WO2018172768A1

WO2018172768A1 - Treatment apparatus for treating a substrate with solid particulate material

Info

Publication number: WO2018172768A1
Application number: PCT/GB2018/050732
Authority: WO
Inventors: Liam Daniel ROBERTS
Original assignee: Xeros Ltd
Current assignee: Xeros Ltd
Priority date: 2017-03-24
Filing date: 2018-03-21
Publication date: 2018-09-27
Anticipated expiration: 2019-09-24
Also published as: GB201704718D0; TW201838729A

Abstract

An apparatus (1) for use in the treatment of a substrate with a formulation comprising solid particulate material and treatment liquor, said apparatus (10) comprising a housing (20) having mounted therein a rotatably mounted drum (40), said drum (40) having side walls and said side walls comprising one or more apertures configured to permit said solid particulate material and said treatment liquor to exit the drum (40), a collector (88), wherein said collector (88) is located beneath said drum (40) and is configured to collect said solid particulate material and said treatment liquor that exits the drum (40), said collector (88) having an upper portion (4) proximate said drum (40) and a lower portion (6) distal to said drum (40), an access means for introducing said substrate into said drum (40) and a recirculation means for recirculating said solid particulate material from said collector (88) to said drum (40).

Description

TREATMENT APPARATUS FOR TREATING A SUBSTRATE

WITH SOLID PARTICULATE MATERIAL

The present disclosure relates to an apparatus that employs a multiplicity of solid particulate material in the treatment of substrates, particularly a substrate which is or comprises a textile. The present disclosure further relates to the operation of an apparatus for the treatment of substrates using solid particulate material. The disclosure particularly relates to an apparatus and method for cleaning of soiled substrates. Conventional methods for treating and cleaning of textiles and fabrics typically involve aqueous cleaning using large volumes of water. These methods generally involve aqueous submersion of fabrics followed by soil removal, aqueous soil suspension, and water rinsing. The use of solid particles to provide improvements in, and advantages over, these conventional methods is known in the art. For example PCT patent publication WO2007/128962 discloses a method for cleaning a soiled substrate using a multiplicity of solid particles. Other PCT patent publications which have related disclosures of cleaning methods include: WO2012/056252; WO2014/006424; WO2015/004444; WO2014/147391 ; WO2014/06425; WO 2012/035343 and WO2012/167545. These disclosures teach apparatus and methods for treating or cleaning a substrate which offers several advantages over conventional methods including: improved treating/cleaning performance, reduced water consumption, reduced consumption of detergent and other treatment agents, and better low temperature treating/cleaning (and thus more energy efficient treating/cleaning). Other patent applications, for instance WO2014/167358, WO2014/167359, WO2016/05118, WO/2016/055789 and WO2016/055788, teach the advantages provided by solid particles in other fields such as leather treatment and tanning.

It would be desirable to provide even better apparatus for treatment methods which involve the use of a multiplicity of solid particles. In particular, it would be desirable to further reduce water consumption, to improve the efficiency and reliability of the apparatus, to improve removal from the apparatus of solid waste fibres, or lint, derived from the substrate, and/or to reduce the power consumption and costs (including capital costs and/or running costs) of the apparatus and the operation thereof. It is an object of the present invention to address one of more of the aforementioned problems.

According to a first aspect of the invention, there is provided an apparatus for use in the treatment of a substrate with a formulation comprising solid particulate material and treatment liquor, said apparatus comprising: a housing having mounted therein a rotatably mounted drum, said drum having side walls and said side walls comprising one or more apertures configured to permit said solid particulate material and said treatment liquor to exit the drum;

a collector, wherein said collector is located beneath said drum and is configured to collect said solid particulate material and said treatment liquor that exits the drum, said collector having an upper portion proximate said drum and a lower portion distal to said drum;

an access means for introducing said substrate into said drum; and

a recirculation means for recirculating said solid particulate material from said collector to said drum;

wherein said lower portion of said collector has a smaller horizontal cross-sectional area than said upper portion;

wherein said lower portion comprises a first outlet for draining treatment liquor and a second outlet in fluid communication with said recirculation means.

Typically, the housing surrounds the drum and the collector. Preferably, the housing comprises a tub, wherein the drum is rotatably mounted within the tub. The tub may surround the drum, preferably wherein the tub and the drum are substantially concentric. Preferably, the collector may be formed from part of the tub. Where the collector is formed from part of the tub, the housing may consist of the tub. Preferably, the walls of the tub are unperforated but have disposed therein one or more inlets and/or one or more outlets suitable for passage of a treatment liquor and/or components of the treatment liquor into and out of the tub. Thus, the tub is suitably water-tight, permitting ingress and egress of liquid, such as the treatment liquor only through pipes or ducting components.

Typically, the drum is mounted substantially horizontally in the housing.

The drum has side walls comprising one or more apertures configured to permit said solid particulate material and said treatment liquor to exit the drum. Typically, the side walls of the drum have one or more apertures having a smallest dimension of from about 1 mm to about 20 mm, preferably from about 1 mm to about 15 mm. Typically, the one or more perforations or the one or more apertures may have a diameter of from about 1 mm to about 10 mm, preferably from about 1 mm to about 8 mm, preferably from about 1 mm to about 6 mm.

Preferably, the drum comprises perforated side walls, wherein the side walls comprise perforations that are larger than the largest dimension of the solid particles to allow passage of the solid particles through said perforations. Typically, the perforations have a smallest dimension of from about 1 mm to about 20 mm, preferably from about 1 mm to about 15 mm. Typically, the one or more perforations have a diameter of from about 1 mm to about 10 mm, preferably from about 1 mm to about 8 mm, preferably from about 1 mm to about 6 mm.

Alternatively or in addition, the drum may comprise one or more lifters, wherein the one or more lifters may comprise one or more apertures providing an alternative route for transfer of the solid particles out of the drum. The inner surface of the side walls of the drum may comprise a multiplicity of spaced apart elongated protrusions affixed essentially perpendicularly to the inner surface. Typically the drum may comprise from 3 to 10, preferably 4, of the protrusions, which are commonly referred to as "lifters". These lifters encourage circulation and agitation of the contents, that is, the substrate(s) and treatment liquor, within the drum during rotation of the drum.

The lifters may be adapted to collect solid particulate material from within the drum and transfer it to the collector. Lifters may comprise collecting and transferring means in the form of a plurality of compartments. The lifters may be located at equidistant intervals on the inner circumferential surface of the drum. The lifters may comprise a first aperture allowing ingress of the solid particles into the lifter and a second aperture allowing transfer of the solid particles into the collector. Optionally, the lifter may comprise a capturing compartment between the first aperture and the second aperture. The dimensions of the apertures may be selected in line with the dimensions of the solid particles, so as to allow efficient ingress and transfer thereof. The one or more apertures are preferably larger than the largest dimension of the solid particles. Typically, the one of more apertures of the lifters have a smallest dimension of from about 1 mm to about 20 mm, preferably from about 1 mm to about 15 mm. Typically, the one or more apertures may have a diameter of from about 1 mm to about 10 mm, preferably from about 1 mm to about 8 mm, preferably from about 1 mm to about 6 mm. The apparatus is preferably a front-loading apparatus, with the access means disposed in the front of the apparatus. Preferably the access means is or comprises a door. It will be appreciated that, suitably, the drum has an opening aligned with the access means, through which opening said substrates are introduced into said drum. The drum is preferably cylindrical, but other configurations are also envisaged, including for instance hexagonal drums. The inner surface of the drum is preferably a cylindrical inner surface.

Typically the recirculation means comprises a pipe or duct between the collector and the drum, the pipe or duct may be described as a "flow pathway pipe".

Preferably, the recirculation means comprises a first pump. The first pump assists in transferring solid particulate material that exits the second outlet of the collector back to the drum. For the pump to operate properly, at least a portion of the treatment liquor in the collector also exits the collector with said solid particulate material via the second outlet and enters the recirculation means, and is thereby recirculated to the drum. Preferably, the recirculation means comprises a separator. The recirculation means separator functions to separate solid particulate material from the treatment liquor that has been recirculated from the collector so that substantially only solid particulate material re-enters the drum. Preferably, the recirculation means separator is mounted in the access means of the apparatus. Alternatively, the recirculation means separator is preferably mounted above the access means. Treatment liquor that is separated by the recirculation means separator is preferably directed back to the collector. The treatment liquor may be returned to the collector via a drain in the access means. Alternatively, the treatment liquor may be returned to the collector via a pipe, wherein the pipe does not pass through the access means. Preferably, the treatment liquor that is separated by the recirculation means separator is directed into the collector via an agitating means comprising at least one nozzle, as described hereinbelow.

The apparatus may further comprise the typical components present in apparatus suitable for the treatment of substrates with solid particulate material and treatment liquor as described in more detail hereinbelow. Preferably, the apparatus comprises a suitable drive means to effect rotation of the drum, and suitably a drive shaft to effect rotation of the drum. Preferably, the apparatus comprises heating means for heating the treatment liquor. Preferably, the apparatus comprises mixing means to mix the components of the treatment liquor. The apparatus may further comprise one or more spray means to apply a liquid, such as the treatment liquor or a rinsing liquid into the interior of the drum and onto the substrate during the treatment thereof. It will be appreciated that the apparatus suitably further comprises a control means programmed with instructions for the operation of the apparatus according to at least one treatment cycle. The apparatus suitably further comprises a user interface for interfacing with the control means and/or apparatus.

Preferably, in the apparatus of the present invention, said lower portion of said collector further comprises a separator, wherein said separator prevents said solid particulate material from passing through and allows treatment liquor to pass through and wherein the separator is arranged within the collector such that said solid particulate material is able to enter said second outlet but is not able to enter said first outlet. The presence of said separator in the lower portion of the collector can advantageously improve recirculation of the solid particulate material from the collector to the drum. In particular, the presence of the separator may provide a shorter path through the collector for the solid particulate to travel towards the second outlet and/or may reduce the time taken for the solid particulate material to reach the second outlet by reducing the amount of treatment liquor through which the solid particulate material must pass. Furthermore, the separator advantageously keeps solid particulate material away from the first outlet, thereby avoiding build-up of solid particulate material in the region of the collector close to the first outlet that might otherwise block the first outlet or reduce the rate of draining of the treatment liquor from the first outlet. The separator may also assist in removal of waste fibres derived from the substrate, such as lint, from the apparatus. In particular, when the solid particulate material encounters the separator, the interaction of the separator and the solid particulate material may help break down waste fibres derived from the substrate, allowing them to pass through the separator and be drained from the collector via the first outlet.

Preferably, the separator is configured to bias said solid particulate material towards said second outlet. Accordingly, solid particulate material that exits the drum and is collected in the collector, is directed towards the second outlet and so reaches the recirculation means more quickly. As such, the residence time in the collector of solid particulate material may be reduced, thereby increasing the amount of solid particulate material elsewhere in the apparatus. This has an advantage of increasing the amount of solid particulate material in the drum at any given time compared to an arrangement where the residence time of solid particulate material in the collector is longer.

The separator comprised in the collector preferably comprises a plurality of apertures. The separator may comprise a web, mesh or grill. Alternatively, the separator may comprise a substrate having a plurality of apertures formed therein, that is, wherein the apertures are created in an existing substrate (referred to herein as post-formed apertures, and wherein the substrate having the post- formed apertures is referred to herein as being "perforated"). The apertures of the web or mesh or grill and the apertures formed in a substrate are sized so as to permit the passage of treatment liquor whilst preventing the passage of the solid particulate material. The size of the apertures in the separator depends on the size of the particles in the solid particulate material that are being used in the method of treating the substrate. As such, the apertures of the separator are required to be smaller than the smallest dimension of the solid particulate material.

The apertures of the separator may be any suitable shape, such as slots, circles, ovals, ellipses or hexagons. Preferably the separator comprises apertures that have a smooth perimeter, such as circles, ovals or ellipses. An advantage of having shapes without vertices, such as circles, ovals and ellipses, is that fouling of the separator by solid waste fragments derived from the substrate being treated (which may be referred to as formation of solid waste fragment stalactites) may be reduced or prevented. The total open area of the separator (wherein the total open area is the total surface area of the apertures as a percentage of the total surface area of the separator) is typically at least about 40%, at least about 45%, at least about 50%, at least about 55%, preferably at least about 60%. The total open area of the separator is no more than about 99%, no more than about 90%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%. Preferably, the total open area is from about 45% to about 70%, preferably from about 60% to about 65%.

An example of a preferred separator comprises a multiplicity of wedge-shaped rods or wires positioned together to form a grill. In this arrangement, the apertures in the separator are comprised of the gaps between the wedge-shaped rods or wires and are linear apertures. Preferably, the wedge-shaped rods or wires are arranged to form a grill in such a way as to present an essentially planar surface on one side of the grill. Preferably, the wedge-shaped rods or wires are arranged so that they are substantially parallel. The separator may be made from or comprise a metal (including an alloy), a polymer (including a polymeric composite (such as a glass fibre reinforced polymer)) or a ceramic. Preferably, the separator comprises metal, more preferably stainless steel.

The separator may be woven (such as a mesh formed from an interlaced network of wire or thread) or a substrate or plate with apertures formed therein (i.e. non-woven). Preferably, the separator is non-woven.

Preferably, the separator is substantially planar. For example, the separator may comprise a plate with apertures formed therein. Preferably, the separator comprises or consists of a non-woven mesh, such as an apertured (also described herein as "perforated") flat plate. Preferably, the separator comprises or consists of a perforated sheet. Preferably, the separator comprises or consists of a perforated metal plate. Having a metal plate with apertures formed therein generally reduces trapping of solid waste fragments compared with woven or mesh structures and allows for easier cleaning. Metal plates with apertures formed therein also suffer less from deformation and therefore require replacing less frequently.

In particular, the use of a metal plate having oval or elliptical apertures formed therein as the separator leads to high levels of solid particulate material separation and reduces the fouling of the separator by solid waste fragments. Furthermore, the use of a metal plate is advantageous as it is durable and better able to withstand cleaning, in particular solid waste fragment removal, without distorting aperture size or shape. Where the separator is substantially planar, the separator is preferably inclined at an angle A to a horizontal plane, wherein angle A is from about 10° to 50°. By inclining the separator from a horizontal plane, at least some of the solid particulate material will tend to roll down the separator, which may further assist in breaking down waste fibres derived from the substrate, allowing them to pass through the separator and be drained from the collector via the first outlet and thus removed from the apparatus.

Alternatively, the separator may be curved in at least one direction. The separator may be curved in one direction and also curved in a second direction. Preferably, the second direction is orthogonal to the first direction. Preferably, the separator is curved in one direction only.

The horizontal cross-sectional area of the lower portion of the collector is smaller than the horizontal cross-section area of the upper portion of the collector. Preferably, the horizontal cross-sectional area at the lowest part of the lower portion of the collector is less than about 50%, preferably less than about 40%, preferably less than about 30%, preferably less than about 20%, preferably about 10% of the horizontal cross-sectional area of the upper portion of the collector. Preferably, the horizontal cross-sectional area at the lowest part of the lower portion of the collector is from about 10% to about 50%, preferably from about 20 % to about 40%, preferably from about 20% to about 30% of the horizontal cross-sectional area of the upper portion of the collector.

Preferably, the collector comprises a channel in the lower portion and also comprises at least one feeder surface for directing said solid particulate material and said treatment liquor into said channel, and said channel comprises said first outlet and said second outlet. By having a channel in the lower portion of the collector, into which the solid particulate material and treatment liquor is directed from a feeder surface, the amount of treatment liquor needed in the apparatus to allow for recirculation of the solid particulate material to take place can be minimised. In particular, where the recirculation means comprises a first pump, the pump needs to be presented with a certain amount of treatment liquor in order that it is able to work properly. If the pump is not presented with enough treatment liquor, it will take in air and either not pump efficiently or will stop pumping. By having a collector arranged in this way with a channel in the lower portion and at least one feeder surface, the treatment liquor congregates in the channel and so maximises the volume of treatment liquor available to the first pump via the second outlet. As such, the total volume of treatment liquor required in the apparatus can be reduced, while maintaining the effectiveness of the substrate treatment. Typically, the volume of treatment liquor required in the apparatus can be reduced significantly, for example by from about 10% to about 50%, or by more than 50%. Furthermore, the arrangement of the channel and the at least one feeder surface can control the flow of the solid particulate material and the treatment liquor within the collector. An advantage of this is, for example, the prevention of the formation of a vortex in the treatment liquor within the collector, which could otherwise potentially lead to air being introduced into the pump.

The channel may additionally comprise a separator as described above. Preferably, the separator is comprised entirely within the channel.

Preferably, the channel extends substantially between a first side wall of said collector proximate said access means and a second side wall of said collector distal to said access means. Where the channel is oriented in this way, preferably the second outlet is located proximate the second side wall. Alternatively or in addition, the first outlet may be located proximate said first side wall.

The channel may be in any suitable shape to allow solid particulate material and treatment liquor to move into the channel and to facilitate the movement of solid particulate material towards the second outlet. For example, the channel may have a curved or arc shape. Preferably, the channel is substantially linear.

The channel may have a cross section in the shape of a square, oblong, trapezoid, trapezium, rhombus or rhomboid along at least part of its length, preferably along its entire length, more preferably the channel has a cross section in the shape of a square or oblong along at least part of its length, preferably along its entire length. Having a channel with a square or oblong cross-section has an advantage of minimizing trapping of particles in corners of the channel, particularly in embodiments where the channel does not comprise a separator.

Alternatively, the channel may have a cross-section comprising a curved portion, for example the channel may have a U-shaped cross section along at least part of its length, preferably along its entire length.

Preferably, the volume of the channel is selected depending on the amount of treatment liquor that will be used in the apparatus during one treatment cycle. Preferably, the volume of the channel is such that the ratio of the volume of treatment liquor in the apparatus to the volume of the channel is greater than 1 :1 , preferably greater than 2:1 , more preferably greater than 3: 1. The volume of the channel should be such that there is sufficient treatment liquor in the channel in order to avoid introducing air into the recirculation means, particularly when the recirculation means comprises the first pump.

Suitably, the width of the channel is selected depending on the diameter of the second outlet and the size of the solid particles in the solid particulate material. Preferably, the width of the channel is larger than the diameter of the second outlet in order to optimise flow of the solid particulate material and the treatment liquor and to avoid the trapping of solid particulate material in regions, such as in corners, of the channel. Typically, the channel has a width of from about 5 cm to about 30 cm, preferably from about 10 cm to about 25 cm, preferably from about 15 cm to about 20cm.

Typically, the channel has a depth of from about 5 cm to about 30 cm, preferably from about 5 cm to about 8 cm.

Preferably, the channel has a sloping floor configured to direct treatment liquor towards the first outlet, preferably the sloping floor is inclined at an angle B to a horizontal plane, wherein angle B is from about 1 ° to about 10°, preferably about 2° to about 5°.

The at least one feeder surface is preferably configured such that the solid particulate material can flow down, roll down or be washed down the feeder surface and into the channel. The at least one feeder surface is preferably inclined at an angle C to a horizontal plane, wherein angle C is from about 10° to about 50°, preferably from about 15° to about 40°, preferably from about 20° to about 30°.

The collector may comprise a single feeder surface, in which case the channel is preferably located along one side of the collector. In a preferred arrangement, the channel is positioned between two feeder surfaces. Where the channel is positioned between two feeder surfaces, each surface is inclined towards the channel. In this arrangement, the channel is preferably positioned centrally in the collector. The collector may comprise two, three, four or more than four feeder surfaces.

The lower portion of the collector may comprise at least a portion of the at least one feeder surface.

Preferably, a first side wall of the collector proximate the access means is inclined at an angle D to a vertical plane, wherein angle D is from about 3° to about 10°, preferably about 5°. Having an inclined first side wall improves the flow of solid particulate material and treatment liquor towards the lower portion of the collector.

The first outlet may be used to drain treatment liquor from the collector. The first outlet may be in fluid communication with a waste drain for disposal of treatment liquor. Preferably, the first outlet is in fluid communication with filtration means for filtering solid waste material derived from the substrate, such as lint, from said treatment liquor. Typically, the filtration means comprises a filter having apertures that allow the treatment liquor to pass through but which prevent solid waste material derived from the substrate passing through. Alternatively, the filtration means may be a hydrocyclone. Preferably, the filtered treatment liquor is recycled into the apparatus. More preferably the filtered treatment liquor is directed into the collector via at least one nozzle.

Preferably, the apparatus further comprises an agitating means for agitating solid particulate material and/or treatment liquor in the collector. The agitating means may be a stirrer in the lower portion of the collector, preferably in the channel. The presence of a stirrer can cause turbulent flow of the treatment liquor and/or the solid particulate material in the lower portion of the collector which can assist in encouraging flow of the solid particulate material towards the second outlet, which can advantageously decrease the residence time of the solid particulate material in the collector, thereby increasing the quantity of solid particulate material in the drum during the substrate treatment.

Alternatively or in addition, the agitating means preferably comprises at least one nozzle configured to direct liquid towards said lower portion of said collector. Preferably, the at least one nozzle is positioned in the upper portion of the collector. Preferably, the at least one nozzle directs liquid to the at least one feeder surface, more preferably to a side of the at least one feeder surface that is proximate to the access means. In this way, the liquid directed into the collector can assist in moving solid particulate material on the at least one feeder surface towards the channel and/or in moving solid particulate material in the channel towards the second outlet. Preferably, the liquid directed by the at least one nozzle is fresh treatment liquor, more preferably the liquid is treatment liquor that has been drained from the collector and has been filtered as described hereinabove.

Where the liquid is treatment liquor that has been drained from the collector and has been filtered, the agitation means preferably comprises ducting for recycling the filtered treatment liquor from the first outlet to the at least one spray nozzle via the filtration means. In this arrangement, the channel may optionally comprise a third outlet through which to drain treatment liquor without recycling to the at least one spray nozzle.

Typically, the agitating means comprising the at least one nozzle further comprises a second pump. In this way, liquid that is directed in to the collector from the at least one nozzle is able to more effectively encourage flow of the said solid particulate material towards the second outlet. This has an effect of preventing the generation of areas within the collector in which solid particulate material and/or solid waste fibres derived from the substrate are substantially static or do not flow towards the second outlet. This also has an effect of advantageously further decreasing the residence time of the solid particulate material in the collector, thereby increasing the quantity of solid particulate material in the drum during the substrate treatment. The apparatus preferably comprises said solid particulate material.

The apparatus of the present invention is preferably configured for the treatment of substrates with solid particulate material in the presence of a treatment liquor. The solid particulate material preferably comprises a multiplicity of particles. Typically, the number of particles is no less than 1000, more typically no less than 10,000, even more typically no less than 100,000. A large number of particles is particularly advantageous in preventing creasing and/or for improving the uniformity of treating or cleaning of the substrate, particularly wherein the substrate is a textile.

Preferably, the particles have an average mass of from about 1 mg to about 1000 mg, or from about 1 mg to about 700 mg, or from about 1 mg to about 500 mg, or from about 1 mg to about 300 mg, preferably at least about 10 mg, per particle. In one preferred embodiment, the particles preferably have an average mass of from about 1 mg to about 150 mg, or from about 1 mg to about 70 mg, or from about 1 mg to about 50 mg, or from about 1 mg to about 35 mg, or from about 10 mg to about 30 mg, or from about 12mg to about 25 mg. In an alternative embodiment, the particles preferably have an average mass of from about 10 mg to about 800 mg, or from about 20mg to about 700mg, or from about 50 mg to about 700 mg, or from about 70 mg to about 600 mg from about 20mg to about 600mg. In one preferred embodiment, the particles have an average mass of about 25 to about 150 mg, preferably from about 40 to about 80 mg. In a further preferred embodiment, the particles have an average mass of from about 150 to about 500 mg, preferably from about 150 to about 300 mg.

The average volume of the particles is preferably in the range of from about 5 to about 500 mm³, from about 5 to about 275 mm³, from about 8 to about 140 mm³, or from about 10 to about 120 mm³, or at least 40 mm³, for instance from about 40 to about 500 mm³, or from about 40 to about 275 mm³, per particle.

The average surface area of the particles is preferably from 10 mm² to 500 mm² per particle, preferably from 10mm² to 400mm², more preferably from 40 to 200mm² and especially from 50 to 190mm². The particles preferably have an average particle size of at least 1 mm, preferably at least 2mm, preferably at least 3mm, preferably at least 4 mm, and preferably at least 5mm. The particles preferably have an average particle size no more than 100mm, preferably no more than 70mm, preferably no more than 50mm, preferably no more than 40mm, preferably no more than 30mm, preferably no more than 20mm, preferably no more than 10mm, and optionally no more than 7mm. Preferably, the particles have an average particle size of from 1 to 20mm, more preferably from 1 to 10mm. Particles which offer an especially prolonged effectiveness over a number of treatment cycles are those with an average particle size of at least 5mm, preferably from 5 to 10mm. The size is preferably the largest linear dimension (length). For a sphere this equates to the diameter. For non- spheres this corresponds to the longest linear dimension. The size is preferably determined using Vernier callipers. The average particle size is preferably a number average. The determination of the average particle size is preferably performed by measuring the particle size of at least 10, more preferably at least 100 particles and especially at least 1000 particles. The above mentioned particle sizes provide especially good performance (particularly cleaning performance) whilst also permitting the particles to be readily separable from the substrate at the end of the treatment method.

The particles preferably have an average particle density of greater than 1 g/cm³, more preferably greater than 1.1 g/cm³, more preferably greater than 1.2g/cm³, even more preferably at least 1.25g/cm³ and especially preferably greater than 1.3g/cm³. The particles preferably have an average particle density of no more than 3g/cm³ and especially no more than 2.5g/cm³. Preferably, the particles have an average density of from 1.2 to 3g/cm³. These densities are advantageous for further improving the degree of mechanical action which assists in the treatment process and which can assist in permitting better separation of the particles from the substrate after the treatment. The particles of the solid particulate material may be polymeric and/or non-polymeric particles. Suitable non-polymeric particles may be selected from metal, alloy, ceramic and glass particles. Preferably, however, the particles of the solid particulate material are polymeric particles.

Preferably the particles comprise a thermoplastic polymer. A thermoplastic polymer, as used herein, preferably means a material which becomes soft when heated and hard when cooled. This is to be distinguished from thermosets (e.g. rubbers) which will not soften on heating. A more preferred thermoplastic is one which can be used in hot melt compounding and extrusion.

The polymer preferably has a solubility in water of no more than 1wt%, more preferably no more than 0.1 wt% in water and most preferably the polymer is insoluble in water. Preferably the water is at pH 7 and a temperature of 20°C whilst the solubility test is being performed. The solubility test is preferably performed over a period of 24 hours. The polymer is preferably not degradable. By the words "not degradable" it is preferably meant that the polymer is stable in water without showing any appreciable tendency to dissolve or hydrolyse. For example, the polymer shows no appreciable tendency to dissolve or hydrolyse over a period of 24hrs in water at pH 7 and at a temperature of 20°C. Preferably a polymer shows no appreciable tendency to dissolve or hydrolyse if no more than about 1 wt%, preferably no more than about 0.1 wt% and preferably none of the polymer dissolves or hydrolyses, preferably under the conditions defined above.

The polymer may be crystalline or amorphous or a mixture thereof. The polymer can be linear, branched or partly cross-linked (preferably wherein the polymer is still thermoplastic in nature), more preferably the polymer is linear.

The polymer preferably is or comprises a polyalkylene, a polyamide, a polyester or a polyurethane and copolymers and/or blends thereof, preferably from polyalkylenes, polyamides and polyesters, preferably from polyamides and polyalkylene, and preferably from polyamides.

A preferred polyalkylene is polypropylene.

A preferred polyamide is or comprises an aliphatic or aromatic polyamide, more preferably an aliphatic polyamide. Preferred polyamides are those comprising aliphatic chains, especially C4-C16, C4-C12 and C4-C10 aliphatic chains. Preferred polyamides are or comprise Nylons. Preferred Nylons include Nylon 4,6, Nylon 4, 10, Nylon 5, Nylon 5, 10, Nylon 6, Nylon 6,6, Nylon 6/6,6, Nylon 6,6/6, 10, Nylon 6, 10, Nylon 6, 12, Nylon 7, Nylon 9, Nylon 10, Nylon 10, 10, Nylon 1 1 , Nylon 12, Nylon 12, 12 and copolymers or blends thereof. Of these, Nylon 6, Nylon 6,6 and Nylon 6,10, and particularly Nylon 6 and Nylon 6,6, and copolymers or blends thereof are preferred. It will be appreciated that these Nylon grades of polyamides are not degradable, wherein the word degradable is preferably as defined above.

Suitable polyesters may be aliphatic or aromatic, and preferably derived from an aromatic dicarboxylic acid and a C1-C6, preferably C2-C4 aliphatic diol. Preferably, the aromatic dicarboxylic acid is selected from terephthalic acid, isophthalic acid, phthalic acid, 1 ,4-, 2,5-, 2,6- and 2,7- naphthalenedicarboxylic acid, and is preferably terephthalic acid or 2,6-naphthalenedicarboxylic acid, and is most preferably terephthalic acid. The aliphatic diol is preferably ethylene glycol or 1 ,4- butanediol. Preferred polyesters are selected from polyethylene terephthalate and polybutylene terephthalate. Useful polyesters can have a molecular weight corresponding to an intrinsic viscosity measurement in the range of from about 0.3 to about 1.5 dl/g, as measured by a solution technique such as ASTM D-4603. Preferably, polymeric particles comprise a filler, preferably an inorganic filler, suitably an inorganic mineral filler in particulate form, such as BaSCU. The filler is preferably present in the particle in an amount of at least 5wt%, more preferably at least 10wt%, even more preferably at least 20wt%, yet more preferably at least 30wt% and especially at least 40wt% relative to the total weight of the particle. The filler is typically present in the particle in an amount of no more than 90wt%, more preferably no more than 85wt%, even more preferably no more than 80wt%, yet more preferably no more than 75wt%, especially no more than 70wt%, more especially no more than 65wt% and most especially no more than 60wt% relative to the total weight of the particle. The weight percentage of filler is preferably established by ashing. Preferred ashing methods include ASTM D2584, D5630 and ISO 3451 , and preferably the test method is conducted according to ASTM D5630. For any standards referred to in the present invention, unless specified otherwise, the definitive version of the standard is the most recent version which precedes the priority filing date of this patent application. Preferably, the matrix of said polymer optionally comprising filler(s) and/or other additives extends throughout the whole volume of the particles.

The particles can be spheroidal or substantially spherical, ellipsoidal, cylindrical or cuboid. Particles having shapes which are intermediate between these shapes are also possible. The best results for treatment performance (particularly cleaning performance) and separation performance (separating the substrate from the particles after the treating steps) in combination are typically observed with ellipsoidal particles. Spheroidal particles tend to separate best but may provide optimum treatment or cleaning performance. Conversely, cylindrical or cuboid particles separate poorly but treat or clean effectively. Spherical and ellipsoidal particles are particularly useful where improved fabric care is important because they are less abrasive. Spheroidal or ellipsoidal particles are particularly useful in the present invention which is designed to operate without a particle pump and wherein the transfer of the particles between the storage means and the interior of the drum is facilitated by rotation of the drum.

The term "spheroidal", as used herein, encompasses spherical and substantially spherical particles. Preferably, the particles are not perfectly spherical. Preferably, the particles have an average aspect ratio of greater than 1 , more preferably greater than 1.05, even more preferably greater than 1.07 and especially greater than 1.1. Preferably, the particles have an average aspect ratio of less than 5, preferably less than 3, preferably less than 2, preferably less than 1.7 and preferably less than 1.5. The average is preferably a number average. The average is preferably performed on at least 10, more preferably at least 100 particles and especially at least 1000 particles. The aspect ratio for each particle is preferably given by the ratio of the longest linear dimension divided by the shortest linear dimension. This is preferably measured using Vernier Callipers. Where a good balance between treating performance (particularly cleaning performance) and substrate care is required, it is preferred that the average aspect ratio is within the abovementioned values. When the particles have a very low aspect ratio (e.g. highly spherical particles), the particles may not provide sufficient mechanical action for good treating or cleaning characteristics. When the particles have an aspect ratio which is too high, the removal of the particles from the substrate may become more difficult and/or the abrasion on the substrate may become too high, which may lead to unwanted damage to the substrate, particularly wherein the substrate is a textile.

According to a further aspect of the present invention, there is provided a method for treating a substrate, the method comprising agitating the substrate with solid particulate material in the apparatus of the present invention, as described herein.

Preferably, in the method of the present invention, the solid particulate material is re-used in further treatment procedures.

The method preferably comprises agitating the substrate with solid particulate material and a treatment liquor.

The method may comprise the additional step of rinsing the treated substrate. Rinsing is preferably performed by adding a rinsing liquid medium, optionally comprising one or more post-treatment additives, to the treated substrate. The rinsing liquid medium is preferably an aqueous medium, i.e. the rinsing liquid medium is or comprises water. In order of increasing preference, the rinsing liquid medium comprises at least 50wt%, at least 60wt%, at least 70wt%, at least 80wt%, at least 90wt%, at least 95wt% and at least 98wt% of water. More preferably, the rinsing liquid medium is water.

Thus, preferably, the method is a method for treating multiple batches, wherein a batch comprises at least one substrate, the method comprising agitating a first batch with solid particulate material, wherein said method further comprises the steps of:

(a) collecting said solid particulate material in the storage means;

(b) agitating a second batch comprising at least one substrate with solid particulate material collected from step (a); and

(c) optionally repeating steps (a) and (b) for subsequent batch(es) comprising at least one substrate.

The treatment procedure of an individual batch typically comprises the steps of agitating the batch with said solid particulate material in a treatment apparatus for a treatment cycle. A treatment cycle typically comprises one or more discrete treatment step(s), optionally one or more rinsing step(s), optionally one or more step(s) of separating the particles from the treated batch, optionally one or more extraction step(s) of removing treatment liquor from the treated batch, optionally one or more drying step(s), and optionally the step of removing the treated batch from the apparatus. In the method of the present invention, steps (a) and (b) may be repeated at least 1 time, preferably at least 2 times, preferably at least 3 times, preferably at least 5 times, preferably at least 10 times, preferably at least 20 times, preferably at least 50 times, preferably at least 100 times, preferably at least 200 times, preferably at least 300 times, preferably at least 400 at least or preferably at least 500 times.

The substrate may be or comprise a textile and/or an animal skin substrate. In a preferred embodiment, the substrate is or comprises a textile. The textile may be in the form of an item of clothing such as a coat, jacket, trousers, shirt, skirt, dress, jumper, underwear, hat, scarf, overalls, shorts, swim wear, socks and suits. The textile may also be in the form of a bag, belt, curtains, rug, blanket, sheet or a furniture covering. The textile can also be in the form of a panel, sheet or roll of material which is later used to prepare the finished item or items. The textile can be or comprise a synthetic fibre, a natural fibre or a combination thereof. The textile can comprise a natural fibre which has undergone one or more chemical modifications. Examples of natural fibres include hair (e.g. wool), silk and cotton. Examples of synthetic textile fibres include Nylon (e.g. Nylon 6,6), acrylic, polyester and blends thereof. As used herein, the term "animal skin substrate" includes skins, hides, pelts, leather and fleeces. Typically, the animal skin substrate is a hide or a pelt. The hide or pelt may be a processed or unprocessed animal skin substrate.

The treating of a substrate which is or comprises a textile according to the present invention may be a cleaning process or any other treatment process such as coloration (preferably dyeing), ageing or abrading (for instance stone-washing), bleaching or other finishing process. Stonewashing is a known method for providing textiles having "worn in" or "stonewashed" characteristics such as a faded appearance, a softer feel and a greater degree of flexibility. Stonewashing is frequently practiced with denim. Preferably the treating of a substrate which is or comprises a textile is a cleaning process. The cleaning process may be a domestic or industrial cleaning process.

As used herein, the term "treating" in relation to treating an animal skin substrate is preferably a tannery process, including colouring and tanning and associated tannery processes, preferably selected from curing, beamhouse treatments, pre-tanning, tanning, re-tanning, fat liquoring, enzyme treatment, tawing, crusting, dyeing and dye fixing, preferably wherein said beamhouse treatments are selected from soaking, liming, deliming, reliming, unhairing, fleshing, bating, degreasing, scudding, pickling and depickling. Preferably, said treating of an animal skin substrate is a process used in the production of leather. Preferably, said treating acts to transfer a tanning agent (including a colourant or other agent used in a tannery process) onto or into the animal skin substrate.

The treatment liquor referred to herein may comprise one or more treatment agent(s) which are suitable to effect the desired treating of the substrate.

Thus, a method according to the present invention which is a cleaning process suitably comprises agitating the substrate with said solid particulate material and a treatment liquor comprising one or more treatment agents, wherein said treatment liquor is preferably a detergent composition comprising one or more of the following components: surfactants, dye transfer inhibitors, builders, enzymes, metal chelating agents, biocides, solvents, stabilizers, acids, bases and buffers.

Similarly, the treatment liquor of a coloration process preferably comprises one or more dyes, pigments, optical brighteners and mixtures thereof.

The treatment liquor of a stone-washing process may comprise an appropriate stone-washing agent, as known in the art, for instance an enzymatic treatment agent such as a cellulase.

The treatment liquor of a tannery process suitably comprises one or more agent(s) selected from tanning agents, re-tanning agents and tannery process agents. The treatment liquor may comprise one or more colourant(s). The tanning or re-tanning agent is preferably selected from synthetic tanning agents, vegetable tanning or vegetable re-tanning agents and mineral tanning agents such as chromium (III) salts or salts and complexes containing iron, zirconium, aluminium and titanium. Suitable synthetic tanning agents include amino resins, polyacrylates, fluoro and/or silicone polymers and formaldehyde condensation polymers based on phenol, urea, melamine, naphthalene, sulphone, cresol, bisphenol A, naphthol and/or biphenyl ether. Vegetable tanning agents comprise tannins which are typically polyphenols. Vegetable tanning agents can be obtained from plant leaves, roots and especially tree barks. Examples of vegetable tanning agents include the extracts of the tree barks from chestnut, oak, redoul, tanoak, hemlock, quebracho, mangrove, wattle acacia; and myrobalan. Suitable mineral tanning agents comprise chromium compounds, especially chromium salts and complexes, typically in a chromium (III) oxidation state, such as chromium (III) sulphate. Other tanning agents include aldehydes (glyoxal, glutaraldehyde and formaldehyde), phosphonium salts, metal compounds other than chromium (e.g. iron, titanium, zirconium and aluminium compounds). Preferably, the tanning agents are substantially free from chromium- containing compounds.

One or more substrates can be simultaneously treated by the method of the invention. The exact number of substrates will depend on the size of the substrates and the capacity of the apparatus utilized.

The total weight of dry substrates treated at the same time (i.e. in a single batch or washload) may be up to 50,000 kg. For textile substrates, the total weight is typically from 1 to 500 kg, more typically 1 to 300 kg, more typically 1 to 200 kg, more typically from 1 to 100 kg, even more typically from 2 to 50 kg and especially from 2 to 30 kg. For animal substrates, the total weight is normally at least about 50 kg, and can be up to about 50,000 kg, typically from about 500 to about 30,000 kg, from about 1000 kg to about 25,000 kg, from about 2000 to about 20,000 kg, or from about 2500 to about 10,000 kg.

Preferably the treatment liquor is an aqueous medium, i.e. the treatment liquor is or comprises water. In order of increasing preference, the treatment liquor comprises at least 50wt%, at least 60wt%, at least 70wt%, at least 80wt%, at least 90wt%, at least 95wt% and at least 98wt% of water. The treatment liquor may optionally comprise one or more organic liquids including for example alcohols, glycols, glycol ethers, amides and esters. Preferably, the sum total of all organic liquids present in the treatment liquor is no more than 10wt%, more preferably no more than 5wt%, even more preferably no more than 2wt%, especially no more than 1 % and most especially the treatment liquor is substantially free from organic liquids.

The treatment liquor preferably has a pH of from 3 to 13. The pH of the treatment liquor can differ at different times, points or stages in the treatment method according to the invention. It can be desirable to treat (particularly to clean) a substrate under alkaline pH conditions, although while higher pH offers improved performance (particularly cleaning performance) it can be less kind to some substrates. Thus, it can be desirable that the treatment liquor has a pH of from 7 to 13, more preferably from 7 to 12, even more preferably from 8 to 12 and especially from 9 to 12. In a further preferred embodiment, the pH is from 4 to 12, preferably 5 to 10, especially 6 to 9, and most especially 7 to 9, particularly in order to improve fabric care. It may also be desirable that the treating of a substrate, or one or more specific stage(s) of a treatment process, is conducted under acid pH conditions. For instance, certain steps in the treatment of animal skin substrates are advantageously conducted at a pH which is typically less than 6.5, even more typically less than 6 and most typically less than 5.5, and typically no less than 1 , more typically no less than 2 and most typically no less than 3. Certain fabric or garment finishing treatment methods, for instance stone-washing, may also utilise one or more acidic stage(s). An acid and/or base may be added in order to obtain the abovementioned pH values. Preferably, the abovementioned pH is maintained for at least a part of the duration, and in some preferred embodiments for all of the duration, of the agitation. In order to prevent the pH of the treatment liquor from drifting during the treatment, a buffer may be used. Preferably, the weight ratio of the treatment liquor to the dry substrate is no more than 20: 1 , more preferably no more than 10:1 , especially no more than 5: 1 , more especially no more than 4.5:1 and even more especially no more than 4:1 and most especially no more than 3: 1. Preferably, the weight ratio of treatment liquor to the dry substrate is at least 0.1 : 1 , more preferably at least 0.5: 1 and especially at least 1 :1. In the present invention, it is possible to use surprisingly small amounts of treatment liquor whilst still achieving good treatment performance (particularly cleaning performance), which has environmental benefits in terms of water usage, waste water treatment and the energy required to heat or cool the water to the desired temperature.

More than one type of treatment liquor may be used during the methods of treating a substrate described herein. For example, a treatment liquor consisting of water may be added initially to the substrate in the drum prior to the introduction of solid particulate material. Subsequently, during agitation of the substrate with the solid particulate material, a treatment liquor comprising water and one or more treatment agents may be used.

Preferably, the ratio of particles to dry substrate is at least 0.1 , especially at least 0.5 and more especially at least 1 :1 w/w. Preferably, the ratio of particles to dry substrate is no more than 30: 1 , more preferably no more than 20: 1 , especially no more than 15:1 and more especially no more than 10: 1 w/w. Preferably, the ratio of the particles to dry substrate is from 0.1 : 1 to 30:1 , more preferably from 0.5: 1 to 20: 1 , especially from 1 :1 to 15:1 w/w and more especially from 1 : 1 to 10:1 w/w.

The treatment method agitates the substrate in the presence of the solid particulate material. The agitation may be in the form of shaking, stirring, jetting and tumbling. Of these, tumbling is especially preferred. Preferably, the substrate and solid particulate material are introduced into the drum which is rotated so as to cause tumbling. The rotation can be such as to provide a centripetal force of from 0.05 to 1G and especially from 0.05 to 0.7G. The centripetal force is preferably as calculated at the interior walls of the drum furthest away from the axis of rotation. The solid particulate material is able to contact the substrate, suitably mixing with the substrate during the agitation.

The agitation may be continuous or intermittent. Preferably, the method is performed for a period of from 1 minute to 10 hours, more preferably from 5 minutes to 3 hours and even more preferably from 10 minutes to 2 hours. The treatment method is preferably performed at a temperature of from greater than 0°C to about 95°C, preferably from 5 to 95°C, preferably at least 10°C, preferably at least 15°C, preferably no more than 90°C, preferably no more than 70°C, and advantageously no more 50°C, no more than 40°C or no more than 30°C. Such milder temperatures allow the particles to provide the afore- mentioned benefits over larger numbers of treatment cycles. Preferably, when several batches or washloads are treated or cleaned, every treating or cleaning cycle is performed at no more than a temperature of 95°C, more preferably at no more than 90°C, even more preferably at no more than 80°C, especially at no more than 70°C, more especially at no more than 60°C and most especially at no more than 50°C, and from greater than 0°C, preferably at least 5°C, preferably at least 10°C, preferably at least 15°C, preferably from greater than 0 to 50°C, greater than 0 to 40°C, or greater than 0 to 30°C, and advantageously from 15 to 50°C, 15 to 40°C or 15 to 30°C. These lower temperatures again allow the particles to provide the benefits for a larger number of treatment or wash cycles. It will be appreciated that the duration and temperature conditions described hereinabove are associated with the treating of an individual batch comprising at least one of said substrate(s).

Agitation of the substrates with the solid particulate material suitably takes place in said one or more discrete treating step(s) of the aforementioned treatment cycle. Thus, the duration and temperature conditions described hereinabove are preferably associated with the step of agitating said substrate(s) with solid particulate material, i.e. said one or more discrete treating step(s) of the aforementioned treatment cycle.

Preferably, the method is a method for cleaning a substrate, preferably a laundry cleaning method, preferably a method for cleaning a substrate which is or comprises a textile. Thus, preferably, a batch is a washload. Preferably the washload comprises at least one soiled substrate, preferably wherein the soiled substrate is or comprises a soiled textile. The soil may be in the form of, for example, dust, dirt, foodstuffs, beverages, animal products such as sweat, blood, urine, faeces, plant materials such as grass, and inks and paints. The cleaning procedure of an individual washload typically comprises the steps of agitating the washload with said solid particulate material in a cleaning apparatus for a cleaning cycle. A cleaning cycle typically comprises one or more discrete cleaning step(s) and optionally one or more post-cleaning treatment step(s), optionally one or more rinsing step(s), optionally one or more step(s) of separating the cleaning particles from the cleaned washload, optionally one or more drying step(s), optionally one or more extraction step(s) of removing treatment liquor from the cleaned washload, and optionally the step of removing the cleaned washload from the cleaning apparatus. Where the method is a cleaning method, the substrate is preferably agitated with said solid particulate material and a treatment liquor, preferably wherein the treatment liquor comprises a detergent composition. The detergent composition may comprise any one or more of the following components: surfactants, dye transfer inhibitors, builders, enzymes, metal chelating agents, biocides, solvents, stabilizers, acids, bases and buffers. In particular, the detergent composition may comprise one or more enzyme(s).

Where the method is a cleaning method, optional post-cleaning additives which may be present in a rinsing liquid medium include optical brightening agents, fragrances and fabric softeners.

In the method of treating the substrate, preferably there is a step of recirculating solid particulate material from the collector to the drum. During the step of recirculating the solid particulate material, the second outlet is preferably submerged beneath said treatment liquor in said lower portion of the collector. In this way, air is prevented from entering the recirculation means, which is particularly advantageous where the recirculation means comprises a first pump.

The invention is further illustrated with reference to the following figures in which:

Figure 1 shows a perspective cut-away view of a collector of the apparatus according to the disclosure;

Figure 2 shows a perspective cut-away view of a collector of the apparatus according to the disclosure;

Figure 3 shows a side view of a collector of the apparatus according to the disclosure;

Figure 4 shows a front view of an apparatus according to the disclosure; and

Figure 5 shows a cross-sectional view of the apparatus of Figure 4 through section X-X. Figures 1 to 3 illustrate a collector (88) of an apparatus according to the present disclosure. The collector (88) has an aperture (13) through which solid particulate material and treatment liquor that exit the drum can fall. The collector (88) has an upper portion (2) proximate a rotatably mounted drum (not shown) and a lower portion (4) distal to the drum. The collector has a first side wall (16) on the side nearest the access means of the apparatus (not shown) and a second side wall (18) distal to the access means. The collector narrows in the direction away from the drum, such that the lower portion (4) of the collector (88) has a smaller horizontal cross-sectional area than the upper portion (2).

The lower portion (4) has a first outlet (6) for draining treatment liquor and a second outlet (8). The second outlet is in fluid communication with a pump (not shown). The lower portion (4) comprises a channel (12). In the arrangement illustrated, the channel has a rectangular cross-section and extends from the first side wall (16) to the second side wall (18) of the collector (88). The first outlet (6) is located in the channel (12) and is proximate to the first side wall (16). The second outlet (8) is also located in the channel (12) but is proximate to the second side wall (18). The channel (12) has a width that is narrow compared to the width of the upper portion (2) of the collector (88).

A separator (1 1) is positioned within the channel (12). In the arrangement illustrated in Figure 1 , the separator (1 1) is located entirely within the channel (12) and is planar. The separator (1 1) is inclined at an angle such that the end of the separator (1 1) closest to the first side wall (16) is higher than the end of the separator (11) closest to the second side wall (18). The separator (11) prevents solid particulate material from passing through and allows treatment liquor to pass through. The arrangement of the separator (1 1) is such that solid particulate material that reaches the separator (1 1) after falling into the collector (88) is biased towards the second outlet (8). Treatment liquor that reaches the separator (11) can pass through the separator (11) and into the cavity (15) below the separator (11) in the channel (12), from where it can be drained from the channel (12) through the first outlet (6).

In the arrangement shown in Figures 1 and 2, the collector (88) has a first feeder surface (14a) on one side of the channel (12) and a second feeder surface (14b) on the opposite side of the channel (12). The first and second feeder surfaces (14a, 14b) are configured to direct solid particulate material and treatment liquor into the channel (88).

Figure 2 shows a collector with similar features to the collector described in relation to Figures 1 and 3 but further comprises nozzles (17a, 17b). Liquid, such as rinsing liquid or treatment liquor may be sprayed from the nozzles (17a, 17b) towards the lower portion (4) of the collector (88) to assist with flow of the solid particulate material towards the second outlet (8). Alternatively, the nozzles may be used to spray liquid in order to clean the lower portion (4) of the collector (88).

With reference to Figure 3, the channel (12) of the collector (88) has a sloping floor (19). The sloping floor (19) is configured to direct treatment liquor towards the first outlet. In the arrangement shown in Figure 3, the first side wall (16) of the collector (88) is inclined at an angle away from the vertical plane. Figures 4 and 5 illustrate an apparatus (10) according to an aspect of the present disclosure comprising a collector (88) such as one of those illustrated in Figures 1 to 3. The apparatus (10) comprises a housing (20). The housing (20) comprises an upper portion (20a) and a lower portion (20b). The housing (20) comprises a rotatably mounted drum (40). The drum (40) may be in the form of a rotatably mounted cylindrical cage. In the arrangement shown in Figures 4 and 5, the drum is horizontally mounted in a casing or a tub (80) and is mounted in the upper portion (20a) of the housing. The tub (80) comprises a curved top portion (84) that circumferentially surrounds a portion of the drum (40). The tub (80) may comprise a first sidewall (not shown) and a second sidewall (not shown) extending from the curved portion (84) to the base of the tub.

The drum (40) has apertures in its walls (not shown). The apertures allow the ingress and egress of treatment liquor and the solid particulate material. The drum may have perforated side walls. Alternatively, the drum may comprise apertures in the side wall and one or more lifters on the inside surface of the drum, in which the one or more lifters comprise a flow pathway that allows solid particulate material and treatment liquor to reach the aperture and exit the drum.

Rotation of the drum (40) is effected by use of drive means (90). The drive means (90) comprises electrical drive means in the form of an electric motor. The operation of the drive means (90) is effected by control means which may be operated by a user.

The base of the tub (80) includes a collector (88), such as described in relation to Figures 1 to 3. The collector (88) is located beneath the drum and functions to collect solid particulate material and treatment liquor that exits the drum.

In the arrangement shown in Figures 4 and 5, the unitary nature of the tub (80) enables the portion containing the drum (40) and the portion comprising the collector (88) to move together as one body in response to vibrations induced by rotation of the drum (40). The apparatus (10) comprises dampers (78) connected to the tub (80) to reduce the extent to which vibrations from the drum are transmitted to the housing (20).

In the particular arrangement shown, the apparatus has a collar or hood (82) that projects out from the front face (22) of the housing (20) around part or all of the opening of the housing through which the drum (40) is accessible. The collar or hood (82) may extend from or be an integral part of the tub (80). The collar or hood (82) comprises an aperture (90). The apparatus has a recirculation means comprising a flow pathway pipe (1 10) having an outlet (140) that defines a path between the collector (88) and a recirculation means separator (100). The flow pathway pipe is configured so that it is mounted in the housing and passes through the aperture (90) of the collar or hood (82).

A pump (not shown) is arranged in the recirculation means so that it is able to pump treatment liquor and solid particulate material from the collector (88), along the flow pathway pipe (1 10) and onto the recirculation means separator (100). The apparatus (10) comprises a door (60) to allow access to the interior of the drum (40). The door (60) is hingedly coupled or mounted to the front (22) of the housing (20). In an alternative arrangement (not shown) the door (60) may be hingedly coupled or mounted to a portion of the tub (80). The door (60) comprises a ring (66) and the ring (66) is adapted to hold the recirculation means separator (100) in position in the door (60). The ring (66) of the door comprises a drain channel (70) located at the bottom of the door (60). The channel (70) is arranged such that material that has passed through the recirculation means separator (100), such as treatment liquor, is able to exit the door through the drain channel (70) and flow into the collector (88).

The door is moveable between an open and a closed position. When the door (60) is in a closed position (as shown in Figures 4 and 5), the apparatus (10) is substantially sealed. When the door (60) is in an open position, the inside of the drum (40) is accessible. In the arrangement shown, when the door is in the closed position, the door abuts and makes a seal with the collar (82).

In a typical treatment cycle using the apparatus (10), substrates to be treated (not shown) are first placed into the drum (40) and the door (60) is closed. An appropriate amount of treatment liquor (for example, water or water and an additional treatment agent) may be optionally added to the drum (40) via delivery means (not shown). Where the treatment liquor comprises water and a cleaning agent, the water may be pre-mixed with the cleaning agent prior to its introduction into the drum (40). However, typically, water is added first in order to suitably wet or moisten the substrate before further introducing any cleaning agent. The treatment liquor may be heated by a heater (not shown).

The treatment cycle commences by rotation of the drum (40). The solid particulate material and optionally treatment liquor residing in the collector (88), which optionally can be heated to a desired temperature using a heater (not shown), is then pumped via the flow pathway pipe (110) into the drum (40), preferably via the recirculation means separator (100) as in the arrangement shown in Figures 4 and 5, where solid particles are propelled from the recirculation means separator (100) and through an outlet in the door and into the centre of the washload in the drum (40). During the course of agitation by rotation of the drum (40), treatment liquor falls or moves through apertures in the drum (40) and into the collector (88). Some solid particulate material may also fall or move through apertures in the side walls of the drum (40) and into the collector (88). Alternatively, lifters (not shown) disposed on the inner circumferential surface of the drum (40) can collect the solid particles as the drum (40) rotates and transfer the solid particles through an aperture in the side wall of the drum and into the collector (88). On transfer to the collector (88), the solid particulate material and treatment liquor flow down the feeder surfaces (14a and 14b) and are directed into the channel (12) of the collector (88). Solid particulate material is prevented from passing through the separator (1 1) and is directed towards the second outlet (8), from where the solid particulate material and treatment liquor enter the recirculation means and are pumped back to the drum (40), where they can be re-used in either a single treatment cycle or in one or more subsequent treatment cycles. The arrangement of the separator (11) within the channel (12) of the collector (88) decreases the residence time of the solid particulate material in the collector (88), which has the effect of increasing the quantity of solid particulate material in the drum during the treatment. Furthermore, by having a collector (88) comprising feeder surfaces (14a, 14b) and a channel (12), the quantity of treatment liquor required to enable solid particulate material to be recirculated in the apparatus can be significantly reduced. Treatment liquor pumped from the collector (88) through the recirculation means separator (100) with the solid particulate material but which does not enter the drum (40) can be returned to the collector (88) via a drain (70) in the door (60).

Furthermore, treatment liquor can be removed from the collector (88) via the first outlet (6). Treatment liquor drained via the first outlet (6) can be sent to a drain as waste. Alternatively, treatment liquor drained via the first outlet (6) can be filtered to remove lint or other solid waste material from the substrate and then the treatment liquor can be re-used in either a single treatment cycle or in one or more subsequent treatment cycles. In a preferred arrangement, treatment liquor is removed from the collector (88) via the first outlet in the channel (12) of the collector (88) and is filtered to remove lint or other solid waste material from the substrate. The filtered treatment liquor is then reintroduced into the collector (88) via the nozzle (17a, 17b) and directed towards the lower portion (4) of the collector (88) in order to agitate solid particulate material in the lower portion of the collector (88) and hence encourage flow of the solid particulate material towards the second outlet (8).

The apparatus (10) can perform a treatment cycle with, for example, the drum (40) rotating at from about 30 to about 40 rpm for several revolutions in one direction, then rotating a similar number of rotations in the opposite direction. This sequence can be repeated for as long as is required to complete the treatment, for example, for up to about 60 minutes. During this period, solid particulate material can be introduced and reintroduced to the drum (40) from the collector (88) in the manner as described above.

The arrangement of the collector means that the apparatus can operate with reduced water consumption and can also operate in a way that increases the proportion of solid particulate material in the apparatus that is within the drum during treatment of the substrate, thereby increasing the efficiency of substrate treatment. As a consequence, the apparatus offers significant environmental and economic benefits.

Features described herein in conjunction with a particular aspect or example of the disclosure are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. As used herein, the words "a" or "an" are not limited to the singular but are understood to include a plurality, unless the context requires otherwise.

Claims

1. An apparatus for use in the treatment of a substrate with a formulation comprising solid particulate material and treatment liquor, said apparatus comprising:

a housing having mounted therein a rotatably mounted drum, said drum having side walls and said side walls comprising one or more apertures configured to permit said solid particulate material and said treatment liquor to exit the drum;

an access means for introducing said substrate into said drum; and

wherein said lower portion comprises a first outlet for draining treatment liquor and a second outlet in fluid communication with said recirculation means; and

wherein said lower portion of said collector further comprises a separator, wherein said separator prevents said solid particulate material from passing through and allows treatment liquor to pass through and wherein the separator is arranged within the collector such that said solid particulate material is able to enter said second outlet but is not able to enter said first outlet.

2. An apparatus according to claim 1 , wherein said separator is configured to bias said solid particulate material towards said second outlet.

3. An apparatus according to claim 1 or 2, wherein the separator comprises a perforated sheet.

4. An apparatus according to any of claims 1 to 3, wherein the separator is substantially planar.

5. An apparatus according to claim 4, wherein the separator is inclined at an angle A to a horizontal plane, wherein angle A is from about 10° to 50°.

6. An apparatus according to any of claims 1 to 3, wherein the separator is curved in at least one direction.

7. An apparatus according to claim 1 , wherein said lower portion comprises a channel and wherein the collector comprises at least one feeder surface for directing said solid particulate material and said treatment liquor into said channel, and wherein said channel comprises said first outlet and said second outlet.

8. An apparatus according to any of claims 1 to 6, wherein said lower portion comprises a channel and wherein the collector comprises at least one feeder surface for directing said solid particulate material and said treatment liquor into said channel, and wherein said channel comprises said first outlet, said second outlet and said separator.

9. An apparatus according to claim 8, wherein the separator is comprised entirely within the channel.

10. An apparatus according to any of claims 7 to 9, wherein said channel extends substantially between a first side wall of said collector proximate said access means and a second side wall of said collector distal to said access means.

1 1. An apparatus according to claim 10, wherein said second outlet is located proximate said second side wall.

12. An apparatus according to claim 10 or claim 11 , wherein said first outlet is located proximate said first side wall.

13. An apparatus according to any of claims 7 to 12 wherein the channel is substantially linear.

14. An apparatus according to any of claims 7 to 13 wherein the channel has a cross section in the shape of a square, oblong, trapezoid, trapezium, rhombus or rhomboid along at least part of its length, preferably along its entire length, more preferably the channel has a cross section in the shape of a square or oblong along at least part of its length, preferably along its entire length.

15. An apparatus according to any of claims 7 to 14, wherein the channel has a U-shaped cross section along at least part of its length, preferably along its entire length.

16. An apparatus according to any of claims 7 to 15, wherein the channel has a width of from about 5 cm to about 30 cm, preferably from about 10 cm to about 25 cm, preferably from about 15 cm to about 20cm.

17. An apparatus according to any of claims 7 to 16, wherein the channel has a depth of from about 5 cm to about 30 cm, preferably from about 5 cm to about 8 cm.

18. An apparatus according to any of claims 7 to 17, wherein the channel has a sloping floor configured to direct treatment liquor towards the first outlet, preferably the sloping floor is inclined at an angle B to a horizontal plane, wherein angle B is from about 1 ° to about 10°.

19. An apparatus according to any of claims 7 to 18 wherein the at least one feeder surface is inclined at an angle C to a horizontal plane, wherein angle C is from about 10° to about 50°.

20. An apparatus according to any of claims 7 to 19, wherein said channel is positioned between two feeder surfaces.

21. An apparatus according to any of claims 7 to 19, comprising two, three, four or more than four feeder surfaces.

22. An apparatus according to any preceding claim, wherein a wall of the collector proximate the access means is inclined at an angle D to a vertical plane, wherein angle D is from about 3° to about 10°, preferably about 5°.

23. An apparatus according to any preceding claim, wherein said first outlet is in fluid communication with filtration means for filtering lint from said treatment liquor.

24. An apparatus according to any preceding claim, wherein the recirculation means

comprises a first pump.

25. An apparatus according to any preceding claim, further comprising an agitating means for agitating solid particulate material and/or treatment liquor in the collector.

26. An apparatus according to claim 25, wherein the agitating means comprises at least one nozzle configured to direct liquid towards said lower portion of said collector.

27. An apparatus according to claim 25 or claim 26, wherein the agitating means comprises a second pump.

28. An apparatus according to any preceding claim which comprises said solid

particulate material.

29. An apparatus according to any preceding claim wherein the particles of the solid particulate material have (i) an average mass of from about 1 mg to about 1000 mg;

and/or (ii) an average volume in the range of from about 5 to about 500 mm³; and/or (iii)

an average surface area of from 10 mm² to 500 mm² per particle; and/or (iv) an

average particle size of from 1 mm to 20 mm, preferably from 5mm to 10 mm.

30. An apparatus according to any preceding claim wherein the particles of the solid

particulate material comprise a polymer, preferably wherein the polymer is or comprises

a polyalkene, a polyamide, a polyester or a polyurethane, preferably a polyalkylene,

polyester or polyamide, preferably a polyamide selected from nylon 6 or nylon 6,6, or a polyalkylene selected from polypropylene, and preferably a polyamide or a polyamide selected from nylon 6 or nylon 6,6.

31. A method of treating a substrate, the method comprising agitating the substrate

in an apparatus according to any of claims 1 to 30 with solid particulate material and

treatment liquor.

32. A method according to claim 31 , comprising a step of recirculating solid particulate material from the collector to the drum, wherein during said step of recirculating solid

particulate material, said second outlet is submerged beneath said treatment liquor in

said lower portion of the collector.

33. A method according to claim 31 or claim 32 wherein the solid particulate material is re-used in further treatment procedures according to the method.

34. A method according to any of claims 31 to 33 wherein the method is a method for treating multiple batches, wherein a batch comprises at least one substrate, the method

comprising agitating a first batch with solid particulate material, wherein said method further comprises the steps of:

(a) recovering said solid particulate material;

(b) agitating a second batch comprising at least one substrate with solid particulate material recovered from step (a); and

35. A method according to any of claims 31 to 34 wherein the substrate is or comprises a textile.

36. A method according to claim 35 wherein the treating of said substrate is cleaning, coloration, bleaching, abrading or ageing, or other textile or garment finishing process.

37. A method according to claim 36 for cleaning a substrate wherein the substrate is a soiled substrate.

38. A method according to any of claims 31 to 34 wherein the substrate is or comprises an animal skin substrate.

39. A method according to claim 38 wherein the treating of an animal skin substrate is a tannery process.