Continuous batch tunnel washer and method

Abstract

A method of washing fabric articles in a tunnel washer includes moving the fabric articles from the intake of the washer to the discharge of the washer through first and second sectors that are a pre-wash zone. In the pre-wash zone, liquid is counter flowed in the wash interior along a flow path that is generally opposite the direction of travel of the fabric articles. The fabric articles are transferred to a main wash zone, and a washing chemical is added to the main wash zone. At about the same time, counter flow is reduced or stopped. The main wash zone can be heated as an option. After a period of time (for example, between about 20 and 120 seconds) counter flow is resumed or increased. In the wash zone, this is considered an intermediate rinse. After the wash zone(s), the increased counter flow after chemical treatment amounts to a pre-rinse. This pre-rinse ensures that the fabric articles are substantially free of soil or the majority of any soil and substantially free of chemicals when they are transferred to an extractor for final removal of excess water. A final rinse (second rinse) is conducted during extraction of excess water.

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, and a plurality of modules that divide the interior into a plurality of zones that include pre-wash, main wash and rinse zones;   b) moving the fabric articles from the intake to one or more modules that are a pre-wash zone;   c) counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in step “b”;   d) transferring the fabric articles to a main wash zone;   e) adding a washing chemical to the main wash zone;   f) reducing counter flow during step “e”;   g) increasing counter flow after step “f” to define a first rinse in a rinse zone;   h) using an extractor to remove excess water after step “g”; and   i) during step “h” rinsing the fabric articles to define a second rinse.   
   
   
       2 . The method of  claim 1  further comprising spraying the rinse water into the extractor in step “i”. 
   
   
       3 . The method of  claim 1  wherein in step “f” counter flow is substantially stopped. 
   
   
       4 . The method of  claim 3  wherein the extractor has a rotary drum with a side wall and an end wall, and wherein the spray has a spray pattern that extends across the drum sidewall. 
   
   
       5 . The method of  claim 3  wherein the rinse fluid of step “i” is sprayed from a position outside the drum. 
   
   
       6 . The method of  claim 1  further comprising the step of heating the main wash zone before step “g”. 
   
   
       7 . The method of  claim 1  further comprising transferring heat to the main wash zone in step “f”. 
   
   
       8 . The method of  claim 1  wherein counter flow is reduced in step “f” for a time period that is less than about five minutes. 
   
   
       9 . The method of  claim 1  wherein counter flow is reduced in step “f” for a time period that is less than about three minutes. 
   
   
       10 . The method of  claim 1  wherein counter flow is reduced in step “f” for a time period that is less than about two minutes. 
   
   
       11 . The method of  claim 1  wherein the counter flow is reduced in step “f” for a time period of between about twenty and one hundred twenty (20-120) seconds. 
   
   
       12 . The method of  claim 1  wherein in step “f” the added washing chemical is heated to a temperature of between about 140 and 190 degrees Fahrenheit. 
   
   
       13 . The method of  claim 1  wherein the counter flow in step “g” the counter flow extends through multiple of the modules. 
   
   
       14 . The method of  claim 1  wherein the main wash zone includes multiple modules. 
   
   
       15 . The method of  claim 1  wherein the rinse zone includes multiple modules. 
   
   
       16 . The method of  claim 1  wherein the main wash zone and rinse zone each include multiple modules. 
   
   
       17 . The method of  claim 1  wherein the main wash zone and rinse zone include the same modules. 
   
   
       18 . 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 divide the interior into a plurality of zones that include pre-wash, main wash and rinse zones;   b) moving the fabric articles from the intake to one or more modules that are a pre-wash zone;   c) counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in step “b”;   d) transferring the fabric articles to a main wash zone;   e) adding a washing chemical to the main wash zone;   f) after the washing chemical reaches chemical equilibrium, resuming counter flow and wherein counter flow does not substantially dilute the washing chemical in step “e” until after a selected time interval;   g) increasing counter flow after step “f” to define a first rinse in a rinse zone;   h) using an extractor to remove excess water after step “g”; and   i) during step “h” rinsing the fabric articles to define a second rinse.   
   
   
       19 . The method of  claim 18  further comprising spraying the rinse water into the extractor in step “i”. 
   
   
       20 . The method of  claim 18  wherein in step “f” counter flow is substantially stopped. 
   
   
       21 . The method of  claim 20  wherein the extractor has a rotary drum with a side wall and an end wall, and wherein the spray has a spray pattern that extends across the drum sidewall. 
   
   
       22 . The method of  claim 20  wherein the rinse fluid of step “i” is sprayed from a position outside the drum. 
   
   
       23 . The method of  claim 18  wherein the rinse fluid of step “i” is sprayed from a position outside of the drum. 
   
   
       24 . The method of  claim 18  further comprising adding starch to the fabric articles during step “h”. 
   
   
       25 . The method of  claim 18  further comprising adding starch to the fabric articles after step “h”. 
   
   
       26 . The method of  claim 24  wherein the starch is sprayed. 
   
   
       27 . The method of  claim 25  wherein the starch is sprayed.