Navis TubeTex Continuous Bleach Ranges are high production, low cost systems designed to bleach and wash a variety of fabrics. The Navis TubeTex model CBR 234 is designed to process cotton fabrics at the lowest possible operating cost while being rugged and simple to maintain.

The Navis TubeTex Continuous Bleach Ranges are currently operating in applications producing from as little as 1,000 kg to as much as 10,000 kg per day. The Navis TubeTex CBR 234 is designed to produce up to 400 kg per hour, running 100% cotton, “full white”. Whatever the production requirement, you can expect 95% operating efficiency with the Navis TubeTex system because of its rugged design and simple procedures.

Chemical costs should average near or below $.03 per lb. ($.06 per kg), less for poly/cotton, slightly more for 100% cotton, "full" white with optical. Total water (and sewer) usage should be approximately 1.25 gallon per lb. (10 liter per kg) of fabric bleached - a fraction of most competing methods and a significant cost in many localities. Direct labor required to operate the range is one operator. (An additional preparation person sews rolls together using optional preparation equipment.) The range operator's major activity is moving out finished goods. The bleach range normally needs little attention during continuous operation.

Process Overview, Navis TubeTex:

• Preparation - Fabric is unrolled using the Unrolling Cradle, sewn end to end in the Dry Scray, and stored in the Dry "J". A single operator handles all dry preparation. (A Navis TubeTex Tube Turner allows reversing fabric at the same time if necessary.)
• Kier InFeed - The innovative Navis TubeTex Squeeze-Less Pulley System which feeds the fabric without imparting crease and crack marks in the fabric, as is common with pinch rolls, pulls fabric into the Kier. A Jet Nozzle wets out the fabric before it enters the first compartment.
• Bleaching - Bleaching starts as the cloth is pulled into the first compartment of the Continuous Kier. A heated (typically 185° F or 85° C) hydrogen peroxide solution is continuously circulated through the cloth while it carries the cloth through each of the bleaching compartments. To minimize crease marks, cloth is transferred through the Continuous Kier without being subjected to any squeeze rolls. The CBR 234 has a volume of 195 cubic feet (5.6 m3). Continuous Kier approximately 75 minutes. Each Kier compartment holds approximately 350 lb. (160 kg) of fabric and 330 gallons (1250 liters) of liquor. Spray pipes over the kier compartments assures that wetting out is uniform. Proximity sensors in the front and “Pre-Tangle” Detectors in the back help keep the Kier full with minimum operator attention. Speed synchronization is automatic, controlled by the PLC to balance the InFeed, Kier, and Washer Drives.
• Navis TubeTex Jet Washers have revolutionized rope washing. Whether used in conjunction with our Continuous Bleach Ranges or as "stand alone" units for wash out after cold pad bleaching or dyeing, for scouring of greige fabrics, natural or synthetic, for wash off after print or after mercerizing treatment, the Navis TubeTex Jet Washer washes twice as clean with half as much water as conventional slack loop washers. At the same time, the gentle handling action and lack of squeeze rolls means far superior quality on crease sensitive goods and the elimination of significant maintenance and down time items, bearing replacement and the recovering of rubber rolls.
• Finished Goods are flat folded coming from the Jet Washer Balloon Squeeze Exit. Typical moisture is 80% and softener can be already on the fabric if desired, eliminating a Pad operation. The single Range operator moves wet boxes in and out while monitoring the Kier and Washer operation.

• First in, first out processing for consistent quality.
• Completely continuous automatic flow through all operations.
• Tubular fabric is never squeezed while in rope form, minimizing creases.
• Bleaching variables are easily stabilized and automatically controlled.
• The entire process is synchronized for full tensionless operation. Because we never squeeze roped fabric, the Navis TubeTex range does not stretch knits one meter in, one meter out! This makes it much easier to control garment shrinkage in finishing.
• The Navis TubeTex design automatically adjusts for varying fabric weights and widths, keeping compartments full without operator involvement, maximizing capacity and whiteness consistency of the Range.
• The Navis TubeTex system incorporates a soft flow for surface sensitive fabrics and to prevent tangling.
• The Navis TubeTex system hydrogen peroxide in a caustic soda bath achieves the highest white with a simple, safe proven, technology.

• High production achieved by 195 cubic feet (5.6 m3) bleaching bath, maximum fabric exposure, and minimum down time.
• Chemical costs are lower than any other continuous range, or batch process. Extra volume of bath and automatic maintenance of complete compartment loading allows user to use "weaker" liquor. Balloon Exit Rolls return extracted liquor to Kier. Wet pickup from Kier should be 80-85%.
• Labor cost is minimal and PLC controlled for greater economy and consistency.
• Continual titrations by an extra person not needed.
• Since the system is continuous, heat can by reclaimed efficiently from the wash water with an optional Navis TubeTex Heat Recovery Unit saving up to US$6.00 per hour of operation = US$900.00 per week.

• A broad range of fabric constructions, weights and fiber contents can be run in the Navis TubeTex. Full white, PFP and PFD, or scour.
• The Navis TubeTex Jet Washer can operate as a stand alone Washer for materials that don't go through the Bleach Range.

• Built with high quality components and engineered to last, Navis TubeTex constantly analyses machines for possible improvements.
• The Navis TubeTex Bleach Kier is uniquely designed with one pump and one heat exchanger maximizing consistency and minimizing complexity and maintenance.

• Dry fabric is fed directly from batching section into the Continuous Kier by means of Navis TubeTex's exclusive Squeeze-Less Pulley System.

• The three compartments Continuous Kier is rated at up to 900 lb (400 kg) per hour. Construction is of 304 stainless steel. The Navis TubeTex CBR's unique design insures that each compartment stays full of fabric, thereby eliminating tangles and maximizing production. Bleach chemicals are heated by one Heat Exchanger and circulated by one Pump to provide optimum efficiency and process consistency. After bleaching, valuable bleach solution is extracted as the fabric exits the Kier and is returned to the range.
• Navis TubeTex Liquor Level Control, Pre Tangle Detectors, and low abrasion Swinging Fabric Stops are standard on the Kier.
• The Kier top and wetted side walls are insulated to provide annual utility saving of approximately $8000.
  Chemical additions are done by a Chemical Metering Pumps System for each chemical used. Typical additions are 4-6 types. This system allows for quick and efficient changes for different fabric requirements.
• Option: A Heavy Duty Screen catches lint in front of the pump/heat exchanger. The access door is above the Kier fluid level to permit cleaning while the range continues to run.

Counter Flow Jet Washer:

• The Jet Washer is fabricated from 304 stainless steel. It is powered by a 5 horsepower (AC Inverter) drive with yardage meter and electrical controls. Speed is variable, up to 100 yd (90 m) per minute.
• The Jet Washer is fitted with a stainless steel pump and jet nozzle for each compartment, which together with a stainless steel reel, carries the fabric from compartment to compartment. All splashing is contained inside the Washer.
• All compartments contain J slide chutes designed to fill the compartment with fabric to operating level. As additional fabric enters the compartment, it actuates the automatic fabric control, keeping the level the same in all compartments.
• Each compartment is fitted with a perforated swing baffle sheet, which senses when the compartment is full and actuates the swinging poteye, stopping the fabric feeding that compartment. This trouble free automatic system keeps the Washer completely full of fabric without operator involvement.
• The Jet washer comes equipped with Navis TubeTex's low abrasion Swinging Fabric Stops.
• The Washer is supplied with all wetted areas and top fully insulated resulting in a yearly energy savings of approximately $4000.00.

• A Finished Goods Plaiter to deliver the wet fabric into square or rectangular boxes. The Plaiter has an adjustable stroke in both directions. It is driven from the Washer, insuring synchronization, which prevents stretching the fabric. Where Balloon Squeeze Exit for the Washer has been selected, a Flat Folder replaces the rope Plaiter.

• The control panel is pre-wired with starters and controls for drives in each section.
• Air pressure controls on exit rolls, fabric stop cylinders, and air injection for balloon squeeze devices.
• The PLC (Programmable Logic Controller) allows complete and precise monitoring and controlling of virtually all range functions. Speeds of the various drives, temperatures, flow rates, pH, and alarms are selectable.

• Option: A Navis TubeTex Heat Recovery Unit for the Washer. This unique self-cleaning, trouble free unit requires no pump. Spent hot wash water is channeled from the center of the Heat Recovery through a double pass across heat transfer coils before passing to the ditch. A dump valve activated by an adjustable timer rapidly dumps all the water from the tank periodically to clear waste buildup from the tank and coils. This option recovers approximately 1,400,000 BTU (350,000 kcal) per hour of operation. A boiler operating at 80% efficiency would use over 45 liters of fuel oil (or the equivalent in natural gas) to provide that much steam. At current US fuel cost, the Navis TubeTex HRU saves over US $6.00 per hour of operation or US $900.00 per week.

Operating Cost.

Chemical Usage: Typically, a full white can be obtained on 100% cotton using this suggested formula: (Severe water hardness and cotton quality might require somewhat higher concentrations.)