Content about Engineering

CHICAGO — Your company is weighing its laundry services options, and pursuing a new plant is a possibility. So what should the average laundry manager know about plant design?

American Laundry News recently invited several engineering, construction and consulting firms with laundry services expertise to respond to some questions about this issue.

ALN: Is there a basic design template that will work for virtually any institutional, industrial or commercial laundry, or is each and every plant’s design unique?

DAVID BERNSTEIN, SENIOR VICE PRESIDENT, TURN-KEY INDUSTRIAL ENGINEERING, CHARLOTTESVILLE, VA.

All institutional, industrial and commercial laundries share certain common design elements (e.g. the need for washers, dryers, finishing equipment, etc.), but outside of those common elements, every laundry design is unique.

Laundry design is dictated by a wide variety of factors, including safety of production employees, the current and future product mix, throughput requirements, local regulatory constraints, and, of course, the budget.

There are certain situations in which a basic design template can be used successfully. Operators who have multiple plants processing essentially the same product mix have for years been successful at duplicating the basic design of a plant in other locations. In these situations, the engineering and design teams simply calculate the current and future production needs of the new facility, and scale the quantity of equipment and the associated building size to meet those needs.

BOB CORFIELD, PRESIDENT/CEO, LAUNDRY DESIGN GROUP, PHOENIX, ARIZ.

If all the business conditions are the same or similar, yes, there can be a general template for design. Large national companies work hard to achieve this by staying highly focused on certain markets. But as the mix of work, type of customers, physical space and growth requirements or restrictions are considered, each plant takes on its own personality.

ED KWASNICK, DIRECTOR OF BUSINESS DEVELOPMENT, LAUNDRY DIVISION, ARCO/MURRAY NATIONAL CONSTRUCTION CO., OAKBROOK TERRACE, ILL.

From 30,000 feet, the production flow and departmental functions for all laundry facilities are similar. They each receive soiled goods, sort the goods by classification, wash, dry, finish, store the goods for delivery, load the clean goods on vehicles, and deliver them to the customer. But that is where the similarities end.

Each laundry must be custom-designed to meet its unique needs based on these issues: type of goods (healthcare linen, hospitality linen, food and beverage linen, industrial garments, mats); rental vs. COG; manual vs. automated systems; single-shift vs. multiple-shift operation; high quality vs. high output; and project budget.

All of these factors must be carefully considered when developing a plant design, and the design must be customized to meet the needs of the operator and their customers.

GERARD O'NEILL, PRESIDENT/CEO, AMERICAN LAUNDRY SYSTEMS, HAVERHILL, MASS.

No, there is not a basic design template that will work for all. Every plant is unique and has different needs. The design will be based on the work load, type of work to be processed, space available, processing needs, future growth, hours of operation, available utilities, local codes/restrictions and, of course, available budget.

GLEN PHILLIPS, P.E., PRESIDENT AND SENIOR ASSOCIATE, PHILLIPS & ASSOCIATES, MINNEAPOLIS, MINN.

Phillips and Associates follows a step-by-step flow diagram for laundry design projects: 1) develop the total annual processing load by pieces and pounds, 2) determine the number of operating hours per week, 3) determine the hourly production requirements, 4) determine space requirements, 5) develop equipment needs, 6) develop labor staffing requirements, 7) develop space cost, 8) develop equipment costs, 9) develop labor costs, and 10) develop a complete financial package: total capital costs, total operating costs, and two years of cash flow.

ALN: What factors dictate just how much square footage a laundry requires?

CORFIELD

Again, it depends on the type of plant and whether or not it serves one customer (an in-house hotel or hospital) or outside customers, and is rental/pool linen or COG processing. If healthcare, do the end-users do bulk delivery, exchange cart, or a combination?

For healthcare, the best formula I have used successfully is 350-500 pounds per square foot, per single shift. So, a 14 million pound hospital plant would be about 38,000 square feet for production plus another 12-18% for employee spaces and offices (estimate 44,000 square feet). Space is also added for other processing types, such as operating room linen. You can project growth either through added processing (equipment) or more hours. Then adjust your building size requirements accordingly. Keep in mind that the best way to expand a building during design is sometimes up and not out to manage cost constraints for land or construction.

KWASNICK

They include the level of automation, type of equipment, the number of shifts per day, operating days per week, clear height inside the building (low height means you are forced to use carts to work in process and move items from department to department; carts require space for staging and travel), and type of laundry (healthcare vs. industrial vs. hospitality vs. mixed).

O'NEILL

Type of work to be processed, amount of growth that is estimated, hours of operation, and type of equipment that will be installed. The level of automation that any plant considers will also greatly influence the square footage needed. We at ALS believe in using the “cube” of any building. This cuts down drastically on the square footage needed to carry out the process.

PHILLIPS

Anyone who is involved with planning a laundry, whether it be in-house or a remote stand-alone facility, has to enter into the discovery process about all sorts of things. Among those discussion points are each of the items mentioned in my answer to the first question. Developing the total annual processing load and determining the operating hours per week and hourly production requirements must be done before attempting to determine space requirements. The driver to/of the entire process is development of the hourly production requirement. Once that number has been determined, everything beyond that point becomes self-evident.

BERNSTEIN

Unless a client already has an existing building in mind for their new facility, we believe that the right way to design a new laundry is from the inside out. In other words, understand and formulate the processes that will be involved in the operation of the new facility; understand the current and future equipment, staffing and infrastructure needs; and then design the building around these elements. In this way, we are able to minimize the amount of wasted space, while ensuring that we’ve designed a safe, productive, efficient and sustainable operation.

ALN: If an institution or business designing a laundry is eager to take advantage of the latest laborsaving and resource-conserving technologies, what might some of them be?

O’NEILL

Tunnel washer technology; high-speed thermal ironer systems with high-production feeders, folders and stackers; soil and clean monorail system (automated or hybrid systems); and smart conveyors will be some of them. The “steamless” concept is also one that should be closely looked at. Having been a big proponent for many years and having now built four steamless or “less-steam” plants, we feel that is a huge resource/energy conservation idea. The advent of wide presses has also had a large impact on the energy conservation ideas in our industry.

KWASNICK

Here’s a list of old tried-and-true technologies that continue to prove their worth: heat reclaimer, stack economizer, water reuse system, and water recycle system.

And here some of the newer technologies to consider: high-efficiency modular boilers, self-contained thermal ironers, wide ironers, new tunnel washer technology that uses less water (aka Milnor’s PulseFlow), RFID technology, production tracking systems, press-to-dryer rail system (provides additional buffer storage between the tunnel press and dryers, and allows you to use fewer dryers), automated bagging machines, and automated wrapping machines.

PHILLIPS

Without going into a lengthy, drawn-out discussion, some of the thoughts our firm delve into are:

1. What type of productivity does the owner want to achieve?

2. What is the owner’s desire in designing a new plant? Stated another way, what is the “hot button” desired by the owner?

3. If it is a reduction in linen losses, then discuss RFID. If it is a reduction in utilities, then discuss 80% water reduction. If it is to reduce the number of accidents, then discuss material-handling systems. Just about every conceivable idea becomes a discussion point and something to serve as a goal.

4. In this time of LEED, then discuss with the owners the power of conserving energy via the building envelope.

BERNSTEIN

Some of the most significant innovations in equipment over the past decade or so have come from Europe, where the cost of labor continues to skyrocket. Examples of laborsaving technologies include highly automated wash rooms, garment auto-sortation systems, load-on-rail soil sortation, RFID technology, and remote ironer feeding/queuing. As might be expected, an added benefit of using these technologies is an increase in employee health and safety, as well as increases in quality, accuracy and productivity.

Among gas-saving technologies are high-efficiency boilers, modular boiler systems, direct-fired hot water heaters, better extraction technologies to reduce the number of dryers and dry times, and the wide variety of heat reclamation technologies, including those that reuse heat from wastewater.

Another such technology, so-called “steamless” plants, is one that has gained a lot of attention over the past couple of years. The idea is to eliminate the need for steam, and therefore boilers, to heat water, ironers and other finishing equipment. When properly applied under the right circumstances, the energy savings can be striking.

Every wash room should be planned with an eye toward water reuse; this goes for conventional and tunnel washers. And don’t forget the fleet. There are a wide variety of energy-efficient vehicle technologies that should be considered, including EV, hybrid-electric, hydraulic-hybrid, diesel hybrid, and natural gas power plants, and composite or plastic bodied vehicles.

We should note one important caveat. Every situation is unique, and before a technology is applied or specified, we strongly recommend the performance of a cost-benefit analysis to ensure that there is a return for every investment. There is a wide range of technologies available, each with its own “gee whiz” and “coolness” factors, but what works in one operation may not necessarily meet the needs, requirements or vision of another.

CORFIELD

This would include any machine or system that reduces the number of “touches” required in packaging, finishing or transporting product. So, conveyors (belt or rail), pickers, auto strapping/wrapping, auto sorting, and stack transport systems are all high-value considerations.

Resource conservation should be a goal, but should not compromise production or quality. Wastewater heat recovery is essential, new high-efficiency dryers can use half the energy of old dryers, and if you have a tunnel, then upgrading your press is a great decision.

ALN: What effect does the type of goods that a laundry processes, or is going to process, have on the plant’s design?

KWASNICK

It has a tremendous effect on laundry design because it affects the type, size and location of equipment. Traditional linen products (e.g. tablecloths, napkins, sheets, pillowcases, etc.) are handled differently than industrial goods (e.g. uniforms, mats, shop towels, etc.). Soil processing for linen requires dedicated soil-count and soil-sort systems that are highly efficient at separating and counting linen pieces. This is typically not the case for industrial goods.

Linen plants can use tunnel washer technology with an extraction press, where industrial or mixed facilities with tunnel washers will typically use centrifugal extractors. Garments require steam tunnels and presses for finishing. However, linen is finished on an ironer or folded after drying. Flat goods are folded and placed in carts for storage and delivery. Garments are placed on hangers and placed on rails or trolleys for storage and delivery.

Large linen plants with tunnel washers and steam ironers require large boilers and mechanical rooms for those boiler systems. Plants that process only mats require hot water for washing, but no steam. Therefore, they don’t need boilers or traditional boiler rooms.

Healthcare plants also need to comply with new guidelines for soil/clean separation, airflow requirements, PPE requirements and other issues that non-healthcare plants do not need to address in their plant design.

Rental plants can process large batch sizes due to consolidation of like goods, while COG plants must process in smaller batches as they strive to keep customer products separated. Large vs. smaller batch sizes will determine the type and size of washroom equipment as well as flow through the finishing department.

As you can see, all of these issues have an impact on space, production flow, and plant design. And these examples barely scratch the surface.

BERNSTEIN

The type of goods being processed is an extremely important factor in determining the design and requirements of every new plant. Prior to putting pen to paper (or mouse to AutoCAD, as it were), there needs to be a detailed analysis of the products and associated volumes to be processed at start-up and at a future point in time. Every single classification, no matter how small the volume, needs to be included in this data-collection phase so that a laundry capacity analysis can be created and used to determine the new facility’s requirements for equipment, space, staffing and infrastructure.

CORFIELD

Healthcare plant vs. hotel plant design can be somewhat similar, with healthcare having 5-15 times more classifications to process. But healthcare is considerably more complex.

General linen (F&B, kitchen), industrial uniform, medical retail, and dust control all have elements that make their designs unique. All have a scale of volume for certain classes of linen or uniforms that makes sense for certain types of automation, washing or waste treatment. Each will also have specific compliance and regulatory issues that can impact design as well.

O’NEILL

Type of goods that a laundry process has everything to do with plant design. It dictates what kind of equipment is required, type of work flow, overall building height, amount of space required at the soil and clean sides, physical separation requirements, etc. For example, an F&B/mixed plant will need a lot more soil-sort classification compared to a hospitality/linen plant. A healthcare plant will need soil/clean separation while a linen or F&B plant will not.

PHILLIPS

Essentially that is one of the very first questions that must be discussed and resolved. If an end point cannot be reconciled on that point, then all other discussion points comes to a halt.

Tomorrow in Part 2: Renovation vs. building new; the biggest challenges; latest trends; and some final nuggets of wisdom

OAKBROOK TERRACE, Ill. — Three textile services companies have completed expansion and renovation of facilities across the United States in recent months with the assistance of ARCO/Murray National Construction Co. and its Laundry Division.

ARCO/Murray completed an 11,000-square-foot addition to the ALSCO plant in Anaheim, Calif. The project included 9,100 square feet of warehouse area, split into two levels, for a clean-side sort system newly installed by Bobco Systems.

The sorting system utilizes a rail system on both levels for the warehouse addition and conveyors on the first level to transfer clean items from the existing plant to the new addition.

The addition included eight dock doors for clean-side loading and 1,900 square feet of ADA-compliant office, break room and restroom area. It allowed ALSCO to consolidate three structures into one and will reduce the labor and time needed to load trucks with clean product.

A conditional use permit, following strict guidelines set forth by the Disneyland Resort Area Mitigation Plan, heavily governed the facility’s design. The exterior was required to meet certain aesthetic requirements while adhering to landscaping, energy saving and site drainage policies above and beyond those of a typical municipality, ARCO/Murray says.

The design and construction firm worked with G&K Services in the addition of a wastewater treatment building at the company’s Denver plant. The project added a 1,700-square-foot building, and retrofitted the existed building, to enclose both new and existing wastewater treatment equipment provided by Norchem Corp. Work on the addition and retrofit was scheduled to minimize conflicts with G&K operations and resulted in no shutdowns or delays.

The new system allows G&K to reclaim heat from 100% of the operation’s wastewater and provide the option to reuse much of the wastewater after treatment.

Another ARCO project was a facility expansion and equipment installation project for CLEAN the Uniform Co. in St. Louis. The project added more than 24,000 square feet to the company’s existing facility, which was built in 1955. The work included a new truck drive-through, soiled separating area, wash floor and finishing area to serve CLEAN’s retail medical operations.

The drive-through features two pit-style platform lifts to allow CLEAN’s route trucks to unload and load products. The finishing area made room for additional folding capacity, ironers, and utilized a belt conveyor to assist in processing. The new wash floor created room for new side-loading washers and new dryers. CLEAN installed an overhead storage rail in the soiled and clean areas within the addition. Construction was completed while the existing plant remained in operation. 

“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!

One 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:

• 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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Click here for Part 3.

BEIJING, China — Suppliers from China, the Czech Republic, Germany, Italy, Japan, Portugal, Switzerland, Taiwan and the United States have confirmed their participation in Texcare Asia, the region’s foremost trading platform for modern textile care. It is scheduled for Nov. 17-19 at the China International Exhibition Center in Beijing.

Held every other year, the trade fair consistently attracts key players such as Castic-SMP, Dow, Hoffman/New Yorker, Jensen Group, Maxi Companies, Primus, Pony, Via-trade and Weishi, says Messe Frankfurt, the show’s organizer.

These suppliers and more—the exhibitor list stands at approximately 110 companies—will present a range of sophisticated, energy-efficient washing, drying and ironing technologies in a trade space of more than 10,000 square meters (approximately 32,000 square feet).

China’s laundry and dry cleaning market presents what Messe Frankfurt calls “significant opportunities” for suppliers of resource-saving technologies as the Chinese government implements a raft of measures to reduce its CO₂ emissions by 45% by 2020.

This has created a demand for environmentally friendly products such as centralized laundry systems, advanced dry cleaning machines, green solvents, energy-saving dryers, and water reclaimers.

Alliance Laundry Systems will launch Over-Dry Prevention Technology (OPT)—which it debuted in the States earlier this year—at the fair. The innovative technology shortens drying time and decreases utility consumption while extending linen life, Alliance says.

“We get to see customers, new and old, from across the Asia-Pacific region at Texcare Asia,” says Kitty Zhang, area sales manager for Alliance. “It is the ideal venue to launch our latest energy-efficient products.”

The Jensen Group from Switzerland hopes to impress visitors with innovations in sustainable laundry automation. “Representatives from our three core technology centers—washroom, flatwork and garment technology—will be at the fair to show how our tools can increase efficiency and boost productivity,” says Gerda Jank, head of marketing at Jensen. “These products will be especially interesting for visitors working in heavy-duty laundries.”

Shanghai Sailstar Machinery Co. is confident that its new SGS Cleaning System will be a popular draw.

“As governments enact ever more legislation to combat climate change, we expect our green SGS Cleaning System will generate a lot of excitement,” says Ivy Zheng, Sailstar’s marketing manager. “This system enhances energy conservation in medium- and large-scale laundry plants. It maximizes output, making washing more economical.”

The fair’s long-standing professional reputation continues to attract new exhibitors wanting access to China’s developing textile care market, Messe Frankfurt says. One such company is German-based BÖWE Textile Cleaning GmbH, which manufactures 12-30-kilogram dry cleaning machines for commercial use and 70-200-kg dry cleaning machines for industrial use.

“Texcare Asia has an established reputation for facilitating trade. We are looking forward to participating in the fair and increasing the visibility of our brand in China,” says Frank Ziermann, managing director.

Kunshan Yingelan Commercial Laundry Equipment is another company exhibiting at the fair for the first time. The Taiwanese firm will present its front- and rear-tilt automatic washer-extractors, front-input and rear-output auto-fast-dryers, dry cleaning machines and solvent recovery dryers, along with finishing and ironing equipment.

“Texcare Asia provides textile care specialists a professional platform for trade,” says Lin Qingguo, vice general manager of Yingelan. “By joining the fair, we hope to get a better understanding of the textile care market in China; this will be useful in marketing the Yingelan brand.”

The 2009 event featured 133 suppliers from 17 countries and regions and welcomed 5,977 visitors from 51 countries and regions, including the United States.

To learn more about Texcare Asia 2011 or to register, visit texcare-asia.com or send an e-mail to texcareasia@china.messefrankfurt.com.

OAK CREEK, Wis. — When Crothall Laundry Services officially opened its new 83,000-square-foot plant during a June 27 ribbon-cutting ceremony, it marked a couple of important firsts for the Crothall Healthcare service line.

The $13 million state-of-the-art facility is the first that Crothall has built from the ground up, and it is reportedly the first laundry in the world to certify (its processing included) under certain LEED (Leadership in Energy and Environ-mental Design) standards. And Crothall managed to complete the construction project—aided by many industry vendors—in nine months.

The Oak Creek plant is one of the few facilities in the country to process laundry without using high-pressure steam boilers, Crothall says. Instead, a Thermal Engineering of Arizona (TEA) Steamless Water Treatment System—using natural gas-fired hot-water boilers and heat exchangers that recover heat from wastewater—provides all the hot water needed for washing.

A gas-fired steam tunnel from Colmac Industries used to condition lab coats generates its own steam independent of a traditional boiler.

Chicago Dryer Co. provided 42 pieces of flatwork finishing equipment to maximize the facility’s production output with minimal utility consumption and enhanced ergonomics.

There are two full ironing lines, each featuring an Edge Maxx cornerless spreader-feeder; Powerhouse self-contained, thermal-fluid, deep-chest ironer; Skyline large-piece folders and Bridge linen transition conveyors.

A small-piece ironing line includes a Rapid Feed small-piece vacuum feeding aid, Powerhouse ironer, Skyline folder and DrawBridge linen transition conveyors to move stacked product from the folder directly to the main conveyor.

There are dedicated systems for a variety of tumble-dried items, including three Blanket Blaster cornerless finishing systems, two Skyline fitted sheet and blanket folders and six Air Chicago folders. All have Bridge conveyors.

All feeding and folding equipment incorporates CHI•Touch, an advanced PC-based control system that offers optimum visualization of operating, electronic and mechanical machine functions, as well as real-time display of production numbers.

Crothall management can set, monitor and maintain desired standards and production levels. CHI•Touch guides employees through each step of machine operation and uses the same logic and uniform style display on every machine so staff members can easily switch to a different piece of equipment.

Click here for Part 1.

PHILADELPHIA — The Missouri Water Environment Association (MWEA) recently honored ARAMARK Uniform Services (AUS) with the Gold Award for its commitment to preserving, protecting and improving the quality of Missouri’s water environment, ARAMARK reports.

The award recognizes the company’s compliance in managing wastewater from its Springfield-based industrial laundry facility. It is the seventh consecutive year AUS has received the honor.

“It recognizes our team’s diligence in ensuring that we reduce our environmental footprint while delivering exceptional operational results,” says Cavin Cowan, AUS general manager.

Operating five days a week, the facility processes approximately 24,000 garments each day and treats approximately 55,000 gallons of wastewater.

The treatment system includes a heat reclaimer that recovers and reuses the heat from the wastewater (wash-water temperature is heated to 160 F), reducing the plant’s gas use by 15%. In addition, a water-reuse system minimizes clean-water use by 20%, saving 2.6 million gallons per year.

An AmericanLaundryNews.com Exclusive

Are you familiar with the design-build concept? Design-build is a method of project delivery, as described by the Design-Build Institute of America, in which one entity works under a single contract with the project owner to provide design and construction services.

Is it possible to design-build a laundry? Absolutely, if you’re able to think outside the box and forget traditional construction and systems-procurement methods.

BOISE, Idaho — There is no mistaking the excitement in Randy Rhodes’ voice. Having spent most of his adult life working in the St. Luke’s Health System laundry, he can’t wait to talk about its pending relocation from the basement of a shared building to a state-of-the-art, semi-automated facility that will be three times larger.

“If we could move in tomorrow, we’d do it,” Rhodes says while speaking by phone about the just-started project.

BISMARCK, N.D. — Central Dakota Hospital Laundry (CDHL) Manager Greg Lorenz was faced with a challenging question. When should he replace an efficient tunnel system that has been working well for many years? Lorenz got his answer when the financing that was available became too good to pass up.

With financing in place and approval from its board, CDHL looked to The Minnesota Chemical Co. for a new Milnor tunnel washer. The local distributor sold the original tunnel system back in 1992.

The inherent dangers of industrial laundering have been well-documented. Potentially contaminated sharps lurk in soiled linen. Heavy slings or bags dangle overhead. Large, moving equipment threatens to maim or even kill if a worker makes a wrong move.

Heat stress doesn’t harbor the immediate threat of these other hazards, but it’s one that can still pack a deadly wallop if treated too lightly.

LOOK FOR WARNING SIGNS

There are many options for getting textiles from Point A to Point B, whether the trip is 10 feet or 10 miles. Last week, we looked at carts and trucks. This week, we tackle material-handling systems and delivery vehicles.

MATERIAL-HANDLING SYSTEMS

Conveyors, shuttles, rail systems and many other devices are designed, and often custom-made, to help laundries get their goods through the system quickly and easily.