TECHNICAL FIELD
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The present invention relates to a washing machine for washing empty containers adapted to be filled with a pourable product, preferably a pourable food product.
BACKGROUND ART
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Washing machines are known which are configured for washing containers upstream of a filling machine and a labelling machine, in which the containers are respectively filled with the pourable product and labelled with respective labels.
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A washing machine is usually configured to be fed with used containers, such as returnable bottles, which have been emptied from the pourable product they are adapted to contain, so as to wash and clean the containers.
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An example of washing machine is known from
EP-A-2727660 in the name of the same Applicant.
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A typical washing machine of the above type essentially comprises:
- a washing tunnel;
- a looped chain conveyor advancing the containers from an inlet station to an outlet station along a washing path which extends inside the washing tunnel;
- a feeding system for feeding containers to be treated to the chain conveyor; and
- a plurality of consecutive treatment zones arranged between the inlet station and the outlet station and through which the chain conveyor advances the containers.
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In detail, the chain conveyor comprises a plurality of beams, which are fed at the inlet station by the feeding system with respective rows of containers to be washed.
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In greater detail, each beam comprises a plurality of aligned pockets organized in respective rows, each pocket being configured to receive one container to be treated at a time, to convey such container from the inlet station to the outlet station through the washing tunnel and along the washing path, and to deliver the respective washed container at the outlet station.
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More precisely, each beam is discharged of the respective washed containers at the outlet station and then is conveyed along a return path back to the inlet station, where it receives new empty containers to be washed.
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Typically, according to the advancing direction of the containers along the washing path and inside the washing tunnel, the treatment zones comprise, in sequence: a prewash zone, a caustic zone (or treatment zone, i.e. wherein the cleaning treatment of the containers occur) and a rinsing zone.
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The prewash zone usually comprises one or more prewash devices. Each prewash device comprises a prewash nozzle, which is configured to spray or sprinkle water towards the containers passing through the prewash device, and a collecting prewash basin, which is configured to collect the sprayed water coming off the containers.
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The caustic zone usually comprises one or more caustic baths, each defined by a respective tank which is filled with caustic chemical agents and through which the containers are advanced.
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The caustic chemical agent is kept at a high temperature, usually around 65°C-80°C to help clean and sterilize the containers.
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The rinsing zone usually comprises a plurality of rinsing devices. Each rinsing device comprises a rinsing nozzle, which is configured to spray or sprinkle clean fresh water towards the containers passing through the rinsing device, and a collecting rinsing basin, which is configured to collect the water sprayed on the containers.
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Generally, the various rinsing devices are arranged in series and are fluidically connected to one another.
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More specifically, the clean fresh water is fed to the last rinsing device which is last crossed by the containers and then is recirculated upstream, and in a direction opposite to the advancing direction of the containers through the rinsing zone and along the washing path, successively in each antecedent rinsing device.
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Therefore, only the last rinsing device is fed with fresh water, while the rinsing nozzles of the upstream rinsing devices are progressively fed with the water collected by the collecting rinsing basin of the immediately downstream rinsing device.
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Furthermore, the containers which exit from the caustic zone have a high temperature when reaching the rinsing zone.
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Hence, the temperature of the rinsing water rise increasingly from the last rinsing device to the first rinsing device which is first crossed by the containers, due to the heat exchanged by the rinsing water with the hot containers entering the rinsing zone.
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In general, the containers need to be treated through the caustic zone for a relatively long time and at relatively high temperatures in order to be effectively deprived from the most encrusted dirt mounds, especially the ones heavily sedimented at the bottom of the containers themselves.
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Hence, the caustic solution has to be heated and maintained at a predetermined temperature for the entire duration of the washing process.
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To this end, the caustic zone comprises a heater for heating the caustic solution.
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It is known in the field to conveniently use the heat of the rinsing water for helping in heating and maintaining the desired temperature in the caustic zone.
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In particular, in some solutions the washing machines comprise a heat exchange system which allows a heat exchange between the rinsing devices and the caustic baths.
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More specifically, in one solution, the washing machine includes:
- a heat pump having an evaporator and a condenser;
- a closed circuit conveying an exchange medium and passing successively through the rinsing basins, for collecting heat from the rinsing water contained therein, through the evaporator and then again through the rinsing basins; and
- a recirculation circuit conveying the caustic solution from the respective caustic bath through the condenser and then back to the caustic bath.
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Hence, residual heat from the rinsing water is absorbed by the evaporator and transferred to the caustic solution by means of the condenser.
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In this way, the workload of the heater for maintaining the desired temperature in the cleaning bath is reduced.
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Although the known washing machines operate satisfyingly well, the Applicant has observed how the washing machines of the type described above are still open to further improvement, in particular as per the simplification of their architecture, as per the efficiency of the heat exchange and the heat recovery between the rinsing water and the caustic solution, as per their hygienic degree, and as per the efficiency of the prewash operation and the reduction of damaged containers when entering the hot caustic zone from the relatively colder prewash zone.
DISCLOSURE OF INVENTION
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It is therefore an object of the present invention to provide a washing machine which is designed to meet at least one of the above-mentioned needs in a straightforward and low-cost manner.
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This object is achieved by a washing machine as claimed in the appended independent claim 1. Preferred embodiments of the present invention are laid down in the appended dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
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Non-limiting embodiments of the present invention will be described by way of example with reference to the accompanying drawings, in which:
- Figure 1 is a schematic lateral view, partially sectioned, and with parts removed for clarity of a washing machine according to a first preferred embodiment of the invention; and
- Figure 2 is a schematic lateral view, partially sectioned, and with parts removed for clarity of a washing machine according to a second preferred embodiment of the invention
BEST MODE FOR CARRYING OUT THE INVENTION
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With reference to Figure 1, number 1 indicates as a whole a washing machine configured to wash empty containers 2 adapted to be filled with a pourable product, preferably a pourable food product, such as beer, wine, water, juice, soft drinks, milk or the like.
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In particular, containers 2 are defined by respective empty bottles (for example, returnable glass bottles) intended to be filled with the pourable product.
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Washing machine 1 comprises:
- a washing tunnel 3 into which empty containers 2 are fed and accordingly washed; and
- a conveyor device 4 configured to convey a plurality of containers 2 along a washing path P in an advancement direction D.
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Preferably, the conveyor device comprises a looped chain conveyor 4 (of the type known and only schematically shown) for advancing containers 2 along washing path P inside washing tunnel 3, so as to convey containers 2 from one end of the tunnel 3 to the other end along a general direction D, preferably horizontal with respect to gravity.
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In detail, chain conveyor 4 may be of the type described in
WO-A-2020119958 and comprises:
- a pair of elongated chains (not shown) parallel to path P and parallel to one another; and
- a plurality of successive conveying beams 5 (laterally shown), which extend between the chains in a transversal and, more in detail, orthogonal manner to the chains and path P.
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Specifically, each beam 5 comprises a row of pockets 6 (laterally shown) aligned orthogonally to path P and configured to receive corresponding containers 2.
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In such a manner, containers 2 carried by a corresponding beam 5 are aligned orthogonally to path P and housed inside the respective pockets 6, individually.
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Washing machine 1 comprises also a feeding system 7 of the known type (only schematically shown in Figure 1) for feeding a sequence of empty containers 2 along direction D and at an inlet station I of washing tunnel 3. Expediently, containers 2 are fed by feeding system 7 along direction D arranged in rows orthogonal to path P.
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In use, the most forward containers 2 of each row of containers 2 are transferred by feeding system 7 to the respective pockets 6 of the beam 5 that is travelling at inlet station I.
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Washing machine 1 further comprises an outfeed system 8, which receives rows of cleaned containers 2 from chain conveyor 4 at an outlet station O of washing tunnel 3.
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In view of the above, path P comprises:
- a washing branch P1, which extends from inlet station I to outlet station O and along which containers 2 are advanced by chain conveyor 4; and
- a return branch P2, which extends from outlet station O to inlet station I and defines a return path along which beams 5 return towards inlet station I after having discharged containers 2.
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Washing machine comprises a plurality of consecutive treatment zones arranged between the inlet station I and the outlet station O and through which the chain conveyor 4 advances the containers 2.
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According to the aforementioned advancing direction of the containers 2 along path P, washing machine 1 comprises in sequence along washing branch P1:
- a prewash zone C1;
- a cleaning zone C2 arranged downstream prewash zone C1; and
- a final rinsing zone C3 arranged downstream cleaning zone C2.
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In the present disclosure, for the sake of clarity, terms like "upstream of" and "downstream of" are to be intended throughout the whole description and claims with reference to the advancing direction of the containers 2 along path P, or with reference to the fluid direction.
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The operation of washing machine 1 at the prewash zone C1, cleaning zone C2 and final rinsing zone C3 is well-known, for example from
WO-A-2020119958 , and therefore will not be described in detail herein.
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Prewash zone C1 includes at least one, and in particular two, prewash devices 10 configured to prewash the containers 2.
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In particular, each prewash device 10 comprises a prewash nozzle or sprinkler 10a, for spraying or sprinkling the containers 2 passing through prewash zone C1 with a prewash fluid, preferably water, and a prewash basin 10b for collecting the sprayed water.
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Preferably, the two prewash devices are fluidically connected with one another by a recirculation duct 10c apt to feed the sprinkler 10a of the upstream prewash device 10 with the water collected in the prewash basin 10b of the downstream prewash device 10.
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Preferably, the water used in the prewash zone C1 is discharged through a discharge duct 11 to a drain 40.
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Cleaning zone C2 comprises at least one cleaning bath 12, in particular a plurality of cleaning baths 12, in the embodiment shown two successive cleaning baths 12.
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Reference will be made in the following to a single cleaning bath 12. However, the features of such cleaning bath 12 apply to each cleaning bath 12 that may be present in cleaning zone C2.
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Cleaning bath 12 includes a tank 13 which is configured for holding a treating solution, such as a detergent chemical solution made of several chemical agents.
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In one embodiment, the treating solution comprises basic aqueous solutions that include, in particular, sodium hydroxide.
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In use, tank 13 is filled with the treating solution up to a predetermined level.
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Expediently, path P, and in particular washing branch P1, extends through tank 13, so that the containers 2 advanced by it are advanced through the treating solution and are temporarily immersed therein.
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In order to effectively remove dirt from containers 2, the treating solution is brought (and maintained) to a predetermined temperature, for instance between 65°C and 80°C.
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Hence, the containers 2 passing through cleaning zone C2 and cleaning baths 12 are cleaned and also heated, due to the temperature of the treating solution.
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Rinsing zone C3 includes a plurality of rinsing devices 14 arranged in series along washing path P.
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Each rinsing device 14 is configured to sprinkle rinsing fluid, preferably water, on the containers 2 passing through the rinsing zone C3.
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To this end, each rinsing device 14 comprises a nozzle or sprinkler 14a, for spraying or sprinkling rinsing water to the containers 2, and a rinsing basin 14b for collecting the sprayed rinsing water.
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A first rinsing device 14 arranged upstream of all the other rinsing devices 14, with respect to the advancing direction of the containers 2, and a last rinsing device arranged downstream of all the other rinsing devices 14, with respect to the advancing direction of the containers 2, can be identified.
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Washing machine 1 includes a supply duct 15 configured to feed clean and fresh rinsing water from a source 16 to the last rinsing device 14.
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Conveniently, rinsing zone C3 further includes recirculation means interposed between each pair of adjacent rinsing devices 14 and configured to collect the rinsing water sprinkled on the containers 2 from the downstream rinsing device 14 of said pair and recirculate it to the upstream rinsing device 14 of said pair.
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Preferably, recirculation means include one recirculation duct 14c interposed between each pair of adjacent rinsing devices 14 and configured to collect the rinsing water sprinkled on the containers 2 from the downstream rinsing device 14 of said pair and recirculate it to the upstream rinsing device 14 of said pair.
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In other words, the rinsing water is first fed to the last rinsing device 14, then it is recirculated to the second-to-last rinsing device 14 via the first duct 14c, and so on up to the first rinsing device 14.
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In this way, the containers 2 are rinsed and progressively cooled, since the clean and fresh rinsing water fed from source 16 via supply duct 15 is significantly colder than the containers 2 exiting from cleaning zone C2.
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Hence, the rinsing water is progressively heated up while being recirculated from the last rinsing device 14 towards the first rinsing device 14 (via the ducts 14c).
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In light of the above, the washing path P, and particularly the washing branch P1, extends through the prewash devices 10, the tanks 13 and the rinsing devices 14.
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Washing machine 1 further comprises a collector tank 17 arranged fluidically downstream of first rinsing device 14 and configured to collect rinsing water from the rinsing devices 14.
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In particular, collector tank 17 is configured to collect the rinsing water from the first rinsing device 14.
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Conveniently, washing machine 1 further comprises a post-cleaning zone C4 interposed, along washing path P, between the cleaning zone C2 and the rinsing zone C3 and comprising a post-cleaning device 18.
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The post-cleaning device 18 is configured to receive rinsing water from the first rinsing device 14 and for clean the containers 2 with the received rinsing water, for pre-rinsing and pre-cooling the containers 2.
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Preferably, as shown in the Figures, the post-cleaning device 18 includes a bath of rinsing water in which the containers 2 are immersed.
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Alternatively, the post-cleaning device 18 may include a sprinkler to sprinkle the containers 2 with the received rinsing water.
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Hence, the water coming off from the containers 2 and supplied by the post-cleaning device 18 is hotter than the water collected by the rinsing basin 14b of the first rinsing device 14, due to the fact that such water comes into contact with the containers 2 right after exiting the cleaning zone C2.
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Conveniently, the collector tank 17 is configured to receive rinsing water also from the post-cleaning device 18.
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In light of the above, the collector tank 17 collects rinsing water at a relatively high temperature.
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The residual heat of the water collected in the collector tank 17 is advantageously used for other purposes which will be described hereinafter.
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Washing machine 1 further comprises a recirculation circuit 19 fluidically connecting the collector tank 17 with the prewash zone C1 for feeding a first part of the collected rinsing water to the prewash devices 10, and in particular to the downstream prewash device 10.
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Therefore, the collector tank 17 defines a buffer for the prewash zone C1.
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In this way, the containers 2 are pre-heated already in the prewash zone C1, before entering the cleaning zone C2.
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This results in a reduction of the risk of damaging the containers 2 when entering the cleaning zone C2 due to the excessive temperature difference.
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Hence, it is desired to maintain the temperature of the water recirculated in the prewash zone C1 as constant and as high as possible.
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It is known in the field, as explained in the introductory portion of the present description, to recover some of the heat of the rinsing water for heating the treating solution.
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However, an excessive lowering of the temperature of the rinsing water may result in a sub-nominal temperature of the water recirculated in the prewash zone C1.
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According to an aspect of the present invention, washing machine 1 further comprises a heat pump 20 configured to receive both a second part of the collected rinsing water from the collector tank 17 and treating solution from at least one of the tanks 13. According to the invention, the heat pump 20 is configured to absorb heat from the received rinsing water (received from the collector tank 17) and to transfer the absorbed heat to the treating solution, thereby determining a heat exchange between the rinsing water from the collector tank 17 and treating solution from the tank or tanks 13.
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In particular, the heat pump 20 comprises a condenser 21 and an evaporator 22.
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Accordingly, the machine 1 comprises a first circuit 23 configured for feeding the collected rinsing water from the collector tank 17 through the evaporator 22, and a second circuit 24 configured for recirculating the treating solution from the tank or tanks 13 through the condenser 21 and back into the tank or tanks 13.
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More precisely, the evaporator 22 is configured for absorbing heat from the rinsing water and the condenser 21 is configured for heating the treating solution (exploiting such absorbed heat).
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Thanks to the presence of the heat pump 20, the overall energy consumption of washing machine 1 for heating the treating solution is significantly reduced.
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In particular, since heat pump 20 withdraws heat from the rinsing water received from the collector tank 17, and not directly from the rinsing water within the rinsing basins 14b, the efficiency of the heat exchange is largely improved for two reasons: firstly, as explained above, the temperature of the rinsing water collected in the collector tank 17 is the highest in the rinsing zone C3, and therefore the COP of the heat pump is increased compared to an exchange with the water in one or more of the rinsing devices 14. Furthermore, exchanging heat directly with the rinsing devices 14 (i.e. by means of a duct passing through the rinsing basins 14b, as in the known art) lowers the temperature of the rinsing water recirculated, through the recirculation circuit 19, towards the prewash zone C1. As said, it is important to maintain the temperature of the water used at the prewash zone in the desired range. Thanks to the configuration of the heat pump 20 according to the invention, this desired effect is achieved.
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Advantageously, washing machine 1 comprises a discharge duct 25 fluidically connected to the heat pump 20 and configured to discharge, after said heat exchange, the received rinsing water towards a drain 26 which is fluidically disconnected from the collector tank 17.
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In one embodiment, drain 26 may define a user device of machine 1 apt to receive the rinsing water discharged by the discharge duct 25 and configured to perform a further operation using such discharged rinsing water.
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In light of the above, the rinsing water coming from collector tank 17 and from which evaporator 22 absorbs heat does not recirculate into collector tank 17 after the heat exchange.
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To this end, first circuit 23 preferably comprises a feeding duct 23a, which fluidically connects the collector tank 17 with the evaporator 22 for feeding the collected rinsing water to the evaporator 22, and the aforementioned discharge duct 25, which connects the evaporator 22 with drain 26.
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This advantageous configuration allows for maintaining the temperature of the rinsing water in the collector tank 17 constant, or at least avoids a decrease of the temperature of the rinsing water in the collector tank 17.
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Hence, the rinsing water recirculated in the prewash zone C1 has the desired temperature, thereby pre-heating the containers 2 before the cleaning zone C2 at the desired level.
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This results in an increased efficiency of the washing process, and therefore of the washing machine 1.
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Moreover, the efficiency of the prewashing is improved, since the temperature of the rinsing water fed to the prewash devices 10 is kept constant and at the desired level, or at least not below the desired level.
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Furthermore, there is a significant reduction in damaged containers when entering the hot cleaning zone C2, since the risk of sudden ruptures due to high temperature difference is reduced (especially with glass containers), due to the fact that the temperature difference between prewash zone C1 and cleaning zone C2 is decreased (or at least maintained more constant or regular).
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Conveniently, washing machine 1 comprises partialization means fluidically interposed between the collector tank 17 and the heat pump 20 and between the collector tank 17 and the recirculation circuit 19, the partialization means 27 being actuatable to adjust the quantity of collected rinsing fluid fed towards the heat pump 20 or to the recirculation circuit 19, selectively.
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In one embodiment, the partialization means comprise a valve member 27 fluidically interposed between the collector tank 17 and the heat pump 20 and between the collector tank 17 and the recirculation circuit 19.
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The valve member 27 is actuatable to adjust the quantity of collected rinsing water fed towards the heat pump 20 or to the recirculation circuit 19, selectively.
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In other words, valve member 27 is configured to selectively allow the passage of the collected rinsing water towards the prewash zone C1 or towards the heat pump 20.
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According to an alternative embodiment not shown, the partialization means comprise a first pump member fluidically interposed between the collector tank 17 and the heat pump 20 and a second pump member fluidically interposed between the collector tank 17 and the recirculation circuit 19, the first pump member and the second pump member being actuatable for adjusting the quantity of collected rinsing fluid fed towards the heat pump 20 or to the recirculation circuit 19, respectively.
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In this way, a precise regulation of the flow of rinsing water towards the prewash zone C1 or towards the heat pump 20 is performed, as not all the rinsing water contained in the collector tank 17 is needed for the prewashing, but only a small fraction.
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Hence, said first part of the rinsing water is smaller than said second part of the rinsing water, and this can be controlled by valve member 27.
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According to a known configuration of the heat pumps, heat pump 20 comprises a closed circuit 28 configured to circulate an exchange medium for transferring heat from the evaporator 22 (and hence from the collected rinsing water) to the condenser 21 (and hence to the treating solution). Closed circuit 28 comprises a lamination valve 29 and a compressor 30, the functioning of which is known and it will not be described herein.
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Figure 2 shows a washing machine 1 according to an alternative second embodiment of the present invention. Washing machine 1 according to the second embodiment is substantially similar to the washing machine 1 according to the previous embodiment described above. Therefore, only the differences between these two will be described hereinafter.
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In particular, the washing machine 1 according to the second embodiment comprises a further collector tank 31 arranged fluidically downstream of the collector tank 17 and fluidically upstream of the heat pump 20. The further collector tank 31 is configured to receive the aforementioned second part of the collected rinsing water from the collector tank 17. The further collector tank 31 advantageously defines a buffer for a further user device 32 of the washing machine 1.
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According to the invention, the heat pump 20 is configured to receive the water collected from the further collector tank 31, thereby determining a heat exchange between such rinsing water from the further collector tank 31 and the treating solution.
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Accordingly, the aforementioned first circuit 23 is configured for feeding the water collected from the further collector tank 31 through the evaporator 22.
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More in particular, first circuit 23 comprises said supply duct 23a, which in this case connects the further collector tank 31 with the evaporator 22 for feeding the water collected from the further collector tank 31 to the evaporator 22, and said discharge duct 25, which connects the evaporator 22 with drain 26.
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Conveniently, washing machine 1 comprises a further valve member 33 fluidically interposed between the further collector tank 31 and the heat pump 20 and between the further collector tank 31 and the further user 32.
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The further valve member 33 is actuatable to adjust the quantity of water fed towards the heat pump 20 or towards the further user device 32, selectively.
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Thanks to the aforementioned configuration, part (i.e. said second part) of the rinsing water collected by the collector tank 17 and transferred to further collector tank 31 may be used both for aiding in heating the treating solution, via the heat pump 20, and for supplying the further user device 32.
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In one embodiment, further user device 32 comprises, and in particular is defined by, a crate washer.
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In this way, and thanks to further valve member 33, only the water needed for user device 32 is withdrawn.
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In summary, the overall efficiency of washing machine 1 is increased, while the water consumption decreases.
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In one embodiment (not shown), since the further user device 32 may not need to be supplied with water at a particular temperature, first circuit 23 may be closed onto further collector tank 31, i.e. without comprising discharge duct 25, for recirculating the water that has exchanged heat in evaporator 22 back into further collector tank 31.
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More in particular, in such a case first circuit 23 comprises feeding duct 23a and a return duct (not shown), instead of discharge duct 25, which connects the evaporator 22 with the further collector tank 31 for recirculating the fluid from the evaporator 22 back into the further collector tank 31.
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In this way, the architecture of the machine is further simplified, and water consumption is further reduced.
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If discharge duct 25 is present, as shown in Figure 2, the temperature of the water in further collector tank 31 can be maintained constant. This is advantageous in those cases in which the further user device 32 needs to be supplied with water at a predetermined temperature.
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The advantages of washing machine 1 according to the present invention will be clear from the foregoing description.
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In particular, thanks to the presence of the heat pump 20, the overall energy consumption of washing machine 1 for heating the treating solution is significantly reduced.
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In particular, since heat pump 20 withdraws heat from the rinsing water received from the collector tank 17, and not directly from the rinsing water within the rinsing basins 14b, the efficiency of the washing machine 1 is largely improved for two reasons: firstly, as explained above, the temperature of the rinsing water collected in the collector tank 17 is the highest in the rinsing zone C3, and therefore the COP of the heat pump is increased compared to an exchange with the water in one or more of the rinsing devices 14. Furthermore, exchanging heat directly with the rinsing devices 14 (i.e. by means of a duct passing through the rinsing basins 14b, as in the known art) lowers the temperature of the rinsing water recirculated, through the recirculation circuit 19, towards the prewash zone C1; as said, it is important to maintain the temperature of the water used at the prewash zone in the desired range. Thanks to the configuration of the heat pump 20 according to the invention, the water temperature in collector tank 17 is not affected by the functioning of the heat pump 20, as the collector tank 17 is continuously fed with new rinsing water at high temperature (from the first rinsing device 14 and/or from the post-cleaning device 18).
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Furthermore, in case further collector tank 31 is present, the above technical effects are even more pronounced and, moreover, a further user device 32 may be supplied with the water which is not needed either for prewash or for heat pump 20. Hence, the efficiency of the washing machine 1 is even more improved.
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In addition, thanks to the configuration of heat pump 20 according to the invention, the architecture of washing machine 1 is significantly simplified, compared to the case in which the heat exchange with the rinsing water is obtained by a duct extending through the rinsing basins 14b.
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Moreover, the hygienic properties of washing machine 1 are also improved, since the rinsing basins 14b are not crossed by any external duct.
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Clearly, changes may be made to washing machine 1 as described herein without, however, departing from the scope of protection as defined in the accompanying claims.