This application claims benefit under 35 USC section 119(e) of provisional application Ser. No. 61/680,025, filed Aug. 6, 2012, entitled: WASHER-DRYER APPARATUS FOR DAIRY TOWELS AND METHOD, the entire contents of which are incorporated herein by reference.
BACKGROUND The present invention relates to an apparatus for washing and/or drying dairy towels, such as dairy towels used to disinfect and clean teats on milking cows, and as a result, the apparatus is used in difficult, hot, and humid environments such as barns and cattle buildings.
Cleanliness and non-contamination of milk is a major task in the dairy industry, since teats of milking cows are difficult to clean and keep clean. The cost of providing disposable towels is excessive. However, the cost of washing towels also can be very expensive in terms of energy cost, inventory of towels, and management of cleanliness and the towel-washing operation. In particular, the environment of milking barns and buildings is hot, humid, and difficult to keep sanitary for food products and difficult to keep sufficiently cool for animals. A towel-washing machine and/or dryer can potentially add considerably to the oppressive heat, humidity, and energy-cost for milking operations. Further, maintenance of washing and drying equipment is difficult, given the high humidity and hard operating conditions.
SUMMARY OF THE PRESENT INVENTION In one aspect of the present invention, an apparatus for washing dairy towels includes a washer with drum supported by bearings for rotation on a horizontal axis, a side door on the drum for opening to facilitate top-down loading of towels into the drum, and an outer enclosure around the drum for containing liquid. The door is pivoted to the drum for movement between an open position allowing access to the opening and a closed position where the door generally matches a cylindrical shape defined by the drum, and skid bearings are provided that abuttingly support the door in the closed position by being located between the door and the outer enclosure at least during a time when the door is biased open by gravity or weight of the towels. A drain is provided for setting a height of water in the outer enclosure. Electrical controls control operation of the washer.
In a narrower aspect, the skid bearings are attached to the door and engage a mating flange on the outer enclosure when the bearings move along the semi-circular lower portion of the tub of the enclosure, thus holding the door closed against a gravitational weight of the door and the wet towels and against centrifugal force of rotation. It is noted that since the towels are in water during this portion of a rotational movement, the supportive force provided by the skid bearings is surprisingly low.
In another aspect of the present invention, a method of washing dairy towels includes providing a washer with drum supported by bearings for rotation on a horizontal axis, a side door on the drum for opening to facilitate top-down loading of towels into the drum, an outer enclosure around the drum for containing liquid, a drain located proximate but below the bearings for setting a height of water in the outer enclosure, and electrical controls located above a height of the drum for operation in a non-moist area on the washer. The method further includes placing the washer in a dairy building containing milking stalls and milking cows, using washed towels to wipe and sanitize teats of milking cows, and then washing the towels in the drum.
In a narrower form, exhaust air from an air compressor of a vacuum milking apparatus is recycled and fed into a hot air inlet in the enclosure to dry the towels, thus providing a great energy savings.
In another aspect of the present invention, an apparatus for washing dairy towels includes a washer with drum supported by bearings for rotation on a horizontal axis, and a side door on the drum for opening to facilitate top-down loading of towels into the drum. The apparatus further includes an outer enclosure around the drum for containing liquid, a drain located proximate but below the bearings for setting a height of water in the outer enclosure, and electrical controls located above a height of the drum for operation in a non-moist area on the washer.
In a narrower aspect, the apparatus includes a hot air inlet and hot air outlet connected to the outer enclosure, with the inlet and outlet being configured and arranged to move hot air through the enclosure to dry the towels after washing the towels. Also, in a narrower aspect, an air compressor of a vacuum milking device is connected to the hot air inlet of the outer enclosure so that exhaust air from the air compressor is fed into the hot air inlet to dry the towels.
These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a perspective view of a washer apparatus embodying the present invention, including the tub, the rotatable drum, drive mechanism, and controls.
FIG. 2 is a perspective view of the drum within the apparatus of FIG. 1.
FIGS. 3-4 are front and side views of the apparatus of FIG. 1.
FIGS. 5-6 are front and side views of the drum of FIG. 2.
FIG. 7 is a front view similar to FIG. 3 but showing some fluid control components and fluid lines.
FIG. 8 is a front view of a modified washer/dryer apparatus, FIG. 8 being similar to FIG. 7 but showing the apparatus modified to include drying capability and hot air flow through the apparatus.
FIG. 9 is a schematic view of a combination system including the washer/dryer apparatus and a hot air supply taking exhaust air from an automatic vacuum milking apparatus, including the muffler and hot air discharge from same connected to the washer/dryer apparatus.
FIG. 10 is a side cross sectional view of a modification where water is fed into a drum through an axle-like hollow member aligned with the tub bearings, the hollow member having apertures for dispensing a spray for rinsing washed towels.
FIG. 11 is a perspective view of a modified washer/dryer apparatus similar to FIG. 1.
FIG. 12 is a view similar to FIG. 11 but with a side panel and end cover and also the drive mechanism shown in dashed lines.
FIGS. 13-15 are orthogonal views of FIG. 12.
FIGS. 16-19 are perspective, top, side, and end views of the enclosure/support housing of FIG. 12, including the pool-holding tub formed in the enclosure.
FIGS. 20-23 are perspective, top, side, and end views of the rotatable drum of FIG. 12, including a tub access opening, but not showing a door covering the access opening.
FIGS. 24-26 are perspective, side and end views of the door for the drum in FIG. 20.
FIGS. 27-28 are side and end views of the drum and door of FIG. 12 including bearings that keep the door closed during rotation of the drum, the door being shown in an open position.
FIGS. 29-29A are views of alternative rapid-spin water extractors that can be used in combination with the washing apparatus of FIG. 11.
FIG. 30 is a side view, partially schematic, showing a system including the washer apparatus of FIG. 11 and the spin extractor of FIG. 29 that can be used in combination to wash and dairy dry towels, FIG. 30 including some fluid lines and controls and an optional rapid dump tank.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The present apparatus includes a washer with horizontal axis that is different from known prior art in that the present system combines a horizontal axis drum with front and rear bearings (no cantilever) and a side-of-drum door opening that faces upwardly when the drum rotation is stopped. Notably, in one version, the door opens outwardly (see FIGS. 11-30) but is held closed during rotation by skid bearings on the door that slidingly engage a mating flange on a semi-cylindrical lower tub portion of the outer enclosure. The drum is stopped at a top position for easy unloading, and sits in a tub containing a pool of water in a larger enclosure during rotation. A water-level-limiting upper drain and bottom/lower water-flow opening, along with other novel features, provide simplicity and improved maintenance, as discussed below. The present washer apparatus is relatively non-complex and mechanically simple, and is particularly adapted for use in the dirty, hot, and high humidity environment of cows/barns such as are often found in the dairy industry. Also, the present apparatus provides great control over energy efficiency, cleanliness, recycling of water, high-volume flow-through of wiping towels, and provides simple controls. The present washer eliminates many, if not all, below-water-level seals, thus eliminating (or at least minimizing) water-leak problems commonly found in known existing washing equipment. It is noted that water/fluid leaks have been a continuing major problem in the field in this industry.
Further, the present washer does not have many of the typical problems with electronics, since its electronics are located high on and to a side of the machine, relatively far away from moisture and away from the damp high-electrical-short-out environment. The present washer can have the ability to provide appropriate liquid content and/or liquid additives at different times during the wash cycle, if desired, though it is contemplated that most of this can be done at a start of the next wash cycle. In addition, in a sophisticated “up level” version of the present apparatus, hot air is piped through the apparatus so that washing and drying can occur in the single apparatus. In the “up level” version, hot air is “sucked” through the tub (instead of blown through at high pressure). This facilitates air filtering that does not tend to get plugged or have other problems associated with high air flow associated with high pressure “force air” flows in most dryers.
It is contemplated that the present apparatus can use hot air from an automatic milker vacuum system for automatically milking cow teats. Specifically, hot air exhaust occurs when operating the vacuum generating system of a milker apparatus. This hot air is normally piped out of the barn to minimize it from raising the atmospheric temperature in the barn. By routing the hot air through the present washer, a tremendous energy cost savings can be obtained. Specifically, it is contemplated that the apparatus can be used in a separate dryer, or can be used in the “up level” apparatus described above (and below). Also, the present apparatus can be combined with a vacuum source of a milker device, where the milker device includes a vacuum generator with a hot air outlet (exhaust) fed into a muffler. The hot air is directed from the muffler into the dryer, thus providing the equivalent of a free source of heated air for drying the towels.
In a first embodiment, an illustrated washing apparatus 20 (FIGS. 1-7) is adapted to efficiently and, in an energy-conserving manner, wash and clean wiping towels 19 (also called “hand cloths”) for wiping/disinfecting a cow's teats prior to milking. The wiping towels 19 are, for example, about 10″×10″ hand cloths (or perhaps 12″×12″ hand cloths) made of particular materials well suited for their intended purpose of wiping and disinfecting a cow's udder and teats. The present apparatus 20 allows rapid and efficient washing of the cloths, including adding disinfectant and the like to the liquid washing solution (water). The apparatus 20 includes an outer enclosure 21 (also called “tub-defining structure” herein) defining a container or tub 21A for holding a pool of wash water and chemicals, and a rotatable drum 22 supported by front and rear bearings 23, 24 in the tub 21A of the outer enclosure 21 for rotation about a horizontal axis A1. A outer door 21B is provided on the outer enclosure 21 to prevent splashing and undesired loss of heat and release of humidity.
The drum 22 (FIG. 2) is formed by an apertured cylindrical sidewall 25 and end walls 26, 27, and has agitator ridges/fingers (not specifically shown) inside the drum 22 for towel agitation as required. The sidewall 25 includes a drum access opening 29, and a door 30 matching the general curvature of the sidewall 25, hinged by a hinge 31 on a side edge that leads the door 30 upon rotation of the drum 22. In the present design, centrifugal forces will tend to keep the door 30 closed, but if necessary, a latch or other closure device (e.g. magnet or detent or other mechanical fastener) could be added at a hinge-opposite edge 32 of the opening 29 to more positively keep the door closed. The door 30 can be a single arc segment or can be multiple arc segments hinged together to open with a one-directional folding action. Also, it is contemplated that the present door 30 can be pivoted outwardly, and held closed using skid bearings (see bearings 232A in FIG. 24) as described below.
The illustrated liquid input and outlet openings 34 and 35 (FIG. 7) are positioned in high and low positions, respectively, in the enclosure 21, and are controlled by a recycle control 34A as needed to create a pool 36 in a bottom of the outer enclosure 21. The fluid/recycle control 34A is operatively connected with a water supply and drain, and controls water flow into and out of the washing apparatus 20 through one or both input and outlet openings 34, 35 and associated water lines. The fluid/recycle control apparatus 34A includes valves (such as solenoid valve 34B) and electrical knobs/controls 38 (such as timers and sensors) for controlling water level of pool 36, and for controlling a concentration of detergent and antibacterial chemical additives during the washing process. The control 34A and controls 38 are located high on the apparatus 20 and at a location spaced from the tub access opening so that they are as far from the heat and moisture and high humidity of hot towels 19 being taken out of the machine. A pivoted panel (not shown) can be put in front of the controls, or the controls can be positioned to a side of the apparatus (see FIG. 11) if desired.
Preferably, a top level of the pool 36 is kept slightly below the axle height of bearings 23, 24, thus eliminating or greatly reducing problems associated with water in the bearings 23, 24. The “high” location of the input opening 34 (FIG. 7) above the associated bearing 23 reduces water leaks and yet provides a pool 36 sufficiently deep for washing the towels 19. Notably, water can be added through one or both of the openings 34, 35 to reduce the time required to bring the pool 36 up to its working depth. Also, the outlet opening 35 can be eliminated, or it can be directed up to a height of the top line/opening 34 to enter the tub and then extended to a bottom of the tub, thus minimizing the potential for water leaks. Alternatively, a valve 34B can be added to control flow of water and fluid into and out of the enclosure 21 in the system (FIG. 7). A direct drive 37 (FIG. 1) is associated with the axle at the front (or rear) bearing 23 and includes items such as a motor, gear reduction device, and belt drive 37A. The control of liquid input/output/recycling is controlled by simple control valves, which are automatic (or manual). Testing suggests that the illustrated drum 22 can be jammed full and will still adequately wash the cloths to a clean/sanitary condition, with total wash cycle time being about every 15 minutes, which results in a thru-put that is far faster than other washers used in this industry.
It is contemplated that the present apparatus 20 can be modified/converted to be solely a dryer apparatus for drying wet towels. In such a modified apparatus 20, a hot air inlet 40 and hot air outlet 41 (FIG. 8) are added to the enclosure 21 (see FIG. 7). Notably, in the modified/converted dryer apparatus, the enclosure 21, the drum 22, and other similar components are structurally the same, except that the water-handling components are eliminated, such as the drain, water inlet, pump, and the like. Also, the rotational drive can be configured to rotate the drum 22 at sufficient speeds to wring out a first amount of water from wet towels prior to a heated drying cycle. By using a same enclosure 21, manufacturing costs are greatly reduced. Also, there is an aesthetic benefit, since the washer and dryer become a visually matched set.
Alternatively, the apparatus 20 (FIG. 8) can be modified to both wash and then dry the towels 19. Specifically, the drive of the present drum 22 can be made to provide a high-rotational speed that is sufficiently quick to wring out a lot of the water from wet towels 19 by centrifugal force. Also, the hot air input passageway/pipe 40 can be connected to the outer enclosure 21 and the hot air outlet passageway/pipe 41 can be connected for routing moisture laden air as desired (e.g. for heating of the barn, or to the outside of the building, or to a recycling apparatus for capturing the energy, etc.). It is contemplated that the airflow can be “sucked through” by a fan 41A instead of using forced air on the air-inlet side, thus simplifying air filters that often get plugged (greatly reducing efficiency of the system). In the illustrated apparatus, there are no door seals that are below a top of the pool 36 (FIG. 7) in the present design that potentially will leak water, which is a great advantage since door seals often create a constant leak problem, leading to water puddling in and around known dairy washing machines. A location of the air inlet and outlet passages can be optimally positioned as desired in opposite sides of the enclosure 21 (and at high and low positions) for optimal flow of heated air through the enclosure 21.
The illustrated drum 22 of apparatus 20 is about 30 inches diameter and 30 inches long, and the drum 22 of the slightly-larger apparatus 20 (solely for drying) would be about 30 inches diameter and about 36 inches long. The tube portion of the outer enclosure is maybe 1-2 inches larger in height/width/depth than the drum 22, as needed to support sufficient liquid within and around the drum 22. The present system operates using high temperature water of about 180-200 degrees F. This allows the apparatus 20 to handle the through-put volume necessary (such as providing 300 towels through-put per 60 minutes). However, it is noted that alternative dimensions and other variations are also believed to be within a scope of the present invention. Notably, a control panel 34A with controls 38 such as an on/off start switch and other controls is located atop the enclosure 21 laterally to a side of the enclosure where the controls are farthest away from the severest heat and humidity around the apparatus 20. See also the arrangement and location of controls in FIG. 12.
FIG. 9 shows a system incorporating the washing apparatus of FIGS. 1 and 8. Automatic milking devices 100 (FIG. 9) (also called “milkers” herein) are used in high volume milking operations. The milkers 100 include vacuum-generating air compressor mechanisms 101 and piping to provide vacuum to the milking stations. The air compressor mechanism 101 generates exhaust hot air 102 that is run through a muffler 103 to reduce noise, and then routed out of the building where it is dumped into ambient atmosphere. The apparatus 20 can use this hot air 102 to greatly reduce energy expense when drying towels.
Specifically, the muffler 103 (FIG. 9) includes an inlet opening for receiving the hot air 102 from the compressor mechanism 101, a casing 105, an internal baffle 106, and an outlet opening 107. The baffle 106 can be designed, as needed, to provide a tortuous path to provide a noise dampening function and also to uniformly heat the air, as needed, for use in the present apparatus 20 for drying. The outlet opening 107 is connected to the hot air input pipe 40 which feeds through an input opening 104 on the apparatus 20. An airflow valve 108 can be connected to the outlet opening 107 or pipe 40 to blend the hot air with ambient air in order to control temperature as needed. The valve 108 can be automatically or manually controlled, and can direct air to the washer/dryer apparatus 20, or direct the air to a dedicated dryer 39, or to ambient atmosphere (e.g. outside the building in the summer, and inside the building in the winter).
FIG. 10 is a side cross sectional view of a modification to apparatus 20 where water is fed from a water supply 120 through a front (or rear) drum bearing 121 into a drum 122 and through an axle-like hollow member 123 aligned with drum bearings 121 and 124. The hollow member 123 has apertures 125 for dispensing a spray for rinsing washed towels 19 (FIG. 8). The water inlet is generally opposite the drum's drive 126.
Modification A modified apparatus 220 is shown in FIGS. 11-28. Similar and identical components are identified using the same number plus “200.” This is done to reduce redundant discussion.
The modified washer/dryer apparatus 220 (FIGS. 11-12) includes an outer enclosure 221 (also called a “support housing” herein) forming a water tub, and a rotatable drum 222 supported by front and rear bearings 223, 224 on the outer enclosure 221 for rotation about a horizontal axis A1 within the tub. The illustrated enclosure 221 and drum 222 are similar in size to that of enclosure 21 and drum 22 described above, keeping in mind that dimensions can be modified for particular needs of a particular installation. The drum 222 (FIGS. 20-23) is formed by an apertured cylindrical sidewall 225 and end walls 226, 227, and has agitator ridges/fingers 228 (FIG. 20) as required. The sidewall 225 includes an access opening 229, and a door 230 (FIGS. 24-26) matching the curvature of the sidewall 225, hinged by hinge 231 on a side edge that trails the door 230 upon rotation of the drum 222.
Notably, the illustrated door 230 pivots outwardly (FIG. 28), and a plurality of door-holding skid bearings 232A (slide blocks or rollers) are attached to the outside of the door 230. As illustrated, two skid bearings 232A (i.e. blocks of lubricious polymer such as nylon) are attached to the door 230 at outer hinge-remote corner locations, and two block bearings 232A are located adjacent but spaced a couple inches from the hinge along a perimeter of the door 230. The skid bearings 232A slidably (or rollingly) engage a mating inside flanged surface on the semi-cylindrical bottom of the tub 221A during a bottom half of the rotation of the drum 222 (see FIGS. 14-15 and 27), thus keeping the door 230 closed during rotation of the drum 222. During an upper half of drum rotation, gravity (and also lack of weight pressure from the towels) keeps the door 230 closed. Restated, the illustrated bearings 232A are located on the door to engage the enclosure 221 whenever the drum 222 positions the door 230 at or below a horizontal center plane of the drum 222 (where the door would tend to fall open). It is contemplated that the door 230 will be naturally held closed by gravity at a top of its rotation during a washing cycle (i.e. when the door 230 is at a top during the drum's rotation). As the door 230 rotates off the top position, the bearings 232A engage the enclosure 221 and prevent the door 222 from opening. Thus, the bearings 232A engage only when they are needed to actively engage and hold the door 222 closed. It is contemplated that the bearings 232A can be a variety of different designs, such as nylon blocks fastened directly to the door 222 or to the outer enclosure 221; and can be lubricious blocks supported on L-brackets on the outer enclosure 221, or can be rollers with axles supported by brackets. Notably, when the skid bearings 232A engage, they are usually under water level 236, such that the water and detergents act as a lubricant.
Notably, the door 230 is shaped to generally match a cylindrical shape of the drum 222, such as being a single arc segment. Alternatively, the door can be made of multiple arc segments or “curtain segments” hinged together to open with a one-directional folding action. A latch for holding the door 230 closed can be provided if desired, the latch being mechanical or magnetic, for example. Liquid input and output openings 234 and 235 are located in low and/or high positions on the enclosure 220 to allow water to be added to form a pool 236 in the tub. It is contemplated that lines connected to the openings 234, 235 will be connected to a recycle tub in the space under a bottom of the outer enclosure 221. (See FIG. 30.) Preferably, the top opening 234 is located slightly above a top level of the pool 236 but slightly below the axle height of bearings 223, 224 to reduce a risk of water leaks causing bearing problems. This feature provides improved leak free life and reduced maintenance. A water/fluid control system can be used similar to that shown in FIGS. 7 and 30 on apparatus 220.
A direct drive 237 (FIG. 16) is associated with the axle at the rear bearing 224, and includes an electric motor, gear reduction device, and belt drive to a pulley at bearing 224. The control of liquid input/output/recycling is controlled by simple control valves, which are automatic (or manual). Thus, the drum 222 can literally be jammed full and will still adequately wash and clean the cloths, with cycle times being about every 15 minutes, which is far faster than other washers used in this industry. An electrical control box 234A (FIG. 11) (also called a “fluid & recycle control”) is positioned on top and to a side of the outer enclosure 221 at a location spaced generally away from moisture, water and wet towels around the present apparatus 220. The control box 234A includes controls 238 such as an on-off switch, temperature control, a timer(s), valve controls and any other controls as needed for operating the apparatus 220.
In one modification, a recycle tank 260 (FIG. 30) is positioned under the outer enclosure 221 for holding rinse water that can be recycled back into the apparatus 220 for washing a next batch of towels 219. Optionally, a quick-dump tank 261 can be positioned on the outer enclosure 221 above the drum 222 for holding recycled water. The quick-dump tank 261 includes a quick-release gate 262 in a bottom or side of the tank 261 that allows recycled water to be dumped within a few seconds into the drum 222, thus saving fill time and reducing overall cycle time for washing towels 219. It is contemplated that the drum 222 and pool 236 can be about 12 gallons in size, but of course different sizes can be designed to fit a particular functional operational requirement. Based on a total cycle time of 15 minutes, the present apparatus 220 can wash about 150 towels per cycle, or about 600 towels per hour, which is considerably faster than known systems, and it can do the washing with considerable increased efficiency and yet low maintenance.
In regard to particular figures, FIG. 11 shows the modified washer/dryer apparatus 220 similar to the apparatus 20 of FIG. 1. FIG. 12 is a view similar to FIG. 11 but with a side panel and end cover shown as “transparent” to better show internal components. FIGS. 13-15 are orthogonal views of FIG. 12.
The outer housing 221 (FIGS. 13-15) includes a separate outer access door 221B (or cover) (FIG. 28) hinged to a top of the outer enclosure 221 at an outer door hinge to fully enclose the pool 236 of hot water and towels 219 during a wash cycle. It is noted that the temperature of the water in a dairy towel washing system is much hotter than typical residential washer, such as 180-210 degrees F., and accordingly it is a significant advantage to fully enclose the hot pool of water so that moisture and heat are contained and thus do not enter the barn/work area at an unacceptably high rate.
The drum direct drive 237 (FIG. 12) includes an electric motor 275, an in-line gear reduction box 276, a drive shaft 277, a pulley 278 and a belt 279 for driving the drum's axle 233 at the associated drum's bearing 224. The motor 275 and gear reduction box 276 are located under the drum 222 (under the tub portion of the enclosure 221), and the drive shaft 277, pulley 278, and belt 279 are located generally at an end of the enclosure 221 under a protective end cover 280. The controls 234A/238 are attached generally above the protective end cover 280, and include all controls desired, such as an emergency stop switch, the on/off switch, timers, temperature sensor controls, heaters, water pump control, and the like.
The drum access door 230 (FIGS. 24-26) includes an aperture panel 282 with perimeter frame comprising curved side flanges 283, a hinge-supporting flange 284, and a hinge-remote flange 285. A latch can be mounted on the hinge-remote flange if desired, but it is contemplated that a latch will not be required due to the door-closing skid bearings 232A, as discussed below. A lower half of the tub portion of the outer enclosure includes semi-circular flanges 283 that abuttingly engage the skid bearings 232A on the drum 222. Notably, the drum 222 does not have to rotate very fast when washing the towels 219, and it is noted that the towels 219 are fully immersed when at a bottom of the drum's rotation, such that there is surprisingly little force or weight against the skid bearings 232A during rotation of the drum 222.
At an end of the wash cycle, the drum 222 (FIGS. 28 and 30) is stopped at a top location where it positions the drum door 230 near the top-located enclosure access door 221B of the outer enclosure 221 (FIG. 30). The drum door 230 can be opened by lifting it upwardly. Depending on a size of the enclosure access door 221B and the drum door 230, the drum 222 may need to be reversely rotated slightly as the drum door 230 is opened. It is contemplated that the drum door 230 can be designed to hold itself open by gravity, or that a magnet or tether can be provided on the enclosure door 221B to hold open the tub door 230. Alternatively, the access door 221B may include a latch or other gripper to hold the drum door 230 open.
The present system can be used in combination with a rapid spin extractor 300 (FIG. 29) that quickly extracts water from the washed wet towels 219. Details of the extractor 300 are not required for an understanding by persons skilled in this art. Nonetheless, it is noted that the illustrated extractor 300 (FIG. 29) includes an apertured drum 301 rotatable about a horizontal axis A2 in an enclosure 302 similar to enclosure 221. The extractor 300 can be front loaded (FIG. 29) or top loaded (see FIG. 29A). The illustrated extractor 300 (FIG. 29) is front loaded, and includes a front door 303 so that towels 219 can be pulled out of the drum 301 (such as using a rake-like tool 304) into a floor tub 305. The floor tub 305 is then carried to a best location for using/distributing the towels 219.
FIG. 30 shows a system incorporating the washing apparatus of FIG. 12 and the rapid-spin water extractor 300. It shows a water lines and associated openings 234, 235 connected to an enclosure tub 221A holding the pool 236, and shows an electrical control box 234A with kill switch 251 and other switches, sensors, and components configured to selectively send dirty/spent water to a drain line 312 or to send semi-clean rinse water to a recycle line 313 that leads to the collection recycle tank 260. Alternatively, or additionally, the water can be recycled through a water line 261A to the quick-dump tank 261 having a gate 262 for rapidly dumping the contents of tank 261 into the tub 221A. The tank 261 and gate 262 can be used to quickly fill the tub 221A at a start of a next washing cycle. Also, a water line 314 directs water collected from the extractor 300 and feeds it back to the tank 260 (or tank 261) of the washing apparatus 220. Also shown is a water supply line 315 that supplies virgin water to the tub 221A or to the tanks 260 or 261.
In operation, the system of apparatus 220 and 300 (FIG. 30) work generally as follows. Towels 219 are loaded into the apparatus 220, and the tub 221A is filled with the pool 236 of water and washing chemicals (e.g. detergents, sanitizers, and anti-microbial agents). The drum door 230 and enclosure door 221B are closed, and the drive system 237 is turned on to rotate the drum 222. Water is added as needed to maintain the pool 236, and/or to cause dirt-laden water to flow out of the tank portion of the enclosure 221. Near an end of the wash cycle, spent water is drained using the lower port on the enclosure 221, and fresh rinsing water is added as desired (if desired). The rinse water is collected in the tank 260 (and/or tank 261). Rotation of the drum 220 is stopped with the door 230 in a top position, and the door 221B and the door 230 are opened (sequentially or simultaneously). Wet towels 219 are removed and placed into the extractor 300. (For example, this can be done by lifting the towels 219 out a top of the enclosure 221 and then sliding the towels 219 down a ramp (or by otherwise moving the towels 219 from the apparatus 220) into the extractor 300. The door 303 of the extractor 300 is then closed, and the drum 301 of the extractor 300 is spun at high speed sufficient to remove a majority of the water from the towels 219. When done, the towels 219 can be removed from the extractor as slightly-damp hot towels ready for use as needed in the dairy operation. The water collected from the extractor 300 and the rinse water in the tanks 260 and/or 261 are recycled back into the enclosure 221. When speed is of the essence, the tank 261 can be used to quickly dump a substantial amount of water into the enclosure 221, thus expediting start of another wash cycle. Testing shows that the present system can through put about 900 towels/hour, which is considered surprising and unexpected given the system's simplicity, durability, robustness of design, and relatively small size.
It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further, it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
