Washing process in tunnel washers
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1 Leonardo da Vinci Project Sustainability in commercial laundering processes Module 3 Washing process Chapter 3 Washing process in tunnel washers Module 3 Washing Process Chapter 3 Tunnel washers 1
2 Content Basics: Washing process in tunnel washers Water flow Bath exchange Carry-over of liquor Spreading of detergent Mechanical effects Settings (zones) Effects of temperature bleaching Special processes Module 3 Washing Process Chapter 3 Tunnel washers 2
3 Learning targets After finishing this chapter, you will have basic knowledge about the washing process in tunnel washers know several possibilities how to use of bath flow and bath exchange know the problem of the carry-over of the liquor know mechanical effects in tunnel washers know the effects of temperature know several bleaching processes (hydrogenperoxide, perborate, peracetic acids, chlorine) Module 3 Washing Process Chapter 3 Tunnel washers 3
4 Washing technology - important aspects Kind, finish and manufacturing quality of the textiles Kind and amount of soiling Kind of washing machine, construction Water quality Detergents and washing aids Demands on washing quality standard Module 3 Washing Process Chapter 3 Tunnel washers 4
5 Soiling Easily removable e.g. dust, earth Hard removable e.g. oils, fats, small pigments Protein-containing soil Soil to be removed by bleach Module 3 Washing Process Chapter 3 Tunnel washers 5
6 Demands on machinery Possibility to choose temperature Heating of particular zones, heat transfer due to conduction/ carry-over Possibility to vary liquor level Possibilities concerning dosage of detergents Into several compartments Kind of laundry transportation within the tunnel washer Carry-over of liquor Module 3 Washing Process Chapter 3 Tunnel washers 6
7 Characteristics tunnel washers Counterflow principle: Constantly dilution of liquor Corrective: standing bath, bath exchange Liquor level nearly not alterable Low mechanics (oscillating) Diversification of mechanics and cycle time effects all compartments. Module 3 Washing Process Chapter 3 Tunnel washers 7
8 Bath flow settings Current flow Pre wash zone, main wash zone (if bath exchange is applied) Counterflow principle Water flows against textiles Rinsing-zone, main wash zone Standing bath pre wash zone, main wash zone, finish zone Bath exchange Last compartment of main wash, rinsing zone Module 3 Washing Process Chapter 3 Tunnel washers 8
9 Principle of bath flow settings Fresh water in rinsing zone Partly usage in main wash zone Rest for pre wash Module 3 Washing Process Chapter 3 Tunnel washers 9
10 Bath exchange laundry Fresh water flow Pre wash Main wash rinse source: ecolab Module 3 Washing Process Chapter 3 Tunnel washers 10
11 Bath exchange Source: Jensen Gruppe Module 3 Washing Process Chapter 3 Tunnel washers 11
12 Bath exchange Source: Jensen Gruppe Module 3 Washing Process Chapter 3 Tunnel washers 12
13 Bath exchange Alkalinity measurements Source: DIVERSEY LEVER Before first bath exchange Alkalinity Before second Bath exchange After second Bath exchange Module 3 Washing Process Chapter 3 Tunnel washers 13
14 Pre wash with press water Main wash Pre wash tank Module 3 Washing Process Chapter 3 Tunnel washers 14
15 Carry-over of liquor Carry-over by laundry (bound liquor) - Kind of fibre - Construction - Manufacturing quality of the textile Carry over my mechanism of transport (free liquor) - Liquor ratio - Bottom transfer, centre transfer - Perforated/ non-perforated drum wall Module 3 Washing Process Chapter 3 Tunnel washers 15
16 Dosage of detergents Counterflow Dosage Dosage Current flow Laundry Laundry Module 3 Washing Process Chapter 3 Tunnel washers 16
17 Spreading of detergents influence parameters Contruction parameters Kind of drums compartments Bathflow Finish Fresh water inlet Operating parameters Carry-over Residual moisture Load liquor ratios Cycle time Dosage Simple dosage Conductivity measures Time - amount measures (dual) Module 3 Washing Process Chapter 3 Tunnel washers 17
18 Mechanics influence parameters Mechanics is determinated by: Drum diameter Revolutions of drum (amount) Kind of drum revolution (oscillating, rotating) Falling angle Reversing (cycle time interval time) Ribs: form, height, arrangement Load ratio (amount of load) Liquor ratio Module 3 Washing Process Chapter 3 Tunnel washers 18
19 Mechanics influence parameters Parameters Height, Falling Impact speed Liquor flow, liquor turbulences Module 3 Washing Process Chapter 3 Tunnel washers 19
20 Tunnel washer rotation of drum Module 3 Washing Process Chapter 3 Tunnel washers 20
21 Rotating oscillating: comparison Higher mechanics important for some kinds of soiling, e.g. work wear fat from skin, motor oil, mineral oils Linen with soil from food (eggs, pigments, starch, oil, milk, cacao) Module 3 Washing Process Chapter 3 Tunnel washers 21
22 mechanics La Reine des Blanchisseusses Queen of washer Le Petit Journal 1893 Rubbing" of laundry slatting" of laundry Module 3 Washing Process Chapter 3 Tunnel washers 22
23 mechanical effects Components of mechanical action: Rubbing Compression Flow through Rubbing Flow through Rubbing Flow through Compression Compression Oscillating washing action Rotating washing action Module 3 Washing Process Chapter 3 Tunnel washers 23
24 Mechanical effects Advantages of compression in comparison to rubbing? Faster absorption of chemistry Faster dilution of chemistry Less keying of textile`s surface Less generation of pilling No distortion of textiles Rotating wash movement is more effective and more gentle than rubbing. Module 3 Washing Process Chapter 3 Tunnel washers 24
25 Compartments amount of compartments Soaking (optional) 1-2 Pre wash zone 2-4 Main wash zone 3-6 Rinsing zone 2-6 Finishing 1-2 (Dewatering) Module 3 Washing Process Chapter 3 Tunnel washers 25
26 Pre wash - parameters Liquor level intermediate to high Bath flow current flow Intensity of bath flow intermediate Origin of water from rinse zone (2/3), dewatering, eventually cold water Drainage into sewage Amount of detergents high Temperature < 40 C, or higher (depends on kind of soil) Number of compartment, duration 2 to 3 compartments Module 3 Washing Process Chapter 3 Tunnel washers 26
27 Main wash - parameters Liquor level low Bath flow counterflow, bath exchange Intensity of bath flow low Origin of water from rinsing zone (1/3) Drainage from first compartment into sewage Amount of detergents intermediate Temperature high Number of compartment, duration 15 min (disinfection), at least 3 compartments Blended fabric cool down Module 3 Washing Process Chapter 3 Tunnel washers 27
28 Rinsing - Parameter Liquor level Bath flow Intensity of bath flow Origin of water drainage Temperature Number of compartment, duration intermediate to high counterflow, eventually with bath exchange high fresh water, eventually press water from the first compartment of pre wash zone and main wash zone into sewage respectively dropping down, cool down for blended fabrics at least three compartments Module 3 Washing Process Chapter 3 Tunnel washers 28
29 Rinsing in counterflow process Load ratio Liquor ratio Liquor capacity 50 L/kg 2 L/kg 14 L/kg Cycle time Kind of textile at least 1,5 min PES/BW Module 3 Washing Process Chapter 3 Tunnel washers 29
30 Finish - parameters Liquor level Bath flow Intensity of bath flow Origin of water drainage Temperature Number of compartment, duration low standing bath without fresh water, from tanks eventually in tanks low at least one compartment Module 3 Washing Process Chapter 3 Tunnel washers 30
31 Disinfection thermal disinfection chemical-thermal disinfection chemical disinfection temperature 92 C, 10 min 85 C, 15 min for cotton für Baumwolle source: Hychem Temperature and disinfection agent C Cotton and polyester-cotton blended fibre CO und PES/CO und sonstige Fasern disinfection agent Room temperature, 12 hours time Module 3 Washing Process Chapter 3 Tunnel washers 31
32 Allocation of temperature Heating of steam injector Bath exchange Bath exchange Module 3 Washing Process Chapter 3 Tunnel washers 32
33 Allocation of temperature Cool Down for blended materials like PES/CO 3 to 4 K/min Thermal disinfection - Observation of heating and mixing-up rate - Machines with one drum: temperature differences may occur Module 3 Washing Process Chapter 3 Tunnel washers 33
34 Bleaching H 2 O 2, Na-perborate, Na-percarbonate - in main wash zone - temperature 80 to 90 C - dosage 80 to 120 mg/l O 2 - duration 8 to 12 min - ph- value 8 to 12 Peracetic acids - in main wash- or rinse section - temperature 40 to 70 C - Dosage 600 to 250 mg/l O 2 - Duration 20 to 15 min - ph- value 6,5 to 12 - high dosage due to low temperatures and low ph-value Module 3 Washing Process Chapter 3 Tunnel washers 34
35 Bleaching Chlorine - In ultimate or penultimate rinse compartment - Temperature 25 to 30 C - Dosage 250 to 400 mg/l active chlorine - Duration 5 to 8 min - ph- value 9 to 10 Module 3 Washing Process Chapter 3 Tunnel washers 35
36 Usage of press water Krankenhaus Technik, 12/1997 Module 3 Washing Process Chapter 3 Tunnel washers 36
37 Special: Konti cold-wet technique washing procedure Module 3 Washing Process Chapter 3 Tunnel washers 37
38 Cold-wet mechanics principle Use of storage period of laundry for wetting before washing. Dosage of detergents for heavily soiled work wear consequence - Smaller pre-wash zone - Less detergents - Less rinsing water (5-7 L/kg) - Less waste water load Module 3 Washing Process Chapter 3 Tunnel washers 38
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