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March 28, 2013

MARIETTA, Ga. — Improvements are leading to lower labor costs, increased productivity, maximized energy efficiency and enhanced linen life

MARIETTA, Ga. — Sustainability, efficiency, and the bottom line are on the minds of every business owner in the current economy. Laundry operations, whether on-premise laundries or linen services, are no exception.

Technology advances are significantly changing business operations and the way services are delivered in every sector. In laundry rooms, they are helping equipment to run smarter and even to contribute useful data to the decision-making process. Improvements in laundry operations are leading to reduced labor costs, increased productivity, maximized energy efficiency, lower utility costs and enhanced linen life. Here is how these evolving machines enable these cost centers to take up a smaller part of the operating budget, while ensuring that the overall operation runs smoothly.

GETTING A JUMP ON THE DAY

Typically, when laundry operators punch in, the first thing they do is load linens, uniforms or other washables into the machines, start them up, and then enter a 35- to 45-minute “dead” period waiting for the first loads. This is no way to start the morning.

Thanks to an advanced-start function engineered into newer washer-extractors, today’s laundry crew could be greeted in the morning by a machine filled with freshly washed clothes and linens. The advanced-start function allows yesterday’s workers to load up the machines at the end of their shift and to program the washers to turn on the next morning about an hour before the morning shift arrives.

The loads will be just finishing and almost ready for the tumble dryer when the first shift comes onto the laundry room floor. This feature also shortens the previous day’s last shift. The time saved adds up to lower labor costs. In addition, having loads washed before the day starts ensures that parts of the operation that depend on laundry availability can be reliably supplied by mid-morning. More timely availability could enable a smaller inventory of linens and uniforms to handle daily demand for on-premise laundries.

MAY THE G-FORCE BE WITH YOU

The secret to efficient clothes drying is that tumble dryers should be asked to deal with as little water as possible. Low-G-force washer-extractors can leave significant amounts of water in the laundry, which means the tumble dryer has to work harder and longer. When operators run fabrics such as all-cotton terry cloth through a low-G-force washer, there can be as much as 90% water retention.

Water-heavy goods present potential ergonomic problems for workers who have to lift laundry and place it in the tumble dryer. It also requires extra drying time, which means more energy to heat the air. It also reduces throughput. High-G-force extraction removes more water from linens, leading to decreased drying times. This high-speed process can reduce the amount of moisture left in the linens by up to 47%, decreasing gas or electricity usage by as much as 35%.

CAN’T BEAT THE CLOCK

You can’t improve what you don’t measure. Using the advanced controls now available on laundry equipment is like having somebody in the laundry room with a notepad, recording information on every cycle run, monitoring machine performance and tracking maintenance history. This can be especially valuable for facilities that run more than one shift.

For example, a chemical company had a customer who complained about the quality of finished laundry. The control system that monitors the equipment in the laundry room downloaded the reports and pinpointed the problem. Reports found that operators on the 2 p.m. to 6 p.m. shift were advancing the machines, skipping the bleach step and skipping a rinse step.

The chemical company was able to show the customer that the problem was not with the chemicals but with how the workers were using the machines. Relying on the control system’s real-time clock, management can download reports and determine exactly what’s happening in the laundry room.

The reports provided by these control systems help administrators better understand and manage workloads and increase throughput. The information also helps determine whether they need to add more machines. Washer-extractors and tumble dryers equipped with advanced controls have a real-time clock telling the operator how long the machine has been sitting idle. Laundry operations paying overtime can check to see whether the extra hours are really necessary.

IN TOTAL CONTROL

The cost of water may not yet be a major issue where you are operating, but it will be a concern in many places before the end of this decade. For many operations, targeting water use is part of a sustainability program. Advanced washer equipment controls enable the operator to match each load with one of 30 different water levels for optimal water and chemical use without compromising cleanliness. This feature can help save thousands of gallons of water each year, which also reduces energy costs since less water is being heated.

Some new tumble dryers make use of moisture-sensing technology to prevent linens from being scratchy and to ensure longer life for linens and uniforms. Operators set the desired moisture level for the finished laundry, usually 4-5%.

Over-drying is one of the biggest wasters of utilities and labor in the laundry room. Impatient operators sometimes check to see whether clothes are dry by stopping the machine and sticking a hand in every now and then. Not only does this waste the operator’s time, stopping and starting the dryer also wastes energy. In addition, improved technology that prevents over-drying can reduce fiber loss by 31%.

MONEY NOT GOING DOWN THE DRAIN

One problem with technology is that sometimes management doesn’t want to invest in it. But that ignores real dollars-and-cents benefits. There is a big difference between lowest cost and lowest price. Whether a laundry service or an on-premise laundry, operations that resist upgrading or that choose a less expensive machine can spend $100 per month for the next 12 to 15 years on additional energy, water, and labor.

Break down the budget of a typical laundry operation. About half of every dollar spent in the laundry goes to labor. Another 10-12% goes to equipment, 10-12% to linen replacement, 8-12% to chemicals, and 10% to utilities. Equipment maintenance completes the cost schedule at 3%. Spending money wisely on equipment can affect the other pieces of the cost pie, reducing them while making better use of the laundry workforce by increasing productivity and throughput.

February 28, 2013

LAKEWOOD, Colo. — Risk of textiles posing as infection source can be minimized with proper laundry equipment, processing protocols

LAKEWOOD, Colo. — While laundry might not be the first thing that comes to mind when thinking about the quality of care at a healthcare facility, it does play an important role.

Every year, hospitals and other healthcare facilities produce more than 5 billion pounds of soiled linens. Laundry managers are consistently updating protocols and procedures to ensure linens are thoroughly cleaned and free of bacteria and other viruses. Studies have shown that a textile can be considered a fomite—an object capable of carrying an organism and serving as a reservoir that can be involved in bacterial transmission. Various types of bacteria can survive up to 90 days on linens, according to published reports.

According to the U.S. Centers for Disease Control & Prevention (CDC), there are multiple methods to hygienically clean textiles. Each method, however, requires an equipment mix designed to incorporate the various processes.

In addition, with a large volume of laundry being processed each year, it’s also important for healthcare organizations to ensure they are being as efficient as possible to keep operation costs low.

With proper laundry equipment and processing protocols, the risk of textiles posing as a source of infection to patients and employees can be greatly minimized, as well as reduce utility costs.

IN HOT WATER

Experts say that in order to kill bacteria and other viruses on linen, laundry should be washed with detergent and bleach for 25 minutes in water that is heated to 160 F. Studies have shown that bacteria, viruses and even bed bugs cannot survive this water temperature or chemical mix.

If your facility has chosen to use this method, it must be able to test water to make sure it’s reaching the 160-degree requirement in case the operation is ever audited. To meet this requirement, the laundry equipment will require an advanced control.

Advanced controls are able to show the exact water temperature inside the washing machine to help employees ensure the laundry is being washed at the correct temperature. These controls also allow users to program fill, wash and rinse water temperatures. Additionally, the controls – either networked or wireless – can send data to a computer, which allows managers to print reports to ensure protocols are being properly followed in the wash. This option also enables supervisors to provide documentation should the facility ever need to prove that its washing procedures meet federal requirements.

If a facility is concerned about water usage, some advanced controls allow users to select from as many as 30 different water levels. Programs such as these will help contribute to a reduction in water costs because employees can select the appropriate water level based on load capacity. It’s reported that spray-rinse machines can reduce water usage up to 11% when compared to traditional bath-style rinse models.

HIGH EXTRACTION SPEED

Regardless of which option is chosen to complete wash cycles, it’s equally critical to make sure machines have high G-force extraction speeds.

This extraction helps maximize water removal from linens in the spin cycle. The higher the G-force, the more water removed from linens. Newer machines offer top speeds of 400 G-force, the highest in the industry. When maximum water is removed in the wash, dry times are greatly reduced, further reducing utility costs.

THE DRYING PROCESS

Since textiles are already put through a rigorous washing process, it’s important to use tumble dryer programs that will help linens last longer and avoid expensive replacement costs. The dryer should work as a system with the washer-extractor, using the same control platform to ensure ease of use and optimal efficiency. This will allow staff to increase throughput, and contribute to lower operating expenses.

When selecting a dryer, make sure the manufacturer has achieved the perfect balance between drying temperature, airflow pattern and usable cylinder space for maximum energy efficiency.

Some equipment on the market offers over-dry prevention technology, which automatically turns a dryer off once the linens inside have reached the optimal dryness level. Over-drying wastes gas and can damage linens and garments, causing replacement costs to rise each year.

It’s estimated that 79% of on-premise laundries over-dry linens by more than eight minutes per cycle when using a 75-pound tumble dryer. By eliminating that extra time per cycle, laundries can save nearly $1,000 in gas costs a year and nearly $5,000 in labor expenses. Additionally, textiles experience 31% less fiber loss when over-dry prevention technology is used, according to reports.

MORE ON ADVANCED CONTROLS

Advanced control platforms offer many benefits to maximize efficiency and productivity in the laundry room. Over the past five years, laundry control platforms have advanced. Previously, there were only a few options to choose from when picking laundry cycles. Today’s healthcare facilities have more programming options available. While some facilities may outsource laundry service, others have taken their laundry operations back in-house so they can have full control, reduce costs and increase quality.

Advanced controls help laundry managers identify expenses within their operations and pinpoint specific areas where they can increase efficiency and reduce costs associated with labor, linen replacement, utilities and maintenance. With nearly 50% of costs associated with labor, up to 25% for linen replacement and roughly 13% on utilities, it benefits managers to be able to easily identify inefficiencies or potential problems and correct them fast.

Features such as delayed start allow employees to load washing machines before the end of their shift and have the first load completed by the beginning of the next day. Laundries can complete one extra load per day, allowing for savings in labor costs.

The real-time clock feature lets managers see what time each cycle was started and stopped, and the idle-time feature monitors the length of time in between the starting and stopping of cycles. Maintenance reminders are ideal for the engineering staff, as reminders are programmed to alert employees for timely servicing.

REDUCE RISK, LOWER UTILITIES

It would be beneficial for healthcare facilities to take a hard look at their on-premise laundry operation and work with their suppliers and product manufacturers to pinpoint areas where they can increase efficiency and reduce costs, and, most importantly, achieve the best results for their patients.

November 8, 2012

ST. JOSEPH, Mich. — Much of hospitality industry working to make OPL facilities more energy- and water-efficient

ST. JOSEPH, Mich. — As word continues to spread about the various benefits of using less energy and water in daily tasks, much of the hospitality industry is now working to make its on-premise laundry (OPL) facilities more energy- and water-efficient. As a result, many hotel owners are finding that the conservation of natural resources is not only good for the environment, but also for business. It can lead to lower utility bills and increased productivity, as well as an improved image in the eyes of hotel guests.

Though it may be tempting to jump right in and start buying new equipment, it’s important for hotel owners to first take a close look at the many options available to them, leading to a more informed decision.

There are a variety of things to do and consider as they begin their research on improvements, which can ultimately lead to higher energy and water efficiency, as well as a higher return on investment (ROI).

FIRST, FIND A DISTRIBUTOR

Whether looking to buy laundry equipment for a new hotel or upgrading an existing operation, hotel owners would be wise to first begin a relationship with an established distributor for product guidance and future maintenance. Look for laundry distributors who have a long history in the business and a well-known reputation for good customer service, both before and after the sale.

It also is a good idea to choose a distributor that offers solid warranty and service agreements, factory-trained service technicians and a full parts inventory, so replacement parts can be obtained with minimal downtime. It is crucial that the distributor send a service technician out promptly with the replacement parts needed for repairs so the laundry facility can keep up with guests’ needs.

ENERGY AND WATER EFFICIENCY

Though the costs of operating an OPL are considerably lower than sending laundry to an outside business, selecting the right equipment for the job can reduce costs even further. Hotel owners can significantly cut utility costs by investing in the latest energy-efficient commercial laundry equipment, including multi-load high-speed washer extractors.

High-Speed Multi-Load Washer-Extractors — The best way to improve overall OPL efficiency is by incorporating multi-load, high-speed washer-extractors. Extracting water in the washer instead of the dryer through higher spin speeds means linens will dry more quickly and gently, and less energy will be consumed.

For the highest level of performance, hotel owners should look for soft-mount washer-extractors with a G-force (G), or spin speed, of at least 300, though certain soft-mount washer-extractors can feature high-speed extraction of up to 350 G.

Higher G-force simply means more water is removed. For example, a 55-pound washer operating at 100 G will leave about 50 pounds of water to be extracted in the dryer, which will take 45 minutes to dry. A 350-G washer, however, will only leave 33 pounds of water, which will reduce drying time to 31 minutes and save linens from additional wear.

When compared to laundries operating with 100-G washers, those operating with 350-G washers can save substantial labor dollars. A laundry operating with 350-G washers can process 10 loads in approximately 2½ hours less time than the laundry operating the 100-G washers. At $10 an hour, increasing washer speed to 350 Gs has the potential to save more than $8,000 a year in labor. Plus, shorter drying time at 170 F will cause less linen wear and tear.

High-speed washer-extractors are an ideal option for OPL operators, as they drastically reduce labor and other operational costs. Of course, to complete the efficiency upgrade package, OPL facilities also need an energy-efficient multi-load dryer.

Multi-Load Dryers — Like multi-load washer-extractors, today’s multi-load dryers can hold larger loads of laundry, reducing the number of loads that need to be dried. These highly efficient dryers come in varying sizes, with the largest ones being able to accommodate loads of more than 150 pounds.

For the highest energy efficiency, hotel owners should look for large dryers with high-performance airflow distribution systems that dry clothes faster using less energy, and sufficient insulation and sealing to prevent the leakage of heated air. This allows the machine to dry clothes faster using less energy.

Washer-Extractors for Smaller Facilities — In addition to the individual size and performance of machines, the size of the OPL facility is an important factor to consider. Though multi-load equipment is ideal for larger facilities, it might not be as good of a fit for some smaller OPLs. Fortunately, there are also equipment options for laundry facilities in smaller hotels.

Owners of smaller OPLs stand to reap the most substantial benefits from an equipment upgrade, usually from a traditional top-loading washer to a front-loading high-speed washer-extractor. When comparing on-premise high-speed washer-extractors with traditional top-loaders, the front-loaders are generally recognized as the more energy-efficient option, and they also use water more efficiently.

For example, a top-loading machine needs enough water to cover all of the fabrics in its drum, while a front-loading machine only requires one-third of that amount of water. The drum in front-loading washer-extractors is horizontally set, so as it turns, it uses gravity to drop the fabrics back into the water. This allows front-loading washer-extractors to use several gallons of water a year less than traditional top-loading machines.

Another front-load washer-extractor advantage is that these machines have no agitator in the middle of the drum, allowing them to hold larger loads, which also saves time and energy. Additionally, agitators inflict gradual wear and tear on fabrics over time, so fabrics washed in a front-load machine should last longer.

ELEMENTS OF PROPER OPL DESIGN

For hotel OPL facilities to operate efficiently, it is also important for owners to properly design the facility, ensuring that all OPL components are positioned in the most beneficial way for hotel staff members.

First, OPL facilities must have a wide swinging door that will easily accommodate in-and-out foot traffic. Then, there’s the placement of the different areas used for separating soiled laundry prior to washing and folding clean laundry after it’s processed. Placing folding stations near washers and dryers helps staff members to be more efficient, as they only have a minimal distance to carry laundry, and also helps keep clean laundry from potentially being dragged on the floor.

Washers and dryers should be in close proximity, while allowing for staff members to easily maneuver laundry carts within the space. Store clean linens near the entrance/exit door for easy access to both housekeeping and other hotel staff members.

Most distributors will have someone on staff who specializes in laundry facility design, or will be able to recommend an outside interior designer or architect who can assist the hotel owner with producing a more efficient laundry room layout.

IN SUMMARY

Under the guidance of a reputable, well-established commercial laundry distributor, hotel owners can make huge improvements to the energy- and water- efficiency of their OPL and significantly reduce operational costs.

High-speed washer-extractors and multi-load dryers are a wise investment for all OPL facility owners, as they help achieve all of these goals and allow staff to spend less time handling laundry and more time on other important duties.

In addition, due to the ROI of the equipment, hotel owners can expect to recoup the price difference between this equipment and traditional less-efficient OPL equipment in utility savings over just a few years.

High-speed multi-load washer-extractors and multi-load dryers also help decrease a hotel’s impact on the environment. So, by making informed energy- and water-efficient decisions for their OPL facilities, hotel owners are not only making a smart move for their bottom line, but are also doing their part to preserve the environment of future generations.

October 25, 2012

GREEN LAKE, Wis. — Resort destination addresses challenges of increased drying times and linen-replacement costs

GREEN LAKE, Wis. — The Heidel House Resort & Spa has been located here since 1945. It sits on 20 picturesque acres of wooded land on the shores of Wisconsin’s deepest inland lake. It started as a restaurant, quickly grew into a family-run retreat, and by the 1970s had become one of Wisconsin’s most popular destination resorts.

Like most high-end resorts and hotels, the Heidel House offers only the highest-quality linens and towels for guest use. But by offering these luxury fabrics, challenges have arisen in its on-premise laundry.

Luxury materials contain a higher percentage of cotton, which absorbs and retains more water than other fabrics. This means heavier loads of laundry with increased dry times, labor and machine use.

Another issue was increasing costs for linen replacement. The resort had older dryers with controls that only offered a few dry settings. Linens were being over-dried, and some were even scorched. Replacing these linens can be costly, according to Jean Westhuis, Heidel House’s executive housekeeper.

To help combat these challenges, the Heidel House partnered with equipment manufacturer UniMac.

THE DRYING SOLUTION

Company representatives recommended installing a 75-pound tumble dryer equipped with a UniLinc™ control system, which includes OPTidry™ Over-dry Prevention Technology.

The tumble dryer was the right fit for the resort because it offered some of the industry’s leading features. For example, its multiple burner heat system provides quick, stable temperature control, ensuring high-quality drying for linens. Additionally, the dryer has a self-cleaning lint filter, which reduces fire hazards.

OPTidry connects sensors located within the lifters to a rotary transfer switch. The result is a pinpoint dryness reading throughout the entire load, which allows the machine to automatically shut off once dryness levels have been reached.

According to research, hotels over-dry laundry by more than eight minutes per load. If this extra time were eliminated, a laundry using a 75-pound dryer could save hundreds of dollars a year in utilities and labor costs. Also, the linens experience 31% less fiber loss when over-drying is eliminated, providing significant savings for on-premise laundries (13-25% of an OPL budget is spent on linen replacement).

“In my first year on the job, we had a number of linens and towels that were ruined from overheating,” Westhuis says. “Using the new tumble dryer with over-dry prevention technology, we’ve yet to see a damaged piece of linen.”

And while the OPTidry-equipped tumble dryer can dry the same volume of linens as the resort’s older tumblers, the loads dry faster, increasing throughput.

TOTAL CONTROL MANAGEMENT

OPTidry is available only through UniLinc. The total control management system records more than 100 functions using a time-and-date stamp of activities. Westhuis can use a computer to download real-time reports that provide operational details.

Upon her first review of reports, she learned employees were regularly using improper drying cycles. By reviewing the dates and times of the improper uses, she was able to pinpoint the staff members responsible and provide a training session for corrective action.

Westhuis also commented how the reports show the amount of time between the end of a cycle and when the tumble dryer door is opened. This information was used to identify linen quality issues. For example, when the linens laid in the tumble dryer for an excessive time, they acquired unsightly wrinkles that were not up to the hotel’s standards.

Additionally, UniLinc alerts provide managers with important maintenance information in order to make sure machines are running at maximum efficiency. The system is available on both washers and tumble dryers, simplifying training and providing a truly networked laundry room.

UPDATING FOR THE FUTURE

The Heidel House faced issues that many other hotels and resorts are dealing with today. By taking a proactive approach to find a solution to the problem, the resort is now saving money through lower natural gas use and less frequent linen replacement. In addition, monitoring laundry operations has never been easier.

September 11, 2012

COLORADO SPRINGS, Colo. — The solution: a hybrid tunnel design utilizing 1,600 pounds of existing conventional wash capacity

COLORADO SPRINGS, Colo. — Water is a big deal in Colorado. Discover Goodwill of Southern and Western Colorado, which operates the Fresh Start mixed plant laundry here, was using almost three gallons of water per pound of laundry processed. Management knew it had to make some changes in order to stay competitive in the marketplace.

DESIGN TEAMS TUNNEL AND CONVENTIONAL WASH AISLE

Over the years, Fresh Start’s conventional wash aisle had grown to 10 machines totaling of 2,250 pounds of wash capacity, but many of the washers were past their normal service life. Heavy soil drove the high water usage. In 2011, the local water utility announced a 300% rate increase to be phased in over three years.

With anticipated growth opportunities also in the mix, a new tunnel washer system made sense, but a significant portion of Fresh Start’s seasonal business included military goods that weren’t compatible with tunnel processing. Staying conventional and installing a state-of-the-art water-reuse system was also under consideration. 

Fresh Start needed a wash aisle that used less water, capacity to double production capability, and significant conventional washer capacity. Available space would not accommodate a full tunnel system plus the conventional wash capacity needed. And the capital cost of new conventional washers plus water reuse was significant.

The solution: a hybrid tunnel design utilizing 1,600 pounds of existing conventional wash capacity. A shared manual gravity rail would service a new line of high-production 450-pound dryers. The shared-dryer design provided adequate dry capacity for the tunnel and conventional washers in a shared space.

COORDINATION IS KEY TO KEEPING DOWNTIME TO MINIMUM

A major equipment change can shut down laundry production for weeks or even months, so with the business in growth mode, this was a concern.

Project scope included major steam, water, electric, HVAC, and air-supply modifications. New roof penetrations were required, old walls had to come down, and installation of new walls and barriers was needed to maintain functional separation between soiled and clean areas. Old dryers and washers would be rigged out before new equipment was brought in and installed.

Fresh Start selected Kannegiesser USA to deliver the equipment and installation solution it needed. Tony Jackson, Kannegiesser’s sales manager, organized a team of local industrial contractors, and the project was squeezed from eight weeks of plant downtime to just three.

“We settled on a very aggressive installation schedule,” says Jackson. “We needed a good collaborative effort to meet the time line goal for full production, and everyone delivered.”

New equipment included a Kannegiesser PowerTrans 10-compartment (165 pounds capacity in each) tunnel washer, Kannegiesser PowerPress 56-bar extraction press, Gardner Machinery heavy I-beam rail system, three CLM 450-pound capacity industrial dryers, and six ADC dryers.

Mech One was responsible for all HVAC and ductwork. Much of the material was pre-fabricated in advance of the equipment delivery. It designed and built modular ductwork above the roof that transitioned the hot dryer exhaust parallel with the roof. While sturdy, the design allows for easy disassembly, providing interior inspection access.

Olson Plumbing & Heating consistently stayed ahead of their schedule commitments for air, gas, water, drain and steam, according to Jackson, and successfully troubleshot a last-minute issue to ensure proper gas pressure was available for the plant’s larger gas utility load.

The new electrical requirements required a block-wide power shutdown to install the new service.  Electric Services of Colorado mobilized during early weekend hours and made the transition seamless for Fresh Start and its affected neighbors.

MATERIAL-HANDLING SYSTEMS ENHANCE ERGONOMICS, SAFETY

Ergonomics and safety were also primary goals of the laundry renovation. Fresh Start employs disabled individuals throughout the laundry. Helping them reach their highest level of personal and economic independence is central to the mission of Goodwill.

Utilizing a manual conveyor on the back side of the tunnel eliminated the safety hazards of an automated shuttle; the conveyor inclines to load press cakes to the dryer rail. The heavy I-beam rail design allows up to three cakes—a full 450-pound dryer load—in each sling. Manual rail can work even when ceiling height is not sufficient for automated rail technology.

Where once dryers had been manually loaded from carts, the new clean rail provides faster, easier dryer loading. The dryer rail also provides nearly 7,000 pounds of staged storage between the tunnel and the dryers. Rail staging can increase tunnel production by eliminating system holds associated with “waiting for dryers.”

The system performed right from the beginning, says Vae Lafano, laundry project manager at Fresh Start. “Summer is our busiest season. The new laundry design shortened our seasonal wash-aisle production by six hours a day. They told me that the tunnel would put pressure on the finishing side of the plant, and it has.”

And how’s the water usage? In the first two months of operation, Lafano reports the tunnel water consumption is averaging 0.5-0.6 gallons per pound. Good news for Fresh Start, and good news for Colorado.

July 18, 2012

CHICAGO — Input from equipment manufacturing, healthcare laundry and chemicals supply sectors

EQUIPMENT MANUFACTURING: KIM SHADY, LAUNDRYLUX CORP, NEW YORK, N.Y.

kim shadyLoading capacity of washers and dryers is quite ambiguous. I was recently in a laboratory with multiple brands of washer-extractors. One of my objectives was to determine load size vs. rated capacity and the effects of under-loading.

The first laboratory result proved that based upon weight, you cannot load a washer beyond the rated capacity of the machine. In fact, it is difficult to place 50 pounds of dry terry cotton towels in a 60-pound washer. In nearly every machine tested, based upon weight, a machine will accept only 85% of the rated capacity. On some washers, because of the shape of the drum, only 75% is achievable. If you test poly/cotton sheets, the weight of the load is even less, as the polyester material has less weight for the amount of volume or space it takes in the wash wheel.

The lesson learned: Don’t expect the actual weight of a load to be equal to the rated capacity of the front-load washer-extractors.

The second laboratory test was to determine what happens when a small load (50% of capacity) is run in a washer. The results demonstrated the water used per actual pound of linen increased. Hence, it is more costly per pound to process. Also, the chemical dispenser did not know the load was smaller, again causing the cost per actual pound processed to increase.

Third result in the test was the washer’s ability to balance the load and advance the cycle to extraction. In some washers, there were multiple attempts to balance the load prior to extraction. This wasted time and water. In some cases, the washers never reached an acceptable balance level and the extraction speed was reduced, hence more residual moisture and longer drying times. As you can see, under-loading is expensive. And more loads per day must be processed, adding even more water, energy and labor costs.

We also tested load sizes in dryers. The objective was to determine drying time and energy cost for terry towels in a fully loaded, 60-pound-rated capacity washer in two different-sized dryers (capacities of 67 pounds and 83 pounds). The test results proved the larger dryer was faster and used less energy to dry the identical load.

At the end of the day, washers can’t be overloaded, while under-loading will significantly raise the cost per pound processed. Dryers can be overloaded, having the same effect on higher costs as under-loading washers.

At the end of the day, supervision and processes are critical. Unless, of course, the washers are smart enough to override human error!

HEALTHCARE LAUNDRY: SCOTT BEATON, KAISER PERMANENTE NORTHERN CALIFORNIA

scott beatonOne of the most important variables affecting wash quality results is mechanical action. Much of the mechanical action controlled by the laundry is affected by loading practices within a given size and type of washer.

Washer loading is expressed as pounds of fabric per cubic foot of cylinder volume. Loading varies with fabric type and with machine type. Overloading and under-loading can affect soil removal and fabric strength and create excessive wrinkling. It can also influence the costs for labor, chemicals, water and energy.

In order to provide consistent standards, load factors are normally based on the weight of clean, dry fabric processed.

Overloading is not conducive to good laundry performance. Supplies cannot be distributed properly throughout the load, and the tightly packed condition of the textiles impedes dilution, lowers soil removal, and results in poor mechanical action.

Additional water levels per operation and longer rinses may be required to remove loose soil and chemical supplies remaining in the load. If these additional steps are not employed, loads may require rewashing.

Overloading of continuous batch tunnel washers may result in jamming up the machine and halting production. Under-loading also can result in poor performance due to less mechanical action and can lead to excessive costs.

Some fabrics must be under-loaded because of their bulk as compared to their weight. Garments containing polyester blends typically are loaded at 3.5 to 4.5 pounds per cubic foot to minimize wrinkling and provide for easier finishing.

All in all, load weights should be determined for each individual plant per machine by weighing soiled loads and comparing the soiled weight to the clean weight for the same load after processing. If proper soil sorting is being practiced, the ratio (soil weight/clean weight) should be consistent by classification/machine and need only be recalculated periodically.

CHEMICALS SUPPLY: MARLENE WILLIAMS, ANDERSON CHEMICAL CO., LITCHFIELD, MINN.

marlene williamsMachine load sizes are designed to optimize machine performance, chemical use, fabric wear, and performance outcomes. There are prices to be paid for load sizes that vary widely from recommended protocols.

Under-loading of machines is largely a matter of wasted resources rather than performance outcomes. Running less-than-capacity loads results in additional loads needing to be run to accommodate total laundry weights. Waste in water (and expensive heated water), chemicals, and labor raise the cost per pound significantly when loads are not full.

Performance is typically not a problem when under-loading unless chemical use results in high foam generation during light loads. Extra foam can result in poor mechanical action with subsequent poor results. In front loaders, high foam levels can result in foam being forced into machine areas that are not typically rinsed. This foam residue, if not cleaned during special cleaning cycles, can provide food for bacteria and accompanying malodors.

Under-loading dryers can result in poor drying or no drying if dryer sensors do not recognize moisture amounts from small loads.

Overloading, on the other hand, is a self-defeating process. A myriad of problems results from overloading, including higher number of rejects, more rewash, lesser quality (lesser soil removal), and setting of stains.

Negative selection, i.e. removal of some stains while leaving other stains to be set in the dryer, is a function of overloading. Lack of mechanical action results in soils not being put into solution and carried away from fabric, excessive fabric wear in some areas of the machine as fabric does not move, and problems with inadequate dilution of chemical resulting in over/under-dosing of chemistry depending on overload dynamics.

Add more labor, chemical, water and time to rewash problem fabric and it becomes clear that running standard load sizes optimizes the laundry process.

Click here for Part 1!

April 18, 2012

CHICAGO — Input from chemicals supply, equipment manufacturing and uniforms/workwear manufacturing sectors

CHEMICALS SUPPLY: MARLENE WILLIAMS, ANDERSON CHEMICAL CO., LITCHFIELD, MINN.

This well-designed question recognizes that optimization of laundry programs and procedures, as well as incorporating new technology options, can facilitate a laundry marlene williamsmanager’s efforts to improve energy efficiency and water conservation. From the chemical supplier’s standpoint, there are two major sources of help available today.

First, technology (proprietary software) to analyze a laundry operation is a strong tool for chemical representatives and laundry managers. A knowledgeable chemical representative can provide valuable assistance with this type of computer analysis, improving not only energy efficiency and water consumption but also creating savings in all areas of program expense.

Secondly, a knowledgeable review of laundry facilities with improved practices and procedures can provide major economies for no additional cost. John White, an industry expert with 35 years of laundry experience, offers a number of valuable tactics:

  1. Work with a knowledgeable chemical supplies representative; this should be your starting point. Experienced reps can help you because they work with many different operators and will be able to give you ideas for savings, ideas that are working for others.
  2. If you’re still using “old school” washing techniques (180-degree water, lots of alkali and bleach, long cycles, lots of rinsing, etc.), be aware that chemistry has dramatically changed. Talk to your rep about low-temperature washing. Consider enzyme washing, allowing for lower wash and bleaching temperatures. Your supplier should be bringing these innovations to you for your consideration.
  3. Replace one rinse step in all your cycles with a medium-speed extract. This will save one high-fill for every load of laundry you process, and, over time, can result in thousands of gallons of water—much of it hot—saved.
  4. Understand the relationship between pH and temperature in the bleach bath. A good rep will be able to set your cycles up to bleach in much lower temperatures by lowering the pH of the bleach bath.
  5. Lower your water levels 1 inch when washing/bleaching, and 2 inches when rinsing. All water levels are adjustable, and the good reps know how to do this. One inch less water in the wash step will not make any difference in quality, but due to the shape of the wash wheel, will save you up to 30% of the hot water you would otherwise use in a typical wash step (same for bleach step and 2 inches on rinse steps).
  6. Focus on sorting laundry by soil load and staining. Unsorted linens must be washed according to the worst pieces. If unsorted, every load becomes a costly heavy-soil load.
  7. Program cycles so that your final rinse temperature is between 115 and 120 degrees (typically it is much lower). This means that the linens will be pre-heated (but not too hot to handle) when they go into the dryer. This will save about five minutes of dryer time/energy per load.
  8. Don’t under-load washers or overload dryers. Weigh loads and follow the manufacturer’s recommendations.
  9. Airflow is far more critical than temperature when it comes to dryer time. Clean lint screens after every load, and periodically have dryer vents professionally cleaned. Lint can easily clog dryer vents and choke off 80% or more of your airflow.
  10. Finally, most dryers can be retrofitted with flue sensors that will shut the dryer down when the load is dry, saving on energy and fabric damage.

EQUIPMENT MANUFACTURING: KIM SHADY, LAUNDRYLUX CORP, NEW YORK, N.Y.

From the perspective of smaller OPL facilities, more new equipment applications have become available in the past several years than have been introduced in the past decade. I’ll break these energy savings into three kim shadycategories: electricity, natural gas, and water.

Electricity — The amount of electricity used to operate an OPL washer or dryer may be less than 2 cents per load. There is very little reward for making improvements to electricity use. Evaluating cycle times in the washer could be one area for savings. Washers with higher extraction rates (G-force) can reduce drying times for more savings.

Natural Gas — Assuming natural gas is your heat source for a dryer, ironer or water heater, this is your largest utility cost. To evaluate areas to trim costs, start with your water heater/boiler. There have been many improvements in efficiency, so is your unit outdated? Could reducing water temperature by 5 or 10 degrees make a difference on an annual basis?

The traditional 75-pound dryer in small OPL facilities has gone through significant energy updates in the past few years. Several companies have slashed gas consumption by 20% through new, energy-efficient axial airflow designs that do not sacrifice drying time. This may be the biggest gain for energy efficiency in the past five years.

Also, the extraction rate has a major role in reducing dryer gas use. Upgrading from 100 to 300 G-force can cut drying time by 25-30%, along with similar amounts of natural gas.

Residual moisture controls are gaining popularity to save time and natural gas in the dryer. No longer does the drying time have to be input by hand. Residual moisture controls automate the process, while preventing the dryer from running past the point where linens are dry.

Large laundries have long understood the energy benefits of ironing vs. drying sheets. When ironing sheets properly, the amount of energy used to remove a pound of water is less than the amount a dryer would use to do the same. With new OPL ironers requiring just one person to feed, fold and stack, there can be energy savings, labor savings and huge improvements in quality.

Water — OPL washers are using newer digital technology to measure water levels, providing more precise control for each fill. This also allows the programmer to experiment with finding the optimum water levels and acceptable cleanliness quality. This experiment could bring surprising results in lower water use. Some washers are smart enough to adjust water levels based upon the linen load size, while at the same time adjusting chemical dosing to keep the ratio to water accurate.

Other water savings may be found with ozone systems. Ozone has proven to reduce water consumption and significantly reduce the need for hot water.

UNIFORMS/WORKWEAR MANUFACTURING: STEVE KALLENBACH, AMERICAN DAWN, LOS ANGELES, CALIF.

This is the central question surrounding one of the most important dynamics of the decade: “green” reusable textiles and related processing. My responses will relate mostly to energy and costs that directly impact textile-processing costs.

steve kallenbachEnergy — Over the past 15 years, our industry has reduced energy costs by more than 40% through the use of heat reclaimers, direct-fire water heaters, continuous batch washers (vs. washer-extractors vs. modular washer and extractor units), high-efficiency gas dryers (vs. steam dryers), as well as energy-friendly textiles.

Additionally, chemical companies and plant managers have worked together to find balanced formulations that assist in energy efficiency. An example of this might be in extraction. Once a washer-extractor achieves extraction speed, it is much more efficient to extract the textile a bit longer, if it reduces dryer time (gas usage) while still protecting textile life.

In some cases, textiles have been built to withstand more energy-efficient processing. In others (example: Signature table linen), fabric has been developed to wash cleaner at lower temperatures, thereby lowering energy costs and even processing time. The most recent textile improvement impacting energy efficiency is microfiber fabrics. They take much less time to dry, thereby reducing gas and electricity costs.

Laundry managers need to follow the best in class: 1) know the industry standards, 2) know your own plant’s performance, and 3) engage with your chemical and textile vendors to continually improve efficiency.

Water — Just like energy, our industry has reduced water usage by more than 40% through the use of water reclamation systems and better chemical formulations, soil sorting (to control the amount of rewash) and textiles.

Water reclamation systems reuse some of the last flushes of a formula as the first flush of the next load. Chemical formulation is a key to water efficiency. We put our chemical suppliers in the delicate position of keeping costs down while keeping our textiles clean. Many times, this balance is off, and some plants have a tendency to “over wash” certain textiles. Additionally, some textiles simply clean better, due to raw-material quality, fiber content, weave, topical soil release, etc.

Managers can discuss these issues with their textile and chemical suppliers, in order to choose the right product for the job. Just like energy efficiency, water conservation and efficiency should first be measured against the known industry standards, and managers should engage with their related suppliers to improve both formulation and textiles.

Technology — In all areas of conservation, support technology has improved drastically over the past 20 years. Retrofitting machinery to allow constant monitoring of efficiencies is now available, and the return on investment is sensible in most cases. Additionally, the industry has developed a number of major software packages that can assist managers in monitoring and managing their plant efficiencies.

Maintenance — Aside from education on standards and available efficiencies, the maintenance of equipment and support technology is more important now than ever before.

Plant maintenance managers of yesteryear were measured on downtime of equipment related to production flow. While this will remain the platform for production flow efficiency, maintenance of the future will center more around equipment efficiencies, simply because they can now be monitored constantly.

For instance, in the past, if a drainpipe were open and leaking profusely, it might not be caught and your maintenance department might not focus on it because the equipment was running. In the future, the equipment must not only run, it must run efficiently, because a rightly upgraded and retrofitted wash machine will be able to “broadcast” the presence of an open/leaking drain to plant management.

Textiles — Great plant managers take a more active role in monitoring textile placement as it relates to efficiency, not only in wear-life (life-cycle) costing but also in choosing the right textile for the job.

A simple example of this is allowing a diesel engine mechanic to wear a lightly colored shirt. This textile choice leads to heavy-soil formulation and rewash. Enough of this textile misuse and plant efficiency is impacted.

Other plants overbuy cotton toweling, putting premium textiles into accounts that simply don’t return them. Because these products are typically heavier in content, the plant washes fewer of them per load, thereby lowering both energy and water efficiencies. In some cases, it’s better to put a standard-quality product into an account that needs just that.

December 28, 2011

“What would you say are the most common errors in laundry processing that lead to higher-than-necessary energy, fuel or water costs?” Answeres from the commercial laundry and equipment manufacturing sectors.

“What would you say are the most common errors in laundry processing that lead to higher-than-necessary energy, fuel or water costs?”

Commercial Laundry: Rick Rone, Laundry Plus, Sarasota, Fla.

Utilities in general are usually the second-largest item on any laundry’s budget, so any and all energy and utility costs should be scrutinized carefully and thoroughly. The single biggest error we make is taking the proper operation of our plants for granted!

rick roneOne of the largest expenses for laundries is natural gas. Whether it is used for firing hot-water heaters, steam boilers, thermal fluid ironers or dryers, natural gas has been deregulated and can be purchased from suppliers other than your local pipeline. Once you are confident that you are purchasing at the best price, you can concentrate on the day-to-day efficient operation of your plant.

If your dryers are set by time and temperature, is everything working properly? Have you been maintaining your thermostats and sensors? If a load is not completely dry, is your staff leaving the load in for a complete extra cycle?

Is your staff cleaning the lint filters as often as necessary? When was the last time you had all your gas burners checked with a combustion analyzer and recalibrated?

Check with your washroom chemical supplier to see if it has any new products that might let you wash at a lower temperature, thus saving money.

When was the last time you confirmed that your steam traps were working correctly? This item alone can be a significant resource saver.

When you process sheets through your ironer, how close together are they? If they are not almost leading edge to trailing edge, then you are probably running your iron faster than you need to, and therefore at a higher temperature than necessary. This wastes gas and causes additional wear and tear on your equipment.

Not everyone needs nor can afford an efficient tunnel washing system. If your plant is using conventional washers, are all drains sealing correctly? A leaking drain will cost the operator in both time and utility cost.

Are all level controls set and working properly? Quite often, the greater mechanical action available in an open-pocket washer will let you set your water levels to a lower point.

Have you ever watched your drain during high-speed final extract? If your washer is programmed for more time than necessary, you are not being as frugal as you could be. If you see the water cease coming out of the drain in five minutes, there is no reason to continue the extract cycle.

One potentially huge savings may be derived from reducing sewage or water disposal fees that are usually at least three to four times the cost of water acquisition. When towels leave the washroom, they are customarily at about 40% or more in moisture content. Your utility company should not be charging disposal fees on that water because it will be evaporated in your dryer. There is precedent, and you should have no problem requiring your utility supplier to modify the sewage charges.

Labor is the largest line item on almost everyone’s budget, and we all deal with labor issues daily. Utility costs traditionally rank second. Take the time to review your plant’s operation. Apply common sense and you will find many additional cost-saving avenues that are available to you.

Equipment Manufacturing: Chuck Anderson, Ellis Corp. San Diego, Calif.

There are many areas in the laundering process that need to be monitored. Some common errors I see in processing that lead to higher-than-necessary energy, fuel and water costs are:

chuck anderson• Pre-sort — ­ I don’t think there is enough emphasis placed on the importance of a good pre-sort department. Stains, rips or tears can be identified in pre-sort before the article is processed, saving energy, water, chemicals and labor. We routinely see textiles make it all the way through the laundering process, and it is the room attendant who rejects the article.

• Washing — Make sure that your operators are utilizing the proper formula for each classification of textile being processed.

On many occasions I have seen textiles processed on the wrong formula, or different classifications of textiles sharing a formula because nobody took the time to build a classification-specific formula. Processing this way leads to longer-than-necessary formula times or shortened formulas that lead to rewash, both of which waste energy and reduce the linen’s useful life.

Check washers for door-seal leaks, steam leaks, leaking drains, etc. These all lead to increases in energy and water usage.

I cannot emphasize enough the importance of using a scale in your laundry. Many times, I see the scale has been removed from the laundry, or it is piled with other items from the laundry for use as a storage area. Also, I hear that the operator has been loading the machine for so many years that he/she knows exactly how much to load by look and feel—yeah, right. Under-loading and overloading washers lead to higher processing costs, machinery wear and tear, and increased rewash.

• Drying — Review your dryer times. Most linen is over-dried by several minutes, wasting valuable energy. I would choose a benchmark of, say, 25 minutes and test each classification and document your findings. You can also weigh the textiles before and after drying to get an idea of the pre-dry and post-dry moisture content. I have many customers who utilize summer and winter drying formulas to maximize efficiency.

Make sure that dryer lint collectors are being blown down and cleaned frequently, and that there is adequate make-up air to the dryer burner.

Flatwork — I routinely see operators pulling pieces off the folder due to wrinkles and mis-folds. Make sure your padding is in good order (note: old sheets do not replace padding) and the folder is properly tuned. Reprocessing items run through the flatwork system is one of the biggest wastes of energy and time that I see.

• Clean-Linen Storage — Once linen is processed, make certain that it is immediately wrapped, covered or stored in a contamination-free environment. Too many times, I have seen linen that had to be reprocessed because it was exposed to a nightly blow-down by engineering.

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September 28, 2011

ST. JOSEPH, Mich. — When striving toward a properly equipped hotel laundry facility, owners and operators have a number of factors to consider, including the right equipment mix, new technologies, types of machines and unique industry challenges.

The proper selection of commercial laundry equipment can have a significant impact on several key operational factors—namely time, money and utilities.

Hard-Mount vs. Soft-Mount Washer-Extractors

There are generally two types of washer-extractors: hard- or rigid-mount and soft-mount. Hard-mount machines cost less, but the installation can be expensive. Soft-mount machines may cost more initially, but are easier to install.

Soft-mount washer-extractors generally don’t need concrete supports, and the suspension system eliminates the need for machine bolt-down. Therefore, upgrading to high-speed washer-extractors can be accomplished without having to replace the existing floor, saving a day or two during the installation process.

Additionally, soft-mount washers can extract much more water than hard-mount washers. Certain soft-mount washer-extractors feature high-speed extraction of up to 350 G’s (G-force) to help cut energy usage and drying time.

An Additional Challenge

Unlike a long-term-care facility or athletic club, the linens and towels make up much of the hotel guest’s experience. If a hotel has scratchy, dirty or uncomfortable bed linens or towels, odds are the guest won’t be a repeat customer. For hotels, every time a guest checks in, the linens need to be in top shape to help ensure repeat customers.

Manufacturers realize this and are doing their part to develop chemical injection systems that take the guesswork out of laundry. By working closely with a local chemical supplier, hotel owners and operators can determine the appropriate type and amount of detergent needed to clean the laundry and meet resident or guest expectations. Incorporating a chemical injection system into the machine will help dispense the precise amount of detergent needed, which ensures the correct amount of chemicals are added to the water and helps guarantee clean laundry.

Check-Out Time

Maximizing the effectiveness of hotel laundry operations requires a good distributor partner, the proper mix and types of equipment and a solid understanding of industry challenges. An efficient laundry room can save a hotel money, time and utilities, positively affecting its bottom line.

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July 7, 2011

CHICAGO — Anyone who has ever been challenged to shoehorn a functional laundry into a tiny space knows that they can perform such a feat, but the sequel is making that laundry work properly.

Operational Considerations

There are many operational issues that should be considered and implemented during the planning and design process, not the least of which is matching the washing task with the drying task. If a compact laundry is using a 35-pound washer-extractor, the dryer should be 1.5 times the washer capacity, or +/- 50 pounds.

One of the most wasteful aspects of a compact, on-premise laundry is the mismatching of equipment. Smaller facilities always have smaller loads, therefore smaller machines should be included in the equipment mix.

All equipment choices should be coupled with a half-size machine. That is to say, if the primary production machine size is 50 pounds, then a 15- to 25-pound machine should be included as well. There is nothing more discouraging than to visit a facility and see a 50- or 100-pound washer (or dryer) being used to process no more than 5-10 pounds.

It costs the same to process a smaller load as it does to process a full-size load in any washer and/or dryer, so washing or drying full loads always makes more sense.

Compact laundries are difficult to staff, and the best way to staff such operations is to do some homework. You need to:

  1. Calculate the maximum daily volume (poundage) that must be processed.
  2. Determine the daily hours of operation the laundry is to operate.
  3. Divide the maximum daily production demands by the daily hours of operation.
  4. Once you determine the hourly production demand, all other decisions should be derived from this one number.
  5. Determine minimum space requirements by multiplying the hourly production demands by 5 square feet/hourly production demand, which equals the total production square footage needed. (This space is not all that is needed. Other ancillary areas must be added into the calculations. And the 5-square-feet figure doesn’t account for soiled- and clean-linen storage.)
  6. If the calculations show an hourly production output of 125 pounds per hour, divide that number by 50 pounds to obtain the number of FTEs (full-time equivalent) needed for each hour that the laundry must operate. In this case, the answer is 2.5 staff members.

Conclusions

Compact laundries can be a convenient way to meet the textile demands of a facility. Their economic viability can be debated since audits show them to be more costly due to the smaller volume.

Frequently, the reason for installing a compact laundry has more to do with location and convenience than the cost-savings potential. Where commercial laundry service is not viable, compact laundries can meet the textile needs of an institutional facility.

Some readers will ask where the break-even point is when considering the installation of a compact laundry. In 1990, that point was 750,000 pounds annually. Due to the rising cost of textiles, utilities, labor and employee benefits, the minimum annual volume for considering such an idea is now around 1.5 million pounds per year.

The decision to install and operate a compact laundry is driven by a number of extenuating factors, all of which must be weighed by the facility considering such a venture.

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