CROSS-REFERENCE TO RELATED APPLICATIONS Priority is hereby claimed to US Provisional Patent Application 60/313, 101, filed 17 August 2001.

US Provisional Patent Application 60/313,101, filed 17 August 2001, is incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not applicable REFERENCE TO A"MICROFICHE APPENDIX" Not applicable BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to continuous batch-type washing machines. More particularly, the present invention relates to an improvement in a continuous batch-type washing machine that features an improved multi-loop water reuse arrangement. Even more particularly, the present invention relates to an improved continuous batch-type washing machine apparatus wherein there are three water"loops"in addition to a fresh water loop. The additional"loops"include reuse water, rinse water, and treated water.

The system of the present invention provides significant energy and water conservation thus reducing operating costs.

2. General Background of the Invention In machines that are known in the industry as"tunnel washers", each of a succession of drums or baskets is mounted for rotation within a housing that includes a bath of liquor during each washing cycle. Each drum is contained within an individual compartment or cell of a succession of cells forming the tunnel. Goods to be cleaned

(such as cloth goods) are transferred sequentially from a drum into the next successive drum. Intermediate washing cycles are provided for causing liquor to circulate through each drum compartment and maintaining a desired level of liquor making up the bath during each washing cycle. Thus, successive batches of cloth goods may be fed via a hopper into the leading drum at the front end and removed from the trailing drum at the rear end of the passage and through intermediate drums.

Depending on the design and arrangement of the individual machines, water may be circulated through one or more drum compartments at the front portion of the machine for pre-wash and soap detergents and pH conditioning chemicals may be added to the water circulated through several of the following drum compartments in the main wash stage of the machine. The goods may then be bleached, unused, or conditioned rinsed with water circulated through one or more succeeding drum compartments. Water is circulated through the final drum compartments. In some cases, liquor may not pass entirely through the machine from one end to the other. For example, certain of the different types of liquor may be prevented from co-mingling.

Various patents have been issued for continuous tunnel washer batch-type washing machines and methods for operating them. The assignee of the present invention, Pellerin Milnor Corporation of Kenner, Louisiana is the assignee of several such"tunnel washer"patents that are listed in Table 1 below: TABLE 1 PELLERIN MILNOR PATENTS PATENT # ISSUE DATE TITLE 4,236, 393 02 Dec. 1980 Continuous Tunnel Batch Washer 4,363, 090 07 Dec. 1982 Process Control method and Apparatus 4,485, 509 04 Dec. 1984 Continuous Batch Type Washing Machine and Method for Operating Same 5,211, 039 18 May 1993 Continuous Batch Type Washing Machine 5,454, 237 03 Oct. 1995 Continuous Batch Type Washing

Machine Other patents have issued that relate generally to the concept of a laundry machine or tunnel type commercial duty washing machine: TABLE 2 WASHER PATENTS PATENT # ISSUE DATE TITLE 3,103, 802 17 Sept. 1963 Washing Machine 3,336, 768 22 Aug. 1967 Washing Machines 3,406, 543 22 Oct. 1968 Washing Machines, Notably Laundry Machines 3,509, 744 5 May 1970 Washing Machines, and Especially Laundry Machines 3,550, 406 29 Dec. 1970 Machine for Washing Laundry 3,693, 639 26 Sept. 1972 Apparatus for Treating Articles With Liquid Treatment Media 3,995, 458 7 Dec. 1976 Laundry Machine 4,020, 659 3 May 1977 Tunnel-Type Commercial-Duty Washing Machine 4,109, 493 29 Aug. 1978 Drum-Type Machine for the Treatment of Textile Material Tunnel washers are typically very large machines that are employed in commercial service. Users can include hotels and hospitals, for example.

Tunnel washers consume a large amount of water on a yearly basis. They also require a substantial amount of energy for heating. On a yearly basis, water and energy costs can be hundreds of thousands of dollars for a large installation.

BRIEF SUMMARY OF THE INVENTION The present invention provides an improved tunnel washer apparatus that can be energy and water saving. The system of the present invention can feature three water loops in addition to the fresh water loop. The additional loops include reuse water, rinse water, and treated water.

The improved tunnel washer of the present invention provides preferably five

stages or zones: wet out, first wash zone, second wash zone, main rinse, and fine rinse/finishing.

The water loops of the present invention help minimize the consumption of fresh water by blending a selected, appropriate quantity of the four types of water that are provided by the four loops. The blending formulation may be selected based upon the type of linen in the various tunnel stages and the dynamic quality of each type of water in the various loops.

The present invention thus provides an improved ratio metric flow arrangement and tunnel washer system.

Process water from a wash zone is treated in line and recirculated in both wash zones of the apparatus. The primary flow in the second wash zone is recirculated. The only makeup water can be used to replace the rejects from the filtration components.

The water treatment uses an oxidizer to breakdown organic material and a centrifugal separation unit to remove suspended solids.

By directly reusing this water, the water remains at the programed temperature, thereby dramatically reducing the heating energy required. Normally this water is sent to a sewer or to a centralized water treatment system, losing energy and adding significant cost to the installed system.

Conventional attempts to use central water treated water have not been successful because of the temperature and chemical incompatibility.

In the second wash zone, the dilution rate is increased over conventional designs because of the recirculated process liquor flowing at up to 300% of the conventional flow rate.

The purpose of increased flow rate is to improve the washing effect by increasing the dilution effect, as illustrated in the following Table 3.

TABLE 3 % of Main Rinse Water Main Rinse Finish of Fine Rinse Fresh Total Fresh Total Fresh Total Fresh Total Fresh Total Water Water Water Water Water Water Water Water Water Water Conven-10 50 65 65 65 65 100 100 5 5 tonal Ration 10 50 0 46-10 300 40-40-0 0- 6580 8020

Sensors (e. g. turbidity sensors) are preferably used to measure the quality of the wash water zone. Upon reaching a selected limit, fresh water is increased to dilute the dissolved solids level. This water is then treated to improve its quality. Ozone, alone or in combination with other oxidizers, can be used directly in the pumped treated water stream to break down organic compounds. Alternative and/or replacement oxidizers can include chlorine dioxide or ultraviolet treatment. These can be used in place of or in addition to ozone. It is optional to filter this treated flow using an inline filter to further clarify the treated water. A cyclone separator or like filter can be used to remove suspended solids which can be reduced to preferably less than between about 50 to 500 parts per million, preferably about 100 parts per million.

The last"module"or cell is configured to primarily use water from the main rinse section as an overflow fine rinse. This water is recovered in a tank and used as reuse water for part of the flushing water in the wet out (inlet) zone.

For operating the present invention, fresh water is introduced into the last cell or module of the main rinse zone after start-up stabilization. The water counter flows to the first module in the rinse zone. The water is collected in a tank. The rate of flow in the rinse zone is selected based on the type of goods that are being washed. The rate of flow can be varied depending on the soil levels in different batches of goods. For example, when heavy soil follows light soil, the rinse zone water may be increased to address higher detergent and alkali levels. Additionally, the level of dissolved solids is measured in the tank. If the level exceeds a selected, programmed limit, the fresh water flow rate is increased. A computer can be used with the sensors to monitor water quality. A plurality of modulating valves can be computer controlled to automatically maintain water quality levels for water that is added to the apparatus at the various cells or at stages

that include multiple cells.

The first wash zone reuses the highest percentage of the rinse water when compared to the flow into the second wash zone and the final rinse zone. The first wash zone can be programmed to blend fresh water if required.

The second wash zone principally reuses its own treated water, blended with approximately 20% rinse water and 10% fresh water. These values can be programmable, generally about 0 to about 65% rinse and about 0 to about 65% fresh water.

The present invention thus provides an improved continuous tunnel batch washer apparatus that includes an elongated outer housing having opposed ends, an inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion for washing goods.

A plurality of lateral walls divides at least a portion of the housing into a plurality of cells. The housing contains a plurality of drums, preferably one drum for each cell.

Each of the drums is rotatably supported within the water containing portion of the frame.

Each drum has an inlet for enabling goods to be washed to enter the drum and a drum outlet for enabling the goods to exit the drum.

A fresh water header is provided for supplying water to the water containing portion of the housing.

A rinse water flow line receives water that has been discharged from the water containing portion of the housing, for reuse.

A treated water flow line receives water that has been discharged from the water containing portion of the housing, for reuse.

Water treatment is provided for removing solid waste material from water that has been discharged from the water containing portion of the housing. Such treated water is transmitted to the treated water flow line.

Water flowing in the treated water flow line is supplied to the second wash zone.

Water flowing in the rinse zone is supplied to the first and/or second wash zones, and optionally the fine rinse and finish zone. Water flowing in the reuse flow line is used in the"wet out"or intake zone. The fresh water header can optionally supply water to the wet out (intake) zone, the first and second wash zones, the main rinse zone and the fine rinse and finish zone.

BRIEF DESCRIPTION OF THE DRAWINGS

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: Figure 1 is a schematic flow diagram of the preferred embodiment of the apparatus of the present invention.

Figure 2 includes some preferred ranges for water.

DETAILED DESCRIPTION OF THE INVENTION In Figure 1, the tunnel batch washer apparatus of the present invention is designated generally by the numeral 20. Tunnel batch washer 20 has an inlet end portion 18 (e. g. hopper) and an outlet end portion 19. A housing 20A is defined by a plurality of cells 1-12. There can be more cells. The maximum number is preferably (but not limited to) 32. The cells 1-12 can be defined by lateral dividing walls of the housing 20A. The housing 20A provides a water containing portion. One or more of the cells 1-12 can provide drums that are rotatable. Chutes on each drum transfer goods from one drum to the next drum. Thus, each drum has an inlet and an outlet so that goods to be washed can enter and exit each drum.

One or more of the above listed Pellerin Milnor patents in Table 1 discloses the general concept of a tunnel batch washer that includes a housing, a water containing portion, a plurality of cells, drums contained within the cells, and chutes associated with each of the drums for transferring clothes or other goods to be cleaned from one drum to the next drum. Each of the above listed patents contained in the Tables 1 and 2 is hereby incorporated herein by reference.

The housing 20A has five (5) zones or stages: wet out first wash, second wash, main rinse, and fine rinse/finish. Next to inlet 18 there is provided a wet out zone 13. The wet out zone 13 provides a hopper or chute that allows clothing, linens, cloth goods or other articles to be washed to be added to the housing 20A. Thus cell number 1 defines the"wet out"or inlet zone 13. Cells 2,3, 4 and 5 define a first wash zone 14. Cells 6,7, 8 and 9 define a second wash zone 15. A main rinse zone 16 is defined by cells 10 and 11. A fine rinse and finish zone 17 is defined by the cell 12.

During operation, the goods to be cleaned move in the direction of arrow 21, entering the housing 20A at inlet 18 and exiting the housing 20A at outlet 19. In general,

water flow in housing 20A is in the opposite direction of arrow 21. The goods that exit outlet 19 can be transported to a press, the details of which are known in the art and therefore not disclosed herein. Pressed water from the press or other extracting device is contained in a tank 22. The arrow 23 schematically illustrates the transfer of goods from housing 20A to a known press so that water can be removed from the linens or other washed goods and collected at press water return tank 22.

The apparatus 20 of the present invention provides four different main headers or flow lines. These include fresh water header 24, rinse water flow line 49, treated water flow line 50 and reuse water flow line 51.

The various headers and flow lines 24,49, 50,51 supply water to different stages or zones of the housing 20A. For example, treated water flowing in the flow line 50 is reused in the second wash zone 15. Rinse water flowing in the flow line 49 is optionally used in the first wash zone 14, second wash zone 15, main rinse zone 16, and fine rinse and finish zone 17. Reuse water flowing in line 51 is the water collected from the press water return tank 22, main rinse 16 and fine rinse and finish 17. This reuse water flows in line 51 to the wet out or inlet stage 13. Fresh water is optionally supplied to the wet out zone 13 using fresh water header 24, first and second wash zones 14,15, main rinse zone 16, and fine rinse and finish zone 17.

A plurality of modulating valves 25-34 are provided for enabling selected control of the percentage of water from the various headers or flow lines 24,49, 50,51 that are added to selected stages. For example, at the wet out stage 13, reuse water and fresh water are supplied through the respective headers 51 and 24. Modulating valve 25 controls the flow of reuse water in line 51. Valve 26 controls fresh water in line 24 that is added to the wet out zone 13. Modulating valve 27 controls the flow of fresh water in header 24 while valve 28 controls rinse water in flow line 49 that is to be added via lines 24,49 to the first wash zone 14. Modulating valves 29,30 and 31 control the flow of water that is added to the second wash zone 15. The valve 29 controls the flow of fresh water from header 24 that is added to the second wash zone 15. The valve 30 controls the flow of rinse water from flow line 49 that is added to the second wash zone and the valve 30 controls the flow of treated water from flow line 50 that is added to the second wash zone. A computer can be used to control the valves 25-34, and pumps that drive flow in the lines 24,49, 50 and 51. Modulating valves 25-34 can be models commercially

available.

The main rinse zone 16 can be supplied by fresh water received from header 24 as controlled by modulating valve 32. The fine rinse and finish zone 17 is supplied with a combination of fresh water from header 24 as controlled by valve 33 and rinse water supplied by flow line 49 as controlled by valve 34.

A tank 35 is provided for receiving water as it exits housing 28 from main rinse zone 16 and fine rinse and finish zone 17. The tank 35 has tank sections 36,37. A tank 38 is provided for receiving flow from the second wash zone via second wash zone flow line 53. Flow line 54 is provided for transferring water from the main rinse 16 and to tank 35. Flow line 55 is provided for transferring water from the fine rinse and finish 17 stages to tank 35. Downstream of second wash zone 15, flow line 53 has a branch portion that includes two valves 46 and 47. These valves 46 and 47 control the flow of water to tank 38, or to be discharged for example, to a sewer. The tank 38 communicates with flow line 60 for supplying water through valve 48 to pump 42. The water flowing in line 60 is water that is to be treated and then reused. Treatment can include centrifugal separator combination cleaner 43, ozone injection 44, carbon filtration, ultraviolet treatment, and/or reverse osmosis filtration. Flow line 61 schematically indicates the discharge of reject solids from separator 43 to a suitable discharge site.

Tank 35 also receives the press water return from tank 22 via flow line 56. The press water return flow line 56 receives flow from pump 39 and pump suction line 57.

Water that is received in tank 35 can be tested for quality using a sensor such as turbidity sensor 45. Water quality can also be tested for total suspended solids being preferably less than 100 parts per million. Suction line 58 receives flow from tank 35 and communicates with pump 40 for pumping water in flow line 49. Some of the water in tank 35 can also be received by suction line 59 for transfer to pump 41 to be pumped as reuse water in line 51 for transfer to the wet out zone 13.

A turbidity sensor 45 can determine the quality of water in tanks 35 and 38.

Water quality can also be tested for total suspended solids being preferably less than 100 parts per million. A determination is made of whether to transfer that water to the rinse flow line 49 or to the reuse flow line 51. If the turbidity sensor 45 at tank 3 5 indicates that the water in tank 35 is too dirty for use as rinse water, the pump 41 will be activated and the pump 40 will be deactivated so that only reuse flow line 51 receives water from tank

35. If the turbidity sensor 45 indicates that the water quality in tank 35 is good enough, pump 41 is deactivated and pump 40 is activated so that the water contained in tank 35 is used in flow line 49 for rinse water.

Flow lines are provided for supplying fluid to the various zones 13-17 after the modulating valves have controlled the percentage of water that flows from various of the different headers or flow lines. For example, the first wash zone flow line 52 receives flow through valves 27 and 28 from either fresh water header 24 or rinse water flow line 49. The second wash zone flow line 53 receives water that passes through valves 29,30 and 31. The valve 29 controls the flow of fresh water, the valve 30 controls the flow of rinse water and the valve 31 controls the flow of treated water. Main rinse flow line 54 receives water directly from header 24 as controlled by valve 32. Fine rinse flow line 55 receives water from valves 33,34 that includes a selective amount of fresh water from header 34 and rinse water from flow line 49.

Computer controls can be programmed to set the ratio of flow for each water loop into each of the 5 zones. These formulas are assigned to a wash classification. When different goods are in adjacent modules, the computer controls can set the water flow and ratios to the program that uses the most fresh water. Additionally, the computer controls can be programmed according to chemical and water loop compatibility setting the formula to the safest chemical formula highest fresh water settings.

Water that exits the wet out zone 13 via flow line 62 is typically waste water that is discarded to a suitable discharge site. Water exiting first wash zone 52 can either be discarded to a suitable discharge site or used as reuse water and added via flow line 63 to reuse flow line 51.

Figure 2 includes some preferred ranges for water for reusing water in various zones. The ranges are about zero to about the amount shown.

PARTS LIST The following is a list of suitable parts and materials for the various elements of the preferred embodiment of the present invention.

PARTS LIST PART NO. DESCRIPTION 1 cell 2 cell

3 cell 4 cell 5 cell 6 cell 7 cell 8 cell 9 cell 10 cell 11 cell 12 cell 13 wet out zone 14 first wash zone 15 second wash zone 16 main rinse zone 17 fine rinse and finish zone 18 inlet 19 outlet 20 tunnel batch washer 20A housing 21 arrow 22 press water return tank 23 arrow 24 fresh water header 25 modulating valve 26 modulating valve 27 modulating valve 28 modulating valve 29 modulating valve 30 modulating valve 31 modulating valve 32 modulating valve 33 modulating valve

34 modulating valve 35 tank 36 tank section 37 tank section 38 tank 39 pump 40 pump 41 pump 42 pump 43 centrifugal separator 44 ozone injector 45 turbidity sensor 46 valve 47 valve 48 valve 49 rinse water flow line 50 treated water flow line 51 reuse water flow line 52 first wash zone flow line 53 second wash zone flow line 54 main rinse flow line 55 fine rinse flow line 56 press water return flow line 57 pump suction line 58 pump suction line 59 pump suction line 60 pump suction line 61 reject solids flow line 62 reject flow line 63 reuse flow line 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.