature) 30 g/L; Fortres GSL (a dispersing agent based on non-ionic surfactants, added mainly to limit backstaining) 10 g/L; citric acid anhydrous (to achieve pH 6.0) 0.4 g/L; and Foaming agent #1 18 g/L. Foaming agent #1 was prepared according to the example shown in Table 2.

[0042] The composition was prepared and within 5 minutes of the initiation of the garment treatment, 700 grams of the foam (per kg of garment) were injected into the washing machine. The treatment with foam was performed in the washing machine for 45 minutes.

[0043] At the end of the treatment with the foam composition, the part of foam that has collapsed was removed. Next, the garments were rinsed. The first rinse was performed with a detergent (Special White LT, 2 g/L) and small amounts of hydrogen peroxide 30% (2 g/L) to remove residues from previous laser and foam treatments. The second rinse was performed with water. The resulting garments had the desired stonewashed appearance (FIG. 4).

TABLE-US-00004 TABLE 4 Illustration of steps executed throughout the experiment and estimated saving in terms of water compared to a traditional process Stonewashed denim Liquor Ratio used in the traditional Water Step Products Dose Time experiment process saving Laser treatment N.A. — — N.A. — Stonewashing ATB 710 (cellulase) 30 g/L 45 min   .sup. 1:0.7 .sup.(1) 1:10 93% Fortres GSL 10 g/L Citric Acid Anhydrous 0.4 g/L Foaming Agent #1 18 g/L Rinse Special White LT 2 g/L 5 min 1:10 1:10  0% Hydrogen Peroxide 30% 2 g/L Rinse Water only — 3 min 1:10 1:10  0% Approximate total volume of water used per Kg of fabric 20.7 Lit 30 Lit Total estimated water saving compared to a traditional process 31% Notes: .sup.(1) 700 grams of solution applied by foam per Kg of fabric

Example 2: Bleaching with NaOCl and Foam on Stonewashed Denim

[0044] Materials and Methods:

[0045] Table 5 contains the materials used throughout the experiment.

TABLE-US-00005 TABLE 5 Materials used Material Supplier Model Lot # Laser equipment Sei Laser, Italy Flexi denim — Foam generating module Kemin Textiles s.r.l., San Marino Prototype (See FIG. 1) — Washing Machine OMI, Italy LCF 16 ST — Denim garment (co 67%; poly Advance Denim, China QA149L5-5 Deep 22%; vis 9.5%; ly 1.5%) blue L ATB 710 Kemin Textiles s.r.l., San Marino — 1901117806 Fortres GSL Kemin Textiles s.r.l., San Marino — 1807109646 Citric Acid Anhydrous Kemin Textiles s.r.l., San Marino — 1812111252 Foaming Agent #1 Kemin Textiles s.r.l., San Marino — — Foaming Agent #2 Kemin Textiles s.r.l., San Marino — 1901115746 Tween 20 Industria Chimica Panzeri, Italy 8693 Tween 80 Industria Chimica Panzeri, Italy 37061 Special White LT Kemin Textiles s.r.l., San Marino — 1901118677 Hydrogen Peroxide 30% Garmon, San Marino — 1904083 Sodium Hypochlorite 14% Garmon, San Marino — B0007829

[0046] Denim garments, five garment samples at 700 grams each, were treated with laser equipment (mode 01hs, resolution: 150.000 dpi on X-axis; 9.000 dpi on Y-axis) to mimic visual effects, such as strikes and lines on the denim. The garments were then treated with foam and liquid cellulase, following the methods described in Example 1. Next, hydroextraction with a centrifuge was performed in order to retain 550 grams of water for each kg of garment (pick-up 55%). The garments were then bleached using a foam and NaOCl treatment; the garments were treated using the same washing machine described above with an aqueous solution comprising: Sodium hypochlorite (NaOCl); 200 g/L; and Foaming agent #2 (80 g/L). Foaming agent #2 was prepared according to the example shown in Table 2.

[0047] The composition was prepared and within 5 minutes of the initiation of the garment treatment, 1200 grams of the foam composition (per kg of garment) was injected into the washing machine. The bleaching process with foam was performed in the washing machine for 20 minutes.

[0048] Following the foam composition treatments, three rinses were performed: the first rinse with water only, the second rinse was performed with a detergent (Special White LT, 2 g/L) and small amounts of hydrogen peroxide 30% (2 g/L) to remove residues from previous laser and foam treatments. The third rinse was performed with water. The resulting garments had the desired appearance (FIG. 5).

TABLE-US-00006 TABLE 6 Illustration of steps executed throughout the experiment and estimated saving in terms of water compared to a traditional process Bleaching with NaOCl and foam on stonewashed denim Liquor Ratio used in the traditional Water Step Products Dose Time experiment process saving Laser treatment — — — N.A. — Stonewashing ATB 710 (cellulase) 30 g/L 45 min   .sup. 1:0.7 .sup.(1) 1:10 93%  Fortres GSL 10 g/L Citric Acid Anhydrous 0.4 g/L Foaming Agent #1 18 g/L Centrifuge — — 2 min .sup.(2) — Bleaching Sodium Hypochlorite 14% 200 g/L 20 min    .sup. 1:1.75 .sup.(3) 1:10 88%  Foaming Agent #2 80 g/L Rinse Water only — 3 min 1:10 1:10 0% Rinse Special White LT 2 g/L 5 min 1:10 1:10 0% Hydrogen Peroxide 30% 2 g/L Rinse Water only — 3 min 1:10 1:10 0% Approximate total volume of water used per Kg of fabric 31.9 Lit 50 Lit Total estimated water saving compared to a traditional process 36.2%   Notes: .sup.(1) 700 grams of solution were applied by foam per Kg of fabric .sup.(2) liquor ratio was 1:0.55 after the centrifuge .sup.(3) 1200 grams of solution per Kg of fabric applied by foam set the liquor ratio to 1:1.75

Example 3: Bleaching with Avol Evanix and Foam

[0049] Materials and Methods:

[0050] Table 7 contains the materials used throughout the experiment.

TABLE-US-00007 TABLE 7 Materials used Material Supplier Model Lot # Laser equipment Sei Laser, Italy Flexi denim — Foam generating module Kemin Textiles s.r.l, San Marino Prototype (See FIG. 1) — Washing Machine OMI, Italy LCF 16 ST — Tumble dryer Lavenda L&TM, Italy ERV77 — Denim garment (co 67%; poly Advance Denim, China QA149L5-5 Deep — 22%; vis9.5%; ly 1.5%) blue L Avol Evanix Kemin Textiles s.r.l., San Marino — 1901100834 Booster OW Kemin Textiles s.r.l., San Marino — 1807112479 Foaming Agent #1 Kemin Textiles s.r.l, San Marino — — Tween 20 Industria Chimica Panzeri, Italy 8693 Tween 80 Industria Chimica Panzeri, Italy 37061 Special White LT Kemin Textiles s.r.l, San Marino — 1901118677 Hydrogen Peroxide 30% Garmon, San Marino — 1904083

[0051] Denim garments, five garment samples at 700 grams each, were treated with laser equipment (mode 01hs, resolution: 150.000 dpi on X-axis; 9.000 dpi on Y-axis) to mimic visual effects, such as strikes and lines on the denim. The garments were then bleached with foam and Avol Evanix through the process of treating the garments in a washing machine with an aqueous solution comprising: Avol Evanix, which is a sodium persulfate activator produced by Kemin Textiles s.r.l., 520 g/L; Booster OW (active substance: sodium persulfate) 86 g/L; and a Foaming agent #1 (24 g/L).

[0052] The composition was prepared and within 5 minutes of the initiation of the garment treatment, 700 grams of the composition (per kg of garment) were injected into the washing machine. The bleaching process with foam was performed in the washing machine for 15 minutes. Next, the garments were inserted into a tumble dryer at 70° C. until dried. Once the garments were dry, the temperature was increased to 90° C. and maintained for 10 minutes.

[0053] Following the foam treatments, two rinses were performed: the first rinse was performed with a detergent (Special White LT, 2 g/L) and small amounts of hydrogen peroxide 30% (2 g/L) to remove residues from previous laser and foam treatments. The second rinse was performed with water. The resulting garments had the desired appearance (FIG. 6).

TABLE-US-00008 TABLE 8 Illustration of steps executed throughout the experiment and estimated saving in terms of water compared to a traditional process Bleaching with Avol Evanix and foam Liquor Ratio used in the traditional Water Step Products Dose Time experiment process saving Laser treatment — — — N.A. — Pre-treatment Avol Evanix 520 g/L 15 min   .sup. 1:0.7 .sup.(1) 1:10 93% Booster OW 86 g/L Foaming Agent #1 24 g/L Tumble drying .sup.(2) — — — — — — Rinse Special White LT 2 g/L 5 min 1:10 1:10  0% Hydrogen Peroxide 30% 2 g/L Rinse Water only — 3 min 1:10 1:10  0% Approximate total volume of water used per Kg of fabric 20.7 Lit 30 Lit Total estimated water saving compared to a traditional process 31% Notes: .sup.(1) 700 grams of solution were applied by foam per Kg of fabric .sup.(2) drying temperature: 70° C., then the temperature was increased to 90° C. for 10 minutes

Example 4: Bleaching with Avol Act and Sodium Hypochlorite

[0054] Materials and Methods:

[0055] Table 9 contains the materials used throughout the experiment.

TABLE-US-00009 TABLE 9 Materials used Material Supplier Model Lot # Laser equipment Sei Laser, Italy Flexi denim — Foam generating module Kemin Textiles s.r.l., San Marino Prototype (See FIG. 1) — Washing Machine OMI, Italy LCF 16 ST — Denim garment (co 67%; poly Advance Denim, China QA149L5-5 Deep 22%; vis 9.5%; ly 1.5%) blue L Avol ACT Kemin Textiles s.r.l., San Marino — 1811108799 Foaming Agent #1 Kemin Textiles s.r.l., San Marino — — Tween 20 Industria Chimica Panzeri, Italy 8693 Tween 80 Industria Chimica Panzeri, Italy 37061 Foaming Agent #2 Kemin Textiles s.r.l., San Marino — 1901115746 Special White LT Kemin Textiles s.r.l., San Marino — 1901118677 Hydrogen Peroxide 30% Garmon, San Marino — 1904083 Sodium Hypochlorite 14% Garmon, San Marino — B0007829

[0056] Denim garments, five garment samples at 700 grams each, were treated with laser equipment (mode 01hs, resolution: 150.000 dpi on X-axis; 9.000 dpi on Y-axis) to mimic visual effects, such as strikes and lines on the denim. Garments were treated with an application of Avol Act (NaOCl booster) by treating the garments in a washing machine with an aqueous solution comprising: Avol Act (a booster for sodium hypochlorite based on a quaternary ammonium compound) 100 g/L; and Foaming agent #1 (6 g/L).

[0057] The composition was prepared and within 5 minutes of the initiation of the garment treatment, 600 grams of the foam composition (per kg of garment) was injected into the washing machine. The application was performed in the washing machine for 15 minutes.

[0058] Next, the garments were bleached using sodium hypochlorite according to the following process: garments were treated in the washing machine with an aqueous solution comprising: Sodium hypochlorite 14% (250 g/L); Foaming agent #2 (100 g/L).

[0059] The composition was prepared and within 5 minutes of the initiation of the garment treatment, 1200 grams of the foam composition (per kg of garment) was injected into the washing machine. The application was performed in the washing machine for 30 minutes.

[0060] Following the treatment with the foam composition, three rinses were performed. The first rinse was performed with water. The second rinse was performed with a detergent (Special White LT, 2 g/L) and small amounts of hydrogen peroxide (2 g/L) to remove residues of chemicals from previous cycles. The third rinse was performed with water. The resulting garments had the desired appearance (FIG. 7).

TABLE-US-00010 TABLE 10 Illustration of steps executed throughout the experiment and estimated saving in terms of water compared to a traditional process Bleaching with Avol ACT and sodium hypochlorite Liquor Ratio used in the traditional Water Step Products Dose Time experiment process saving Laser treatment — — — N.A. — Pre-treatment Avol ACT 100 g/L 15 min   .sup. 1:0.6 .sup.(1) 1:10 94%  Foaming Agent #1 6 g/L Bleaching Sodium Hypochlorite 14% 250 g/L 30 min   .sup. 1:1.8 .sup.(2) 1:10 88%  Foaming Agent #2 100 g/L Rinse Water only — 3 min 1:10 1:10 0% Rinse Special White LT 2 g/L 5 min 1:10 1:10 0% Hydrogen Peroxide 30% 2 g/L Rinse Water only — 3 min 1:10 1:10 0% Approximate total volume of water used per Kg of fabric 31.8 Lit 50 Lit Total estimated water saving compared to a traditional process 36.4%   Notes: .sup.(1) 600 grams of solution were applied by foam per Kg of fabric .sup.(2) 1200 grams of solution per Kg of fabric applied by foam set the liquor ratio to 1:1.8

Example 5: Dyeing with Pigments CPD (Cold Pigment Dyeing) and Foam

[0061] Materials and Methods:

[0062] Table 11 contains the materials used throughout the experiment.

TABLE-US-00011 TABLE 11 Materials used Material Supplier Model Lot # Laser equipment Sei Laser, Italy Flexi denim — Foam generating module Kemin Textiles s.r.l., San Marino Prototype (See FIG. 1) — Washing Machine OMI, Italy LCF 16 ST — RTD white garments Advance Denim, China — — Geopower PFD Extra Kemin Textiles s.r.l., San Marino — 1902114698 Foaming Agent #1 Kemin Textiles s.r.l., San Marino — — Tween 20 Industria Chimica Panzeri, Italy 8693 Tween 80 Industria Chimica Panzeri, Italy 37061 Black BL Kemin Textiles s.r.l., San Marino — 1807113933 Linex Surf Kemin Textiles s.r.l., San Marino — 1901102627

[0063] White garments (ready-to-dye), five garment samples at 700 grams each, were treated using 2% owf (on the weight of the fabric) of an enzymatic formulation (Geopower PFD Extra) containing amylase and cellulase, at 50° C. for 15 minutes, liquor ratio 1:10, in order to remove the sizing starch from the fabric. A rinse with water was performed, followed by an hydroextraction (about 550 grams of water were left for each kg of fabric).

[0064] Next, the garments were treated in a washing machine with an aqueous solution comprising: Black BL (pigment) 6 g/L; and Foaming agent #1 (24 g/L).

[0065] The composition was prepared and within 5 minutes of the initiation of the garment treatment 1250 grams (per kg of garment) were injected into the washing machine. The application was performed in the washing machine for 15 minutes, followed by hydroextraction (about 800 grams of water are left for each Kg of fabric).

[0066] The garments were then treated with a foaming composition comprising a fixing agent. The garments were treated in the washing machine with an aqueous solution comprising: Linex Surf (cationizing agent/fixing agent) 80 g/L; and Foaming agent #1 (100 g/L).

[0067] The foaming composition containing a fixing agent was prepared and within 5 minutes of the initiation of the garment treatment, 1400 grams of the composition (per kg of garment) were injected into the washing machine. The application was performed in the washing machine for 10 minutes.

[0068] Following these treatments, two rinses were performed to remove residues of chemicals from previous cycles. The resulting garments had the desired appearance (FIG. 8).

TABLE-US-00012 TABLE 12 Illustration of steps executed throughout the experiment and estimated saving in terms of water compared to a traditional process Dyeing with pigments CPD (cold pigment dyeing) and foam Liquor Ratio used in the traditional Water Step Products Dose Time experiment process saving Pre-treatment Geopower PFD Extra 2% owf 15 min 1:10 1:10 0% Centrifuge — — 2 min .sup.(1) — Dyeing with pigments Black BL 6 g/L 15 min  .sup. 1:1.8 .sup.(2) 1:10 87%  Foaming Agent #1 24 g/L Centrifuge — — 2 min .sup.(3) — Pigment fixation Linex Surf 80 g/L 10 min  .sup. 1:2.2 .sup.(4) 1:10 86%  Foaming Agent #1 100 g/L Rinse Water only — 3 min 1:10 1:10 0% Rinse Water only — 3 min 1:10 1:10 0% Approximate total volume of water used per Kg of fabric 32.7 Lit 50 Lit Total estimated water saving compared to a traditional process 34.6%   Notes: .sup.(1) final liquor ratio was 1:0.55 .sup.(2) 1250 grams of solution applied by foam per Kg of fabric set the liquor ratio to 1:1.8 .sup.(3) final liquor ratio was 1:0.8 .sup.(4) 1400 grams of solution per Kg of fabric applied by foam set the liquor ratio to 1:2.2

Example 6: Dyeing with Direct Dyes OVD (Old Vintage Dyeing) and Foam

[0069] Materials and Methods:

[0070] Table 13 contains the materials used throughout the experiment.

TABLE-US-00013 TABLE 13 Materials used Material Supplier Model Lot # Laser equipment Sei Laser, Italy Flexi denim — Foam generating module Kemin Textiles s.r.l., San Marino Prototype (See FIG. 1) — Washing Machine OMI, Italy LCF 16 ST — Hydro-extractor CO.ME.VI, Italy ZP40 — RTD white garments Advance Denim, China — — Geopower PFD Extra Kemin Textiles s.r.l., San Marino — 1902114698 Foaming Agent #1 Kemin Textiles s.r.l., San Marino — — Tween 20 Industria Chimica Panzeri, Italy 8693 Tween 80 Industria Chimica Panzeri, Italy 37061 Black Deep C-D Kemin Textiles s.r.l., San Marino — 1901115576 FST 34 Kemin Textiles s.r.l., San Marino — 1902110496

[0071] White garments (ready-to-dye), five garment samples at 700 grams each, were treated using 2% owf (on the weight of the fabric) of an enzymatic formulation (Geopower PFD Extra) containing amylase and cellulase, at 50° C. for 15 minutes, liquor ratio 1:10, in order to remove the sizing starch from the fabric. A rinse with water was performed, followed by hydroextraction (about 550 grams of water were left for each kg of fabric).

[0072] Next, the garments were treated with an application of dyestuff with foam. The garments were treated in a washing machine with an aqueous solution comprising: Black Deep C-D (direct dye) 10 g/L; and Foaming agent #1 (80 g/L).

[0073] For each kg of garment, 1,550 gr of foam deriving from the above-mentioned solution was injected into the washing machine within 5 minutes. The application was performed in the washing machine for 15 minutes, followed by hydroextraction (about 1000 grams of water were left for each kg of fabric).

[0074] The garments were then treated with a foam composition that contained a fixing agent. The garments were treated in the washing machine with an aqueous solution comprising: FST 34 (fixing agent) 60 g/L; and Foaming agent #1 (80 g/L).

[0075] The foaming composition containing a fixing agent was prepared and within 5 minutes of the initiation of the garment treatment and 1600 grams of the foaming composition was injected into the washing machine. The application was performed in the washing machine for 10 minutes.

[0076] Following this treatment, two rinses were performed in order to remove residues of chemicals from previous cycles. The resulting garments had the desired appearance (FIG. 9).

TABLE-US-00014 TABLE 14 Illustration of steps executed throughout the experiment and estimated saving in terms of water compared to a traditional process Dyeing with direct dyes OVD (old vintage dyeing) and foam Liquor Ratio used in the traditional Water Step Products Dose Time experiment process saving Pre-treatment Geopower PFD Extra 2% owf 15 min 1:10 1:10 0% Centrifuge — — 2 min .sup.(1) — Dyeing with direct dye Black Deep C-D 10 g/L 15 min  .sup. 1:2.1 .sup.(2) 1:10 84%  Foaming Agent #1 80 g/L Centrifuge — — 2 min .sup.(3) — Dye fixation FST34 60 g/L 10 min  .sup. 1:2.6 .sup.(4) 1:10 84%  Foaming Agent #1 80 g/L Rinse Water only — 3 min 1:10 1:10 0% Rinse Water only — 3 min 1:10 1:10 0% Approximate total volume of water used per Kg of fabric 33.2 Lit 50 Lit Total estimated water saving compared to a traditional process 33.6%   Notes: .sup.(1) final liquor ratio was 1:0.55 .sup.(2) 1550 grams of solution applied by foam per Kg of fabric set the liquor ratio to 1:2.1 .sup.(3) final liquor ratio was 1:1 .sup.(4) 1600 grams of solution per Kg of fabric applied by foam set the liquor ratio to 1:2.6

Example 7: Bleaching with Peroxidase-Based Products and Foam

[0077] Materials and Methods:

[0078] Table 15 contains the materials used throughout the experiment.

TABLE-US-00015 TABLE 15 Materials used Material Supplier Model Lot # Laser equipment Sei Laser, Italy Flexi denim — Foam generating module Kemin Textiles s.r.l., San Marino AFM15 — Washing Machine OMI, Italy LCF 16 ST — Tumble dryer Lavenda L&TM, Italy ERV77 — Hydro-extractor CO.ME.VI, Italy ZP40 — Denim garment (co 67%; poly Advance Denim, China QA149L5-5 Deep — 22%; vis 9.5%; ly 1.5%) blue L ATB710 Kemin Textiles s.r.l., San Marino — 1901117806 Fortres GSL Kemin Textiles s.r.l., San Marino — 1807109646 Citric Acid Anhydrous Kemin Textiles s.r.l., San Marino — 1812111252 Acetic Acid Merck, Germany — K32690263-345 Foaming Agent #1 Kemin Textiles s.r.l., San Marino — — Tween 20 Industria Chimica Panzeri, Italy 8693 Tween 80 Industria Chimica Panzeri, Italy 37061 Foaming Agent #2 Kemin Textiles s.r.l, San Marino 1901115746 Peroxidase (Novozym 59127) Novozymes, Denmark — OQ70001201 Hydrogen Peroxide 30% Garmon, San Marino 1904083

[0079] Denim garments, five garments at 700 gram each, were treated with laser equipment (mode 01hs, resolution: 150.000 dpi on X-axis; 9.000 dpi on Y-axis) to mimic visual effects, such as strikes and lines on the denim. The garments were then treated with foam and liquid cellulase, following the methods described in Example 1.

[0080] The composition was prepared and within 5 minutes of the initiation of the garment treatment, 700 grams of the foam (per kg of garment) were injected into the washing machine. The treatment with foam was performed in the washing machine for 45 minutes.

[0081] At the end of the treatment with the foam composition, the part of foam that has collapsed is removed. Next, garments were rinsed. The first rinse was performed with water, in order to remove residues of chemicals from previous treatment, at a temperature of 28° C., for 3 minutes and rotation of 27 rpm. The second rinse was performed with hydrogen peroxide 30%, 1 g/L, to remove residues from previous laser and foam treatments, for 10 minutes, at the temperature of 40° C. and 27 rpm of rotation. Hydrogen peroxide had also the function of acting synergistically with the peroxidase to perform bleach in a subsequent step. The rinses were followed by an hydroextraction with a centrifuge, in order to obtain a pick-up of 100% (1000 grams of water were left for each Kg of fabric).

[0082] Next, the garments were treated in a washing machine with an aqueous solution comprising: peroxidase-based product (See Table 9), 7 g/L; Acetic Acid, 0.5 g/L; and Foaming agent #2, 100 g/L.

[0083] The composition comprising the two products mentioned above was prepared and, within 5 minutes of the initiation of the garment treatment, 800 grams of the foam per kg of fabric were injected into the washing machine. The treatment with foam was performed in the washing machine for 20 minutes at a temperature of 28° C., pH=4.5 and rotation speed of 27 rpm.

[0084] Next, a rinse with water was performed, in order to remove residues of chemicals from previous treatments, at a temperature of 28° C., for 3 minutes and rotation of 27 rpm. The rinse was followed by an hydroextraction with a centrifuge, in order to have a pick-up of 55% (550 grams of water are left for each Kg of fabric). Next, the garments were treated in a tumble dryer at a temperature of 70° C. for 40 minutes. The resulting garments had the desired appearance (FIG. 10).

TABLE-US-00016 TABLE 16 Illustration of steps executed throughout the experiment and estimated saving in terms of water compared to a traditional process Bleach with peroxidase-based product and foam Liquor Ratio used in the traditional Water Step Products Dose Time experiment process saving Laser treatment — — — N.A. — Stonewashing ATB 710 (cellulase) 30 g/L 45 min   .sup. 1:0.7 .sup.(1) 1:10 93% Fortres GSL 10 g/L Citric Acid Anhydrous 0.4 g/L Foaming Agent #1 18 g/L Rinse Water only — 3 min 1:10 1:10  0% Rinse Hydrogen peroxide 30% 1 g/L 3 min 1:10 1:10  0% Centrifuge — — 3 min .sup.(2) — Enzymatic bleach Peroxidase-based product 7 g/L 20 min   .sup. 1:1.8 .sup.(3) 1:10 92% Acetic Acid 0.5 g/L Foaming Agent #2 100 g/L Rinse Water only — 3 min 1:10 1:10  0% Centrifuge — — 4 min .sup.(4) — Drying — — — — — — Approximate total volume of water used per Kg of fabric 31.5 Lit 50 Lit Total estimated water saving compared to a traditional process 37% Notes: .sup.(1) 700 grams of solution applied by foam per Kg of fabric .sup.(2) final liquor ratio was 1:1 .sup.(3) 800 grams of solution per Kg of fabric applied by foam set the liquor ratio to 1:1.8 .sup.(4) final liquor ratio was 1:0.55

[0085] The present invention provides enhanced productivity compared to existing systems based on sprays. The example described below is understood to be exemplary and is provided to emphasize the advantage in terms of productivity compared to existing methods aimed to save water consumption.

Example 8: Foam Production

[0086] The prototype schematized in FIG. 1 was modified substituting the peristaltic pump with a membrane pump with an adjustable flow rate (maximum 20 lit/min). A solution consisting of 15 g/L of Foaming agent #1 was prepared according to the example shown in Table 2. The modified prototype produced roughly 20 liters of foam in 18 seconds using one liter of the solution. The same volume of solution required 215 seconds to be sprayed using a Nimbus spraying system from Garmon (spray nozzle orifice diameter=0.1 mm). Both systems were connected to the same compressed air pipeline (6 bar). The adoption of pumps with increased flow-rate allows increasing significantly the volume of foam produced per unit of time, also reducing significantly the dose of foaming agent needed.

TABLE-US-00017 TABLE 17 Time required to transfer one liter solution into washing machine adopting different techniques and concentrations of foaming agent Measured time Theoretical Concentration to transfer 1 liter time to achieve of Foaming of solution into a 1:1 liquor agent #1 the washing ratio with 50 (See Table 2) Application machine Kg of garments Foam density 30 g/L By Foam 62 sec. 52 min ~0.07 g/ml 25 g/L By Foam 32 sec. 27 min ~0.06 g/ml 20 g/L By Foam 20 sec. 17 min ~0.05 g/ml 15 g/L By Foam 18 sec. 15 min ~0.05 g/ml 10 g/L By Foam 20 sec. 17 min ~0.05 g/ml 15 g/L Nimbus (spray) 215 sec.  2 h, 59 min.sup.(1) n.a. Note: .sup.(1)Nimbus system is suitable only for small loads of fabric.

[0087] Another aspect of the present invention relates to the process for making the foaming composition. According to at least one embodiment, as depicted in FIG. 11-12, the foam generating module, or foam generator, has a T-junction with two inlets and one outlet. The first inlet includes a liquid solution pumped to the T-junction. The second inlet includes compressed air pumped to the T-junction. The outlet takes the combination of the liquid solution and the compressed air and urges the combination through an outlet that includes a foam generating element, and then into a washing drum that has the textiles to be treated. These elements will be described in detail below.

[0088] The first inlet includes a liquid mixture that is mechanically pumped to the T-junction. The liquid mixture includes water, a foaming agent, and the chemical treatment intended to treat the textiles. The liquid mixture or solution is held is a vessel such as a flask. The liquid mixture is then pumped from the vessel to the T-junction via a pump. This pump is preferably a peristaltic pump which is more sterile because it does not need extra valves or seals to function. One example of a suitable peristaltic pump is the Digital Peristaltic Pump PV from Bram Dosing Systems. The pump may also be any other pump with or without an adjustable flow rate, a suitable venturi device, or a pulse pump if higher flow rates are needed for larger washing machines.

[0089] The second inlet is a line for compressed air. Ambient air is pulled in and compressed in an air compressor. The compressed air is preferably compressed to about 6 bar, and urged through a flow rate regulator. An example of a preferred flow rate regulator is the RFO-346 by Camozzi which has a nominal pressure of 6 bar.

[0090] The liquid mixture or solution of the first inlet and the compressed air of the second inlet are introduced in the T-junction. The T-junction may also be replaced by a venturi suction device. In certain applications, both the T-junction and the pump may be replaced by a venturi suction device. The solution and the air are mixed and are then urged out of the outlet of the T-junction by the pressure of the solution from the pump and the pressure of the air from the compressor. The outlet includes a PVC pipe or cartridge filled with stainless steel sponges. The cartridge is preferably about 32 cm long and about 4.5 cm internal diameter. The liquid solution and air mixture are urged through the sterile stainless steel sponges which creates a tremendous amount of turbulence within the mixture as it is urged through the sponges, which then creates the foam that is delivered to the textiles within the wash drum.

[0091] The present invention solves the problem of excessive use of water caused by nebulization systems. In nebulization systems, small droplets of water are sprayed inside the washing machines. The water droplets, which act as a carrier of chemicals, can easily escape from the washing machines if they are not adequately sealed, or if operators open the door of the washing machine to perform checks on the textiles. To avoid leaks of fog containing the treatment chemicals, the washing machines require technical modifications to ensure proper sealing. The inventors have addressed these problems through the present invention, which provides for a foam application that can remain inside the washing machine.

[0092] Further, the potential inhalation of chemicals by employees remains a serious problem during garment treatment processes, particularly where employees frequently may be exposed to toxic fumes when checking on the garments during the conventional industrial laundering process. This concern can be addressed by the present invention, e.g. through structural modifications on washing machines, as described herein. For instance, the any traditional washing machine could be easily adapted in order to work with the new system and coupled with an external module that has the purpose to produce foam with different densities, in different amounts, and with different amounts of chemicals dispersed, by simply adjusting the pressures of the first or second inlets, and by varying the density and amount of stainless steel sponge. No special or expensive dedicated washing machines (sealed washing machines) are required. The cost of the hardware is consistently lower than other system that have the aim to save water and energy. The module of the present invention may also be designed to fit internally in and integrally with a washing machine.

[0093] It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

[0094] For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0095] It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0096] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

[0097] It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.