ALPHA TUNNER WASHER

ALPHA TUNNEL WASHER

JENSEN revolutionized the market with the ALPHA TW5 tunnel washer, being the most versatile tunnel washer that reuses energy and water internally. The combination of processing the greatest variety of linen types while keeping consumption at extremely low levels is now tuned to perfection with QuickSoak, and EcoTune to reach higher levels of operational efficiency. This combination of efficiency and productivity has been continuously optimized in recent years through ongoing innovations developments, with the result that even today the ALPHA TW5 can lay claim to a leading position in the world market.

 

Action:

An important feature of the ALPHA TW5 is its highly efficient wash action and its reliable transport method.Compared with other tunnel washers, which require considerably larger drum diameters, the ALPHA TW5 makes far more efficient use of the drum diameter thanks to its patented eccentric Archimedian helix, and enables high drop curves for outstanding wash action. This is reinforced even further by the washboard-type shape of the helix. An optimized drum design ensures an outstanding mechanical action and the most reliable batch transfer. The speed of the drum can be varied using the frequency-controlled drive motor, thus allowing for specific control of the mechanical action required by the goods being processed.

How to save energy and money:

A tried and tested wash action with a superior reuse technique has enabled the consumption of resources by the ALPHA TW5 tunnel washer to be considerably reduced. The process water is recovered from various zones and fed to a number of tanks and could reach an amazing 100% reclaim. This water reclamation system allows for the process water’s heat and chemistry to be reused in the pre-wash, main wash, and rinse zones, having been accurately measured and controlled by inductive flow meters.

The enormous versatility of ALPHA TW5 tunnel washers means that a great variety of wash processes can be used to meet individual requirements. It goes without saying that this also includes low-temperature cycles. There are also various optional packages that allow the ALPHA TW5 to be adapted to suit special requirements such as the washing of work wear, dust mats and so on.

 

Have a look inside

 

In the basic configuration of the ALPHA TW5, washing is done in standing baths in the pre-wash and main wash areas (bath exchange process) and rinsing is in counterflow. JENSEN was the first manufacturer in the world to develop this process and bring it to market. Every batch stays in its own bath until the start of the rinse zone and has its own individually programmed quantity of detergent, process water temperature, bath level etc. In the basic version of the ALPHA TW5 the rinse process uses a counterflow . A patented rinse process ensures that consumption of fresh water is reduced by up to 10%.

 

A drain valve in the first rinse compartment is controlled in such a way that it opens several times and the process water is very rapidly diluted, thus producing an excellent rinse effect and an outstanding lint removal while using a minimal amount of rinse water. As another option, the ALPHA TW5 can be fitted with a device for using excess water from the press or centrifuge in order to save approximately 40% fresh water.In the post-treatment zone, the ALPHA TW5 has a double drum with an automatic drain valve that reduces the level in the bath, depending on the program, and this again greatly reduces the consumption of washing additives (acids, starch, softeners etc.). The process water that is drained off is, of course, recovered in a special tank in the tunnel wash.

Tuned to perfection

To adapt to different types of linen, and to optimize media consumption even further, the ALPHA TW5 can be fitted with the following options from our range:

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  • QuickSoak (pat. pend.) is optionally available and gives an extra shower for the linen in the first compartment for maximum soaking and drenching, achieving best wash performance and highest productivity.
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  • EcoTune (standard configuration) completes the tuning concept: A rotary encoder for individual swiveling angles and the level control in double drums form EcoTune and improves wash quality, provides less wear and tear, and generates lower energy consumption.
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  • Pre-rinsing with excess press or centrifuge process water to reduce fresh water consumption
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  • LintEx, the modular cascade filter system
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  • Additional lint filter combined with specially designed lint catch boxes on the double drums.
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  • Specially designed recovery tanks for processing dust mats

The heart of the ALPHA TW5

State-of-the-art wash process: JENSEN is the master of process technology.

The heart of the tunnel washer is its drum, with an eccentric Archimedian helix that makes the optimal use of the drum volume and thus produces a highly efficient wash action while securely transporting the linen batch. JENSEN’s smart drum design allows a lighter drum without compromising the strength resulting in less energy to operate. This unique design, plus the fact that the helix is fully welded to the inner drum throughout (with no vertical bulkheads), gives the drum an extraordinary degree of strength and stability.

 

The ALPHA TW5 therefore does not need any oversized drum plates, with their comparatively high weight and consequently greater consumption of drive power. The eccentric design of the helix makes far better use of the drum volume than is the case in conventional machines with drums of similar diameterand depth. Deep beaters ensure that the linen and process water are thoroughly mixed together and the outstanding washing action is made even more efficient by the washboard-shaped helix which offers multi-directional mechanical action. The drum is driven by a frequency-controlled geared motor and an extremely robust and durable toothed chain. This drive design has proved reliable a thousand times under the most severe conditions.

 

The frequency-controlled drive is very smooth-running and protects all the drive components. An automatic electronically monitored system ensures that the chain is always perfectly lubricated. Specially designed drain valves on the double drums ensure that solid matter such as sand or metal particles from work wear etc. is always removed from the compartment and damage due to catalysis is safely avoided. Generously designed rapid drain outlets with ball valves that open up the entire opening ensure that drain times are very short, bath exchange is efficient and there is no risk of lint accumulating. The specially designed wash beaters assist rapid bath exchange and the efficient transport of the linen batch.

 

All the drain valves also have clamp fasteners for ease of maintenance and can be opened without tools for inspection purposes – this is a tremendous advantage for the laundry manager as it saves time and money. The correct function of the drain valve can be checked through an inspection window in the discharge nozzle. Specially designed steam nozzles are ideally adapted to the drum geometry. Their position on the bottom of the double drums means that the steam very rapidly enters the process water and ensures very short heating stages even when cycle times are short and a perfect heat distribution within the batch. There is no time loss like on conventional machines with simple heating boxes below the drum.

Everything under control: Smart Automation

 

The recently developed machine control provides the user with a convenient operating interface, together with a highdegree of efficiency and safety. Operation is displayed and controlled from an industrial PC with a touch screen.

The Interbus design of the modular control enables the entire group of machines to be networked together so that every machine in a full wash line can be viewed and operated from every industrial PC. With conventional controllers, if one operator terminal fails it usually affects the whole system and causes a stoppage. The new control system has the unique advantage of compound redundancy meaning that the wash system can then continue to operate from another PC in the network, thus providing secure operation and avoiding a production failure. This high availability saves a lot of time and money. If, even so, a programming error or data loss occurs, the settings that have been previously saved on a flash card can quickly and easily be restored. The user-friendly control system offers you the following advantages:

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  • The whole of the wash process is displayed in real time
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  • Individual configuration of up to 100 wash programs
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  • The highest possible standard of security against production failure and data loss
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  • Allocation of individual access rights for up to 40 users provide a high degree of protection against programming errors or misuse
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  • Very user-friendly: Many languages are available for a flexible operation all over the world, even at the same time, e.g. a Spanish operator could work at the tunnel washer’s PPC, an American operator at the press and a Chinese operator at the dryers.
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  • Uniform control hardware on all plant components
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  • Convenience of operation thanks to the Windows-based display and the same tabular structure on the individual machines
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  • Quick and simple data backup on modern storage media
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  • Clear production statistics
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  • Detailed maintenance program offering the ability to generate a maintenance schedule for individual periods of time in the future.

In addition JENSEN provides an extraordinary after sales service through a worldwide network of highly qualified Sales and Service Centers and distributors, all with their own maintenance and spare parts services.

Machine Parts

Drum Bearing

Tooted Chain