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.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit of U.S. Provisional Patent Application Ser. No. 62/102,279, filed 12 Jan. 2015; and U.S. Provisional Patent Application Ser. No. 62/059,212, filed 3 Oct. 2014, which are hereby incorporated herein by reference and priority of each is hereby claimed. 
    
    
     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 washers or tunnel washers. More particularly, the present invention relates to an improved method of washing textiles or fabric articles (e.g., clothing, linen) in a continuous batch multiple module tunnel washer wherein the textiles are moved sequentially from one module to the next module. A counter flowing rinse is boosted (e.g., using pumps) to elevate and/or maintain a selected flow rate or flow pressure head. Even more particularly, the present invention relates to a method and apparatus for washing fabric articles in a continuous batch tunnel washer using an improved flow arrangement wherein the pressure head is boosted at selected modules of the multiple modules of the continuous batch tunnel washer using one or more booster pumps that maintain substantially constant pressure of the rinse liquid that is counter flowed. Multiple dual use modules can be employed which provide faster rinsing with high velocity counterflow, more through put with less water usage by recycling water. After a final module, fabric articles can be transferred to a liquid extraction device (e.g., press or centrifuge) that removes excess water. 
     2. General Background of the Invention 
     Currently, washing in a commercial environment is generally conducted with a continuous batch tunnel washer. Such continuous batch tunnel washers are known (e.g., U.S. Pat. No. 5,454,237) and are commercially available (www.milnor.com). Continuous batch washers have multiple sectors, zones, stages, or modules including pre-wash, wash, rinse and finishing zone. 
     Commercial continuous batch washing machines in some cases utilize a constant counterflow of liquor. Such machines are followed by a centrifugal extractor or mechanical press for removing most of the liquor from the goods before the goods are dried. Some machines carry the liquor with the goods throughout the particular zone or zones. 
     When a counterflow is used in the prior art, there is counterflow during the entire time that the fabric articles or textiles are in the main wash module zone. This practice dilutes the washing chemical and reduces its effectiveness. 
     A final rinse with a continuous batch washer has been performed using a centrifugal extractor or mechanical press. In prior art systems, if a centrifugal extractor is used, it is typically necessary to rotate the extractor at a first low speed that is designed to remove soil laden water before a final extract. 
     Patents have issued that are directed to batch washers or tunnel washers. The following table provides examples of such patented tunnel washers, each listed patent of the following table being hereby incorporated herein by reference. 
     
       
         
               
               
               
             
           
               
                 TABLE 
               
               
                   
               
               
                 PATENT NO. 
                 TITLE 
                 ISSUE DATE 
               
               
                   
               
             
             
               
                 4,236,393 
                 Continuous tunnel batch washer 
                 2 Dec. 1980 
               
               
                 4,485,509 
                 Continuous batch type washing 
                 4 Dec. 1984 
               
               
                   
                 machine and method for operating 
               
               
                   
                 same 
               
               
                 4,522,046 
                 Continuous batch laundry system 
                 11 Jun. 1985 
               
               
                 5,211,039 
                 Continuous batch type washing 
                 18 May 1993 
               
               
                   
                 machine 
               
               
                 5,454,237 
                 Continuous batch type washing 
                 3 Oct. 1995 
               
               
                   
                 machine 
               
               
                 US20110296626 
                 Continuous batch tunnel washer 
                 8 Dec. 2011 
               
               
                   
                 and method 
               
               
                 WO2011/153398 
                 Continuous batch tunnel washer 
                 8 Dec. 2011 
               
               
                   
                 and method 
               
               
                 WO 2015/095179 
                 Floor Mat And Particulate Laden 
                 25 Jun. 2015 
               
               
                   
                 Material Washing Apparatus And 
               
               
                   
                 Method 
               
               
                 US 2015/0167221 
                 Floor Mat And Particulate Laden 
                 18 Jun. 2015 
               
               
                   
                 Material Washing Apparatus And 
               
               
                   
                 Method 
               
               
                 8,689,463 
                 Clothes Dryer Apparatus With 
                 8 Apr. 2014 
               
               
                   
                 Improved Lint Removal System 
               
               
                 WO 2014/031757 
                 Washer Extractor Apparatus And 
                 27 Feb. 2014 
               
               
                   
                 Method 
               
               
                 US 2014/0053344 
                 Washer Extractor Apparatus And 
                 27 Feb. 2014 
               
               
                   
                 Method 
               
               
                 US 2014/0053343 
                 Continuous Batch Tunnel Washer 
                 27 Feb. 2014 
               
               
                   
                 And Method 
               
               
                 WO 2014/031625 
                 Continuous Batch Tunnel Washer 
                 27 Feb. 2014 
               
               
                   
                 And Method 
               
               
                 US 2013/0291314 
                 Continuous Batch Tunnel Washer 
                 7 Nov. 2013 
               
               
                   
                 And Method 
               
               
                 US 2013/0213244 
                 Laundry Press Apparatus And 
                 22 Aug. 2013 
               
               
                   
                 Method 
               
               
                 8,370,981 
                 Integrated Continuous Batch 
                 12 Feb. 2013 
               
               
                   
                 Tunnel Washer 
               
               
                 8,365,435 
                 Laundry Press Apparatus And 
                 5 Feb. 2013 
               
               
                   
                 Method 
               
               
                 WO 2013/016103 
                 Laundry Press Apparatus And 
                 31 Jan. 2013 
               
               
                   
                 Method 
               
               
                 US 2013/0025151 
                 Laundry Press Apparatus And 
                 31 Jan. 2013 
               
               
                   
                 Method 
               
               
                 8,336,144 
                 Continuous Batch Tunnel Washer 
                 25 Dec. 2012 
               
               
                   
                 And Method 
               
               
                 US 2012/0304487 
                 Clothes Dryer Apparatus With 
                 6 Dec. 2012 
               
               
                   
                 Improved Lint Removal System 
               
               
                 8,166,670 
                 Clothes Dryer Apparatus With 
                 1 May 2012 
               
               
                   
                 Improved Lint Removal System 
               
               
                 US 2012/0023680 
                 Integrated Continuous Batch 
                 2 Feb. 2012 
               
               
                   
                 Tunnel Washer 
               
               
                 WO 2012/009360 
                 Modulated Air Flow Clothes Dryer 
                 19 Jan. 2012 
               
               
                   
                 And Method 
               
               
                 US 2011/0283557 
                 Modulated Air Flow Clothes Dryer 
                 24 Nov. 2011 
               
               
                   
                 And Method 
               
               
                 US 2011/0225741 
                 Continuous Batch Tunnel Washer 
                 22 Sep. 2011 
               
               
                   
                 And Method 
               
               
                 WO 2011/109371 
                 Washer Extractor And Method 
                 9 Sep. 2011 
               
               
                 US 2011/0209292 
                 Washer Extractor And Method 
                 1 Sep. 2011 
               
               
                 7,971,302 
                 Integrated Continuous Batch 
                 5 Jul. 2011 
               
               
                   
                 Tunnel Washer 
               
               
                 US 2010/0313440 
                 Laundry Press Apparatus And 
                 16 Dec. 2010 
               
               
                   
                 Method 
               
               
                 WO 2010/144715 
                 Laundry Press Apparatus And 
                 16 Dec. 2010 
               
               
                   
                 Method 
               
               
                 WO 2010/124076 
                 Continuous Batch Tunnel Washer 
                 28 Oct. 2010 
               
               
                   
                 And Method 
               
               
                 WO 2009/129362 
                 Continuous Batch Tunnel Washer 
                 22 Oct. 2009 
               
               
                   
                 And Method 
               
               
                 US 2009/0260161 
                 Integrated Continuous Batch 
                 22 Oct. 2009 
               
               
                   
                 Tunnel Washer 
               
               
                 US 2009/0260162 
                 Continuous Batch Tunnel Washer 
                 22 Oct. 2009 
               
               
                   
                 And Method 
               
               
                 US 2009/0255145 
                 Clothes Dryer Apparatus With 
                 15 Oct. 2009 
               
               
                   
                 Improved Lint Removal System 
               
               
                 CN 1553973 
                 Continuous Tunnel Batch Washer 
                 8 Dec. 2004 
               
               
                   
                 Apparatus 
               
               
                 EP 1425455 
                 Continuous Tunnel Batch Washer 
                 9 Jun. 2004 
               
               
                   
                 Apparatus 
               
               
                 US 2003/0110815 
                 Continuous Tunnel Batch Washer 
                 19 Jun. 2003 
               
               
                   
                 Apparatus 
               
               
                 WO 2003/016608 
                 Continuous Tunnel Batch Washer 
                 27 Feb. 2003 
               
               
                   
                 Apparatus 
               
               
                   
               
             
          
         
       
     
     BRIEF SUMMARY OF THE INVENTION 
     The present invention provides an improved method of washing fabric articles in a continuous batch tunnel washer. Embodiments of the method include providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid. 
     Embodiments of the method of the present invention provide a counterflow (or counter flow) of liquid in the washer interior during rinsing including some interrupted counterflow. The counterflow is along a path that is generally opposite the direction of travel of the fabric articles. Booster pumps can be placed at intervals to increase the pressure and/or velocity of counter flowing rinse water. For example, in a twelve (12) module continuous batch washer there can be booster pumps placed at the fourth and eighth modules. 
     At a final module, the fabric articles are transferred via the discharge to a water extraction device or extractor (e.g., press or centrifuge). The extractor is used to remove excess water from the fabric articles after they have been discharged from the continuous batch tunnel washer. 
     For the greatest part of each cycle, processing without counterflow creates standing baths so that chemicals are allowed to do their job without being diluted. Then, for a very short portion of each cycle, high-velocity counterflow is applied, thus providing the first part of the required dilution effect. A second stage of dilution ensures the goods move into far cleaner water every time. Dedicated rinse modules are not required, meaning more production from fewer modules. 
     The counterflow is stopped for about the first 65-75% of each transfer cycle. The entire amount of counterflow water is then pumped at a very fast rate in the final 25-35% of the time remaining. The pumps are preferably high-volume, variable speed inverter-driven so that both flow rate and duration of the counter-flowing water can be fully varied based on goods being processed. The high speed flow gives better rinsing action and uses far less water. 
     Washers of the present invention achieve very low fresh water consumption. For light soil linen, the water consumption is about 0.3 gallons per pound (2.5 liters per kilogram) of linen processed. For most heavy soil linen, the expected water consumption is about 0.5 gallons per pound (4 liters per kilogram). 
     The method and apparatus of the present invention saves water with these features: 
     1) Interrupted Counterflow—Water only flows for rinsing which is about the last 25-35% of each cycle; 
     2) Controlled Flow—Water is delivered by high-volume inverter pumps with vigorous flow that removes suspended soil and uses chemistry faster, with less water; 
     3) Dual-Use Modules—Each module is used for both standing bath washing and counterflow rinsing; and
         4) Full Water Availability—Fresh water and recycled press water are collected in a single tank mounted within the washer frame (e.g., under the load scoop). No external tanks are required.       

     The present invention is able to achieve maximum chemical performance with standing bath washing and high-velocity counterflow rinsing. High-speed water recirculation within the first module allows fast sluicing and wet-down, causing the chemistry to instantly penetrate the soiled linen. 
     After the transfer of the goods, the counterflow is interrupted creating a standing bath with no water flow so that chemistry is not diluted. Chemicals work at full concentration from the start of each bath. Chemicals work faster because of the large cylinder volume and fast intermixing with the goods. 
     Programmable high-volume pumps create a vigorous flow to remove exhausted chemistry and suspended soil effectively. Fixed partitions between each module prevent chemical mixing and leakage. No seals are required between modules. 
     Flow is paused at the start of each cycle to create standing baths without dilution so that chemicals work faster. Counterflow water is pumped at high volume for the very last portion of the cycle. Vigorous flow removes contaminants from fabric articles or linen much more quickly, thus reducing overall cleaning time. All wash modules are used for two functions: 1) standing bath and 2) high-speed counterflow for faster, better rinsing. Because of the dual-use modules, fewer modules are required. Rinsing occurs immediately after chemical action in each wash module. No separate rinse modules are required. Water and chemistry recirculate at high-velocity within the first module. Goods are sluiced faster and more completely into the machine. Wet-down of the fabric articles to be washed is almost instantaneous. Chemistry penetrates the fabric articles or linen instantly which is important for protein stains. The first module can thus be a working module. 
     The present invention requires fewer modules because of faster rinsing with high-velocity counterflow, more throughput with dual-use modules, and less water usage by recycling water. 
     The present invention includes a method of washing fabric articles in a continuous batch tunnel washer. The method includes providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid. The fabric articles are moved from the intake to the modules and then to the discharge in sequence. In the step of moving the fabric articles, multiple of the modules define a dual use zone having dual use modules that function as both wash modules and rinse modules and adding a washing chemical to the volume of liquid in the dual use zone. After a selected time period, a rinsing liquid counterflows in the dual use zone along a flow path that is generally opposite the direction of travel of the fabric articles. During the step of counter flowing, pressure of the counter flowing rinsing liquid can be boosted with a pump at one or more positions spaced in between the intake and the discharge. 
     In the step of boosting pressure, multiple booster pumps can be provided, each pump boosting counter flowing rinsing liquid flow rate at a different one of the modules. 
     During the step of counter flowing, the counter flow can be at a flow rate of between about 20 and 300 gallons (76-1,136 liters) per minute. 
     In one embodiment, during the step of counter flowing, the counter flow is at a flow rate of between about 25 and 220 gallons (95-833 liters) per minute. In one embodiment, during the step of counter flowing, the counter flow is at a flow rate of between about 35 and 105 gallons (132-397 liters) per minute. 
     In one embodiment, the booster pumps are spaced apart by more than one module. 
     In one embodiment, the booster pump discharges liquid into a module that is a dual use module wherein textile articles are both washed and rinsed. 
     In one embodiment, the booster pumps each discharge liquid into a module that is a dual use module wherein textile articles are both washed and rinsed. 
     In one embodiment, liquid flow in the dual use module is substantially halted for a time period that is less than about five minutes. 
     In one embodiment, liquid flow in the dual use zone is substantially halted for a time period that is less than about three minutes. 
     In one embodiment, liquid flow in the dual use zone is substantially halted for a time period that is less than about two minutes. 
     In one embodiment, 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. 
     In one embodiment, a volume of liquid in a plurality of the modules is heated to a temperature of between about 100 and 190 degrees Fahrenheit (38-88 degrees Celsius). 
     In one embodiment, the counter flow during the step of counter flowing extends through multiple of the modules. 
     In one embodiment, the dual use zone includes multiple modules. 
     In one embodiment, each booster pump discharges counter flowing fluid into a module that is not a module closest to the discharge. 
     The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of 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 define a dual use zone having modules that each function as both wash and rinse modules, moving the fabric articles from the intake to the discharge, adding a washing chemical to the dual use zone wherein modules in the dual use zone wash the fabric articles with a combination of water and said washing chemical, after a selected time interval and after the step of adding a washing chemical, counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in the step of moving the articles, and counter flowing water through the modules of said dual use zone to effect a rinse of the fabric articles. 
     In one embodiment, the present invention further comprises boosting the flow rate in the step of counter flowing so that it is maintained at a desired value. 
     In one embodiment, multiple booster pumps are employed in order to boost the flow rate. 
     In one embodiment, there are a plurality of modules in between the booster pumps. 
     The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules that segment the interior, and wherein a plurality of said modules define a dual use zone, moving the fabric articles from the intake to the discharge and through the modules in sequence, the fabric articles traversing the dual use zone during the step of moving the fabric articles from the intake to the discharge, adding a washing chemical to the dual use zone, and rinsing the fabric articles in the dual use zone by counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in prior steps. 
     In one embodiment, the present invention further comprises extracting excess fluid from the fabric articles after the step of rinsing the fabric articles. 
     In one embodiment, there is substantially no counterflow during the step of adding a washing chemical to the dual use zone and for a time period after this step. 
     In one embodiment, the time period is less than about five minutes. 
     The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior, the interior including at least one dual use zone that includes multiple of said modules that each function as both a wash module and a rinse module, moving the fabric articles and a volume of liquid in a first direction of travel from the intake to the discharge and through the dual use zone, washing the fabric articles with a chemical bath in the dual use zone, and rinsing the fabric articles by counter flowing a rinse liquid in the dual use zone along a second flow path that is generally opposite the first direction of travel of the fabric articles in the step of moving the fabric articles. 
     In one embodiment, the present invention further comprises the step of boosting the flow pressure head of the counter flowing liquid in the step of rinsing the fabric articles by counter flowing at one or more modules. 
     In one embodiment, in the step of rinsing the fabric articles by counter flowing, the counter flow has a duration of between about 2 and 6 minutes. 
     In one embodiment, the counter flow is at a flow rate of between about 20 and 300 gallons (76-1,136 liters) per minute. 
     In one embodiment, the counter flow is at a flow rate of between about 25 and 220 gallons (95-833 liters) per minute. 
     In one embodiment, the counter flow is at a flow rate of between about 35 and 105 gallons (132-397 liters) per minute. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS 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: 
         FIG. 1  is a schematic diagram showing a first embodiment of the apparatus of the present invention; 
         FIG. 2  is a schematic diagram showing a second embodiment of the apparatus of the present invention; and 
         FIG. 3  is a schematic diagram showing a third embodiment of the apparatus of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       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 . 
     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 . 
     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. 
     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. 
       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  10 A ( 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 ,  10 A each provide tunnel washer  11  or  11 A 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 . 
     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 . 
     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 . 
     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. 
     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. 
     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 . 
     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. 
     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. 
     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. 
     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. 
       FIG. 2  shows a second or alternate embodiment of the apparatus of the present invention, designated generally by the numeral  10 A. Textile washing apparatus  10 A 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  10 A provides a tunnel washer  11 A 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. 
     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  11 A. 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 . 
     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 . 
     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&#39;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 . 
     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 . 
     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 . 
     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 . 
     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). 
     
       
         
               
             
               
               
             
               
               
               
             
               
               
               
               
               
               
             
           
               
                 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 
               
               
                   
               
             
          
         
       
     
       FIG. 3  shows a third embodiment of the apparatus of the present invention designated generally by the numeral  10 B. In  FIG. 3 , there can be seen a tunnel washer  11 B having an inlet end portion  12  and an outlet or discharge end portion  13 . The tunnel washer  11 B has an intake hopper  26 . The tunnel washer  11 B 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 . 
     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. 
     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 . 
     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 . 
     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 . 
     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 . 
     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  15  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 . 
     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 . 
     The following is a list of parts and materials suitable for use in the present invention. 
     
       
         
               
             
               
               
             
           
               
                   
               
               
                 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 
               
               
                   
               
             
          
         
       
     
     All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. 
     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.