Continuous batch tunnel washer and method

Abstract

A method of washing fabric articles in a tunnel washer that includes moving the fabric articles from the intake of the washer to the discharge of the washer and through multiple modules or sectors. Liquid can be counter flowed in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles. A dual use zone includes multiple of the modules or sectors. In a dual use zone, a module or modules can be used to both wash and thereafter rinse the fabric articles. While counterflow rinsing, the flow rate can be maintained at a selected flow rate or flow pressure head. One or more booster pumps can optionally be employed to maintain constant counterflow rinsing flow rate or constant counterflow rinsing pressure head. During rinsing, extracted water or reuse water is first used to rinse followed by a clean water rinse.

Claims

1. A method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of: a) providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid; b) moving the fabric articles from the intake to the modules and then to the discharge in sequence; c) wherein in step b multiple of the modules define a dual use zone having modules that function initially as wash modules and later as rinse modules; d) adding a washing chemical to the volume of liquid in the dual use zone; e) washing the fabric articles after step d in multiple modules that are said dual use modules: f) after a selected time period, counter flowing a rinsing liquid in multiple said dual use zone modules and along a flow path that is generally opposite the direction of travel of the fabric articles in steps b and c; g) extracting water from the fabric articles with an extractor that is downstream of the modules after step f; and h) wherein step f includes rinsing using a first volume of water that is reuse water that was extracted from fabric articles in step g followed by a second volume of water that is clean water and not the extracted water of step g.

2. The method of claim 1 wherein one or more booster pumps are provided, each pump boosting counter flowing rinsing liquid flow rate at a different one of said plurality of modules.

3. The method of claim 2 wherein the one or more booster pumps are spaced apart by more than one module.

4. The method of claim 2 wherein the one or more booster pumps discharge liquid into a module that is a dual use module wherein textile articles are both washed and rinsed.

5. The method of claim 4 wherein liquid flow in the dual use module is substantially halted for a time period that is less than about five minutes.

6. The method of claim 4 wherein liquid flow in the dual use zone is substantially halted for a time period that is less than about three minutes.

7. The method of claim 4 wherein liquid flow in the dual use zone is substantially halted for a time period that is less than about two minutes.

8. The method of claim 4 wherein liquid flow in the dual use zone is substantially halted for a time period that is between about twenty and one hundred twenty (20-120) seconds.

9. The method of claim 2 wherein each booster pump discharges counter flowing fluid into a module that is not a module closest to the discharge.

10. The method of claim 1 wherein the counter flow of step f is at a flow rate of between about 20 and 300 gallons per minute.

11. The method of claim 1 wherein the counter flow of step f is at a flow rate of between about 25 and 220 gallons per minute.

12. The method of claim 1 wherein the counter flow of step f is at a flow rate of between about 35 and 105 gallons per minute.

13. The method of claim 1 wherein a volume of liquid in the plurality of modules is heated to a temperature of between about 100 and 190 degrees Fahrenheit.

14. A method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of: a) providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior, wherein multiple of the modules are dual use modules that define a dual use zone having modules that each function initially as wash modules and later as rinse modules; b) moving the fabric articles from the intake to the discharge; c) adding a washing chemical to the dual use zone wherein the dual use modules in the dual use zone wash the fabric articles with a combination of water and said washing chemical; d) after a selected time interval and after step c, rinsing the fabric articles by counter flowing rinse liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in step b; e) extracting water from the fabric articles with an extractor that is downstream of the modules after step d; f) transmitting the extracted water of step e with a first flow line from the extractor to a reuse water tank; and g) wherein said rinse liquid in step d includes: 1) counter flowing a first volume of water through the dual use modules to affect a first rinse of the fabric articles, wherein said first volume of water is from the reuse tank followed by 2) counter flowing a second volume of water that is clean water and not extracted water through the dual use modules to effect a second rinse.

15. The method of claim 14 further comprising boosting a flow rate of step g so that the flow rate is maintained at a desired value.

16. The method of claim 15 wherein multiple booster pumps are employed in order to boost the flow rate.

17. The method of claim 16 wherein there are a plurality of modules in between the booster pumps.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

(2) FIG. 1 is a schematic diagram showing a first embodiment of the apparatus of the present invention;

(3) FIG. 2 is a schematic diagram showing a second embodiment of the apparatus of the present invention; and

(4) FIG. 3 is a schematic diagram showing a third embodiment of the apparatus of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(5) FIG. 1 shows a schematic diagram of the textile washing apparatus of the present invention, designated generally by the numeral 10. Textile washing apparatus 10 provides a tunnel washer 11 having an inlet end portion 12 and an outlet end portion 13. In FIG. 1, tunnel washer 11 provides a number of modules 14-25. The plurality of modules 14-25 can include modules which can be dual use modules in that the dual use modules function as both main wash and rinse modules. The total number of modules 14-25 can be more or less than the number of modules shown in FIGS. 1-2.

(6) Inlet end portion 12 can provide a hopper 26 that enables the intake of textiles or fabric articles to be washed. Such fabric articles, textiles, and goods to be washed can include clothing, linens, towels, and the like. An water extractor device 30 can be positioned next to the outlet end portion 13 of tunnel washer 11. Flow lines are provided for adding water and/or chemicals (e.g., cleaning chemicals, detergent, etc.) to tunnel washer 11.

(7) When the fabric articles, goods and/or linens are initially transferred into modules 14-25, an interrupted counterflow for a part of the batch transfer time is used. By using this interrupted counterflow for part (e.g., between about fifty and ninety percent (50-90%), preferably about seventy-five percent (75%)) of the batch transfer time, each module 14-25 performs as a separate batch. Batch transfer time can be defined as the time that the fabric articles/linens remain in a module before transfer to the next successive module.

(8) By halting counterflow when some of the modules are functioning as main wash modules, this creates essentially a standing bath for the washing process and allows the cleaning chemicals to perform their function fully without any dilution from a counterflow of fluid within the tunnel washer 11. Counterflow returns for the last part (e.g., last 25%) of the transfer time and is pumped at a higher rate (e.g., between about three hundred and four hundred percent (300%-400%)) of the normal rate. This higher rate is thus higher than the flow rate of prior art machines using full time counterflow. For example, prior art machines with full time counterflow typically employ a flow rate of between about ten and thirty (10-30) gallons (38-114 liters) per minute and create a full rinsing hydraulic head. The present invention eliminates the need to have additional modules dedicated to the function of rinsing and finishing as required in the prior art, thus saving cost and floor space.

(9) FIGS. 1 and 2 show first and second embodiments of the apparatus of the present invention illustrated generally by the numerals 10 (FIG. 1) and 10A (FIG. 2). FIGS. 1-2 also illustrate embodiments of the method of washing fabric articles in a continuous batch tunnel washer. Textile washing apparatus 10, 10A each provide tunnel washer 11 or 11A having inlet end portion 12 and outlet end portion 13. Tunnel washer 11 interior 31 is divided into sections or modules. These modules can include modules 14-25 (FIG. 1). These modules can include additional modules or fewer modules such as modules 14-21 of FIG. 2.

(10) In FIG. 1, water extracting device 30 (e.g., press or centrifuge) is positioned next to discharge 27. The extraction device 30 is used to remove excess water or extracted water from the fabric articles after they have been discharged from the tunnel washer 11 and placed within the extractor 30. Extraction devices 30 are commercially available. An extraction device 30 could be used with the embodiments of FIG. 1 or 2.

(11) The modules 14-25 in FIG. 1 or the modules 14-21 of FIG. 2 can include dual use modules. If a module is a dual use module, it is used for both standing bath washing and counterflow rinsing. The modules 14-25 can thus include pre-wash modules, main wash modules, and rinse modules, with some modules being dual wash modules. For example, modules 14-24 can be dual use modules in FIG. 1. Modules 14-20 can be dual use modules in FIG. 2.

(12) When functioning as a main wash or standing bath, counterflow via lines 28, 36 can be slowed or halted for a time. Then, counterflow resumes during rinsing. In FIG. 1, a fresh water storage tank 29 can provide fresh water via flow line 38. Module 25 can be injected with a selected sour solution and/or a selected finishing solution that is delivered via inflow line 32. Flow line 32 transmits the sour solution and/or finishing solution from tank 37 to module 25. Finishing solutions can be any desired or known finishing solution, for example a starch solution or an antimold agent.

(13) An extracted water tank 33 can be positioned to receive extracted water from an extraction device 30. Flow line 34 is a flow line that transfers water from extraction device 30 to tank 33. Water contained in tank 33 can be recycled via flow lines 35 or 36. A sour or finishing solution can be injected at module 25 via inflow tank 37. Fresh water can be added to tank 33 via freshwater inflow line 38. Flow line 35 is a recirculation line having pump 39 that transfers extracted water from tank 33 to hopper 26. Another recirculation flow line is flow line 36. The flow line 36 transfers extracted water from tank 33 to flow line 28 and then to interior 31 of tunnel washer 11, beginning at module 24 and then by counterflow to modules 23, 22, 21, 20, 19, 18, 17, 16, 15 in sequence. For the continuous batch washing apparatus 10 of FIG. 1, twelve modules are shown as an example. The modules 14, 25 can have a temperature of around 40 degrees Celsius. The modules 15, 16 can have a temperature of around 70 degrees Celsius. The module 19 can have a temperature of around 50 degrees Celsius.

(14) In the example of FIG. 1, each of the modules 14-24 can be dual use modules. In FIG. 1, each of the modules 14-24 could thus be part of both a wash function and then a rinse function. In FIG. 1, rinse liquid counterflows via flow line 28 to module 24, then to module 23, then to module 22.

(15) The flow lines 35 and 36 can be provided with pumps in order to boost pressure in those flow lines. Pump 39 is provided in flow line 35 for transmitting water to hopper 26 via flow line 35. Pump 40 is provided in flow line 36 for transmitting water to tank 37 or flow line 28 for counterflow rinsing.

(16) The flow line 36 splits at tee fitting 47 into flow line 28 and flow line 32. The flow line 32 is a flow line that carries re-circulated extracted water from tank 33 to tank 37. Inflow tank 37 can be used to supply sour or finishing chemicals via flow line 32 to the final module 25, which can be a finish module.

(17) Flow line 28 is a re-circulation flow line that enters module 24 and then flows water in counterflow to modules 23, 22 in sequence. A booster pump 41 receives flow from flow line 28. The booster pump 41 then discharges its flow via flow line 43 to module 21. Flow then transfers from module 21 to module 20 then to module 19 and then to module 18 where it transfers via flow line 43 to booster pump 42. Booster pump 42 then discharges its counter flowing rinsing fluid via flow line 44 to module 17 and then to module 16 and then to module 15. At module 15, the rinsing fluid can be discharged via discharge valve 45. A discharge valve 46 can also be provided for module 14. The booster pumps 41, 42 ensure that counter flowing rinsing fluid is maintained at a selected flow rate, flow volume and flow pressure. The booster pumps 41, 42 ensure that a desired pressure head is maintained.

(18) In the example of Table 1 below, a batch size can be between about fifty (50) and three hundred (300) pounds (23-136 kg) of fabric articles, lines or textiles. Total water consumption could be about 0.62 gallons per pound (5.1 liters/kg) of cotton textile fabric articles. Total water consumption could be about 0.64 gallons per pound (5.3 liters/kg) for poly cotton fabric articles.

(19) FIG. 2 shows a second or alternate embodiment of the apparatus of the present invention, designated generally by the numeral 10A. Textile washing apparatus 10A in FIG. 2 is an eight module machine, providing modules 14, 15, 16, 17, 18, 19, 20, and 21. As with the preferred embodiment of FIG. 1, the textile washing apparatus 10A provides a tunnel washer 11A having an inlet end portion 12 and an outlet end portion 13. The outlet end portion 13 can provide a water extraction device 30, not shown in FIG. 2 for purposes of clarity.

(20) Inlet end portion 12 provides hopper 26 for enabling fabric articles such as linen articles to be added to the interior 31 of tunnel washer 11A. A discharge 27 receives effluent from the last or final module 21 where it enters an extractor 30 (not shown). Fluid is then discharged via flow line 51 for collection and extracted water tank 33. Pump 50 receives flow from extracted water tank 33. Pump 50 then transfers fluids from extracted water tank 33 to pulse flow tank 54. A valve 53 can be provided in flow line 52. Pump 55 can be a variable speed pump that transfers fluid from pulse flow tank 54 to flow line 70 and then to module 20. Flow line 70 can be provided with valve 71 and flow meter 72. Line 70 discharges at flow line discharge 73 into module 20.

(21) Pump 56 transmits fluid from pulse flow tank 54 to flow line 67 and then to final module 21. The flow line 67 can be provided with a tee fitting 87. Flow line 67 discharges at flow line discharge 69 into module 21. Flow line 67 can be provided with valve 68. Flow line 86 communicates with flow line 67 at tee fitting 87. Flow line 86 can be provided with valve 88 and flow meter 89. The flow line 86 discharges into hopper 26 as shown in FIG. 2.

(22) Pulse flow tank 54 can receive make up water from flow line 57. Flow line 57 can be valved with valve 58 to receive influent water from a user's water supply. Flow line 57 can be provided with flow meter 59. Flow line 57 can also be provided with a back flow preventer or check valve 60.

(23) Pump 62 can be a variable speed pump. Pump 62 receives flow from module 18 through suction line 61. Pump 62 then transmits fluid through flow line 63 to module 17 at flow line discharge 66. Flow line 63 can be provided with valve 64 and flow meter 65.

(24) A number of chemical injectors or chemical inlets 74-82 can be provided for transmitting a selected chemical into a selected module of the modules 14-21. Examples are shown in FIG. 2. Module 14 has a chemical inlet 74 for adding or injecting alkali. Module 14 is also provided with a chemical inlet 75 for adding or injecting detergent. Similarly, chemical inlets 74 and 75 are provided on module 15. Module 16 is provided with chemical inlet 76 and 77 which enables injection or addition of peracetic acid and peroxide respectively. Modules 17 and 18 can be fitted with chemical inlets 78 for the addition or injection of bleach. Modules 19 and 20 are fitted with chemical inlet 79 that can be used to inject any selected chemical. Module 21 is a final module that can receive finishing chemicals such as a sour, softener, and bacteriostat. The chemical inlet 80 designates sour injection. The chemical inlet 81 designates softener injection. The chemical inlet 82 can be for injecting a bacteriostat. Multiple steam inlets 83 can be provided as shown in FIG. 2. In FIG. 2, a steam inlet 83 is provided for each of the modules 14-21.

(25) Flow line 84 receives flow from module 14. Pump 90 then pumps flow received from flow line 84 into flow line 85 which then discharges into hopper 26 as shown in FIG. 2. A flush zone is thus created in hopper 26 by water entering the hopper 26 from flow line 85 as well as water entering hopper 26 from flow line 86 as shown in FIG. 2. The effect of these flow lines 85, 86 is to transform the hopper 26 and first module 14 into a process area where fabric articles, linen or fabrics are quickly wetted and initially cleaned. A flow line 91 can be provided for counterflow of one module (e.g. module 20) to the previous module (e.g. module 19). Flow lines 91 can be provided for each module 15, 16, 17, 18, 19, 20 as seen in FIG. 2.

(26) Table 1 show examples of water flow rates (in gallons per minute and liters per minute) for light soil and heavy soil for either embodiment (FIG. 1 or FIG. 2). Water flow time (examples) are shown in seconds. Exemplary weights (linen) are shown in pounds and in kilograms. Fresh water consumption is shown for light soil linen in gallons per pound (e.g., 0.1-0.8 gallons per pound) and liters per kilogram (e.g., 1.7-6.7 liters per kilogram for heavy soil linen).

(27) TABLE-US-00002 TABLE 1 Water Volumes Linen Classification Light Soil Heavy Soil GPM LPM GPM LPM Water Minimum 25 95 50 190 Flow Rate Middle 105 398 120 455 Maximum 220 833 220 833 Seconds Seconds Water Minimum 10 10 Flow Time Middle 30 30 Maximum 360 360 Pounds KG Pounds KG Linen Minimum 50 23 50 23 Weight Middle 110 50 110 50 Maximum 300 137 300 137 Gal/Lb L/Kg Gal/Lb L/Kg Fresh Minimum 0.1 0.8 0.2 1.7 Water Middle 0.3 2.5 0.4 3.3 Consumption Maximum 0.8 6.7 0.8 6.7

(28) FIG. 3 shows a third embodiment of the apparatus of the present invention designated generally by the numeral 10B. In FIG. 3, there can be seen a tunnel washer 11B having an inlet end portion 12 and an outlet or discharge end portion 13. The tunnel washer 11B has an intake hopper 26. The tunnel washer 11B can have a plurality of modules such as eight modules shown in FIG. 3 and referenced by the numerals 14, 15, 16, 17, 18, 19, 20, and 21.

(29) Fresh water tank 92 can be positioned next to reuse water tank 94. Another tank that is provided is an extracted water tank 93 that receives water from an extractor 140 (e.g., press or centrifuge). Extractor 140 can be used to remove water from fabric articles, linen, or clothing or other items to be cleaned and after discharge from final module 21. Such extractors are commercially available and well-known in the art. Pump 96 discharges fluid from extracted water tank 93 into flow line 97. The flow line 97 can be provided with a valve 98. The flow line 97 discharges into reuse tank 94 as shown.

(30) Flow line 99 is a discharge flow that discharges fluid from reuse tank 94. Flow line 99 can have valve 139. Flow line 100 is a flow line that discharges water from fresh water tank 92. Flow line 100 can have valve 138. A tee fitting 101 is provided for joining line 99 into line 100. The flow line 103 is downstream of tee fitting 101 and communicates with variable speed pump or pump 102. The pump 102 discharges fluid into flow line 104 which discharges into module 20. Flow line 104 can be provided with a valve 105 and flow meter 106.

(31) In various embodiments, counterflow rinsing first uses the extracted water from tanks 93 and 94 followed by clean water from tank 92. Flow line 107 is a flow line that receives fresh water from tank 92 and pump 108. The flow line 107 discharges into hopper 26. The flow line 107 can be provided with valve 109 and flow meter 110. Flow line 111 is a flow line that produces counterflow from module 18 to module 17. The flow in line 111 is boosted (i.e., increased pressure or head) by pump 112 which can be a variable speed pump. The line 111 has valve 113 and flow meter 114. By providing the pump 112, increased flow rate or pressure or increased head can be provided to the counter current or counter flow which begins at module 20 and then progresses to module 19, then to module 18, then to module 17, then to module 16, then to module 15, then to module 14. Flow line 115 is a flow line that conveys fluid from module 14 to hopper 26. Pump 116 can be provided in flow line 115.

(32) Counterflow rinsing begins at module 20, then to module 19 and then to module 18. A pressure drop can occur from module 20 to module 18. Thus, pressure for counterflow rinsing is increased by pump 112 which transfers counterflow rinse from module 18 to module 17 via flow line 111.

(33) A plurality of chemical inlets 117 can be provided, preferably one or more for each module 14-21 as shown. Additionally, steam inlets 118 can be provided for heat transfer, preferably one for each module 14-21 as shown. Steam inlets 118 can discharge into counterflow lines 121-125 for each module 14-21. Module 21 provides a drain 119. Flow line 95 has valve 120 for transferring fluid from module 21 to extracted water tank 93. Arrow 141 schematically illustrates transfer of articles from module 21 to extractor 140. Line 142 is a flow line for carrying extracted water from extractor 140 to extracted water tank 93.

(34) In FIG. 3, there are a number of counterflow lines 121-125. The counterflow line 121 enables counter flow of rinse fluid from module 20 to module 19. The counterflow line 122 enables counter flow of rinse fluid from module 19 to module 18. The counterflow line 123 enables counter flow of rinse fluid from module 17 to module 16. The counterflow line 124 enables counter flow of rinse fluid from module 16 to module 15. The counterflow line 125 enables counter flow of rinse fluid from module to module 14. A drain line 126 and valve 127 are provided for draining fluid from module 15 and for transferring that drain fluid to a sewer 130. Drain line 126 can also be provided with valve 128. Counterflow line 125 can be provided with valve 145. When valve 145 is closed, fluid can drain from module 15 to sewer 130. When valve 145 is open, counterflow line 125 enables counter flow of rinse fluid from module 15 to module 14.

(35) Drain line 129 enables draining of fluid from module 14. The drain line 129 can be provided with valve 131. The drain line 129 can be used to drain fluid from module 14 into a sewer 130. Flow line 132 enables fresh water to be added to fresh water tank 92 from fresh water source 143. The flow line 132 can be provided with valve 133 and flow meter 134. The flow line 135 enables fresh water from source 144 to be added to the final module 21. The flow line 135 can be provided with valve 136 and flow meter 137. Line 135 enables flow of fresh water from source 144 to module 21.

(36) The following is a list of parts and materials suitable for use in the present invention.

(37) TABLE-US-00003 PARTS LIST Part Number Description 10 textile washing apparatus 10A textile washing apparatus 10B textile washing apparatus 11 tunnel washer 11A tunnel washer 11B tunnel washer 12 inlet end portion 13 outlet end portion 14 module 15 module 16 module 17 module 18 module 19 module 20 module 21 module 22 module 23 module 24 module 25 module 26 hopper 27 discharge 28 flow line 29 fresh water tank 30 water extraction device 31 interior 32 flow line 33 tank, extracted water tank 34 flow line 35 flow line 36 flow line 37 inflow tank 38 freshwater flow line 39 pump 40 pump 41 booster pump 42 booster pump 43 flow line 44 flow line 45 valve 46 valve 47 tee fitting 50 pump 51 flow line 52 flow line 53 valve 54 pulse flow tank 55 pump 56 pump 57 flow line 58 valve 59 flow meter 60 back flow preventer/check valve 61 suction line 62 pump 63 flow line 64 valve 65 flow meter 66 flow line discharge 67 flow line 68 valve 69 flow line discharge 70 flow line 71 valve 72 flow meter 73 flow line discharge 74 chemical inlet (alkali) 75 chemical inlet (detergent) 76 chemical inlet (peracetic acid) 77 chemical inlet (peroxide) 78 chemical inlet (bleach) 79 chemical inlet 80 chemical inlet (sour) 81 chemical inlet (softener) 82 chemical inlet (bacteriostat) 83 steam inlet 84 flow line 85 flow line 86 flow line 87 tee fitting 88 valve 89 flow meter 90 pump 91 flow line 92 fresh water tank 93 extracted water tank 94 reuse water tank 95 flow line 96 pump 97 flow line 98 valve 99 flow line 100 flow line 101 tee fitting 102 pump/variable speed pump 103 flow line 104 flow line 105 valve 106 flow meter 107 flow line 108 pump 109 valve 110 flow meter 111 flow line 112 pump/variable speed pump 113 valve 114 flow meter 115 flow line 116 pump 117 chemical inlet 118 steam inlet 119 drain 120 valve 121 counterflow line 122 counterflow line 123 counterflow line 124 counterflow line 125 counterflow line 126 drain line 127 valve 128 valve 129 drain line 130 sewer 131 valve 132 flow line 133 valve 134 flow meter 135 flow line 136 valve 137 flow meter 138 valve 139 valve 140 extractor 141 arrow 142 flow line 143 fresh water source 144 fresh water source 145 valve

(38) All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.

(39) The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.