Content about Textiles

April 17, 2013

Controlling Linen Loss is Key to ‘Saving Par’ (Conclusion)

CHICAGO — Input from hotel/motel/resort laundry and chemicals supply sectors

Hotel/Motel/Resort Laundry: Charles Loelius, The Pierre New York, New York, N.Y.

charles loelius Abraham Lincoln once said, “You can’t do business from an empty wagon.” Nothing has a greater impact on a laundry’s sales, service, operation, and reputation than an inadequate circulating linen inventory.

The lack of a sufficient amount of linen in circulation necessitates operating the plant longer hours than would otherwise be necessary. Labor, maintenance and utility costs increase, while both efficiency and morale plummet. Operating costs increase without the benefit of added revenue.

Laundering the linen more frequently than would otherwise be necessary shortens its life, resulting in higher depletion and additional replenishment cost.

Equally important, insufficient circulating linen results in decreased fill rates. The inability to provide complete orders negatively impacts both revenue and customer confidence.

The first step in managing circulating linen inventory is to recognize that linen loss will occur. The next step is to ascertain where this loss is prone to occur, and develop policies and programs to prevent unnecessary depletion.

How linen is processed, distributed, utilized, returned and monitored will have a direct bearing on both linen loss and replenishment costs.

Planned losses, such as discards and rag-outs, are the result of quality control programs. Planned depletion, along with a corresponding linen replenishment program, is necessary to maintain a viable circulating linen inventory.

At my hotel, I budget annual rooms linen replacement cost at $2.50 per occupied room; annual food-and-beverage linen replacement cost is budgeted at 20 cents per cover.

Consequently, I am able to completely turn over the circulating linen inventory every three years.

There are two types of linen depletion: actual and artificial. Actual loss represents a permanent depletion in circulating linen (the linen is not retrievable). This loss is the result of discard, abuse and theft, either deliberate or inadvertent. Artificial loss represents linen that, while not accessible to circulating inventory, is still retrievable. This loss is caused by linen being overstocked at the end-user location, which results in an under-utilized inventory.

In linen rental operations, overstocking at the customer not only renders linen inaccessible, it precludes generating additional rental revenue via “turning” the linen.

Conducting physical inventories on a regular basis will provide the information needed to determine if the amount of linen in circulation is sufficient for the operation. Physical inventories also help in the planning of future purchases, and are essential in determining linen loss.

Due to storage limitations typical at a Manhattan hotel, it is necessary to employ the practice of just-in-time ordering. Ordering less linen more often reduces the space needed for storage, but increases the reliance on accurate physical inventories. Like the carpenter’s credo of “measure twice cut once,” proper linen procurement relies on conducting exact physical inventories.

Conducting precise physical inventories will also serve as the basis for determining unexplained linen loss. This loss can be determined through this formula: Prior inventory – discards + linen injections – current inventory = unexplained loss.

Conducting physical inventories at the customer’s premises is a daunting task, but is necessary to properly gauge both linen loss and linen utilization. Complete inventories should be conducted at least annually. Salient information can also be gleaned from “informal” inventories, shelf counts, and linen abuse “spot checks” that can be conducted as part of sales, service, and goodwill calls.

Linen loss and abuse charges, as well as linen utilization fees, when implemented and enforced, can aid in reducing both actual and artificial linen losses.

There is the caveat, however, that enforcing these type charges, even if contractually stipulated, may result in strained relations with the customer.

Regardless of the laundry operation type, it is crucial to involve, educate and monitor the end-users, in properly controlling the linen at their disposal.

Chemicals Supply: Philip L. Bodner, Metro-Chem, Kearny, N.J.

One of the main challenges in purchasing new textiles is taking extra care to know exactly what it is you are being sold.

We are in a time of exciting new textiles and innovative, high-performance, high-quality fabrics, yet we are also in an era of low-cost outsourcing from places around the globe offering seemingly value-priced purchasing options that sometimes don’t perform to our standards and expectations.

philip bodner Processing of “commercial level” quality textiles or an innovative new fabric is usually easy enough to accomplish. As always, make your purchasing considerations based on colors, sizes and fabric types. When placing your first order with a vendor, make sure to ask for a printed copy of the manufacturer’s laundering and processing recommendations.

Get all the info that’s available and then the correct laundering and finishing of these textiles becomes a matter of putting the manufacturer’s recommendations together with you and your trusted vendor’s experience to arrive at the correct processing routines. When handled properly, the mid- to higher-quality imported or domestic textile will stay in usable condition longer and will offer a good return on investment through its extended service life.

If you are buying large quantities of any textiles, or if you’re buying something new to your operation (or even trying to get a bargain), do two things to save yourself some potential grief. First, ask your distributor salesperson to let you speak to some customers who have purchased the same goods to get direct feedback on performance. Secondly, have an adequate quantity of sample products sent in advance to test-wash and finish to get a leg up on what to expect.

As far as how much linen inventory is enough, answers vary for each operation’s actual needs. One thing is sure: the same budgetary constraints we suffer today, the ones that send people bargain shopping, also tend to lead to inadequate par levels. This lack of linen—I call it “LoL”—can often leave a trail of major inefficiencies cascading down the line.

Both the planned and un-planned consequences of LoL are no laughing matter when they start costing you money. It starts the clock ticking on an investment that will surely wear out before it should. It’s just like wearing the same pair of shoes every day instead of alternating among a few pairs throughout the week. At the end of some shortened period of time, you will be reordering new replacement linens and those pesky invoices will start to play tag with accounts payable.

LoL also puts stress on everyone involved in your laundry or the laundry that provides your linen service. This can lead to processing shortcuts that can affect quality in laundering and finishing because nobody can take the time to do it right. Today’s soil is also today’s or tomorrow’s clean linens, so just get out of the way! We see this “hurry and scurry” approach played out over and over in many laundry operations.

LoL flies in the face of “green” initiatives. It’s carbon-intensive to burn all of that diesel fuel the linen service uses to drive back and forth seven days a week with the linen you absolutely have to have now. By adding par, you solve this, and may even put yourself in a better negotiating position when the next service contract is written. Your provider now only has to come rolling out to see your loading dock four times a week, which is a win-win situation for all except the oil companies.

Finally, it’s the unplanned consequences always lurking around that can and will affect you in not-so-pleasant ways. You have probably experienced some of these seat-clenching moments already.

Do you agree that laundry equipment never breaks, the delivery trucks always start in winter, it never snows, and everyone else’s workers always show up in force when needed just like yours do? If you don’t, then you’re a realist, and having that one or two extra par on hand in case of emergency is your buffer when reality hits. This option sure beats watching your employees stand around waiting for miracle linen to appear. Besides, the guests usually don’t stay humorous for long without clean sheets.

Having more par available keeps the goods looking better and lasting longer. More par means less stress and more time to get things done right. More par is more green. More par gives you breathing room when the best plans go awry. And we can all agree that having one less thing to worry about is always a good thing.

January 30, 2013

White Plains Linen Expands Offerings Through New Alliance

PEEKSKILL, N.Y. — Agreement opens access to vast assortment of specialty linens

PEEKSKILL, N.Y. — White Plains Linen | LINENS à la Carte reports that a new alliance expands the product lines for specialty linens it can now offer.

The agreement with Total Table, a large special events linen company in the Northeast, provides White Plains Linen access to a vast assortment of inventory—it can now provide more than 1,200 new patterns and designs, it says—from a warehouse covering more than 30,000 square feet.

It presents the caterers, golf courses, country clubs, catering halls, hotels, corporations, etc., that White Plains Linen services with an opportunity to set themselves apart from competitors in terms of the linens they offer.

“White Plains Linen | LINENS à la Carte is extremely excited to offer our customers such a vast and beautiful selection of special-event linens,” says Mike Ritter, White Plains Linen general manager. “Our partnership with Total Table will help to enhance and strengthen the service we can provide.”

White Plains Linen President Bruce Botchman called the new venture “an arrangement that is conducive for all parties involved.”

“With this partnership, White Plains Linen and Total Table can now provide customers with the perfect blend of everyday, functional linens, as well as fanciful linens needed for special occasions,” says Ann Davis, president of Total Table.

The new product line is now accessible through the White Plains Linen | LINENS à la Carte Essentials catalog.

October 17, 2012

Educate Users on True Cost of Linen Abuse (Part 2)

CHICAGO — Input from textiles, hotel/motel/resort, and at-large sectors

TEXTILES: TOM LANGDON, ENCOMPASS GROUP, MCDONOUGH, GA.

tom langdon Approaching this issue from a textile sourcing and laundry processing point of view, we see varying degrees of linen abuse, depending on how our customers process. With the development of more resource-saving equipment, the linen has to be more durable today that it has in the past. For example, most of the newer tunnel washers reuse water from the first cycle, and if linen (especially apparel) is not colorfast, you can end up with cross-contamination staining on other items.

Everyone throughout the supply chain is cost-conscious, so one of the first steps is making sure your linen has been properly processed when you receive it.

There have been instances in which PVA (polyvinyl alcohol) used in the weaving process was not completely removed in the finishing process. This can end up creating a buildup on flatwork ironer equipment. Depending on the process, this linen may process fine in one laundry and create havoc in another. PVA is water-soluble and disperses in wash temperatures of 160 F. It can redeposit on the linen, however, if not thoroughly rinsed.

The second step is to test suspect linen for abuse. There are ways to determine if the fibers have been damaged through chemical or excessive heat during processing. One method is the Fehling’s solution test. This process can detect the presence and amount of certain chemical residue that can damage cellulose fiber, primarily cotton. If these fibers become damaged, they weaken and will wear out prematurely.

Historically, the primary test for evaluating linen durability has been the AATCC 1961-IVa method for Colorfastness to Commercial Laundry. This test is becoming outdated with regards to the healthcare industry. It calls for a 2% solution of chlorine bleach, and most of our industry has moved away from chlorine in favor of hydrogen peroxide or other less aggressive chemistry in efforts to extend linen life. The industry or related agencies need to develop and publish an updated test method that includes the newer formulas and equipment being used in the industry.

The third step is to evaluate your linen. You could be using the wrong type, construction or blend. The move to higher-content synthetic fibers has raised the bar for the life expectancy of today’s linen. If you try comparing a 100% cotton bath blanket or terry towel to a blend, you will see a significant difference in life expectancy.

The fourth and final step is to be an educated user. Many of you that have been around a long time may be familiar with some of the information I’ve covered. But those of you who are less experienced should enlist your linen provider’s help. Your provider can help you get acquainted with the techniques and quick checks to help manage your linen purchases and usage. Also, check with your chemical supplier, as many can provide a troubleshooting guide to linen abuse.

HOTEL/MOTEL/RESORT LAUNDRY: JR NORRIS, DELTA UNIFORM AND LINEN

JR Norris Isn’t this the pot calling the kettle black? During almost 20 years in the restaurant business, I witnessed my fair share of regular linen abuse. Now, after being in the linen supply business for the past several years, and seeing the other side of this equation, I find myself cringing at the condition of items I see coming back. Some might think that’s a good dose of Karma for me, but I like to think my experience gives me an alternate viewpoint and advantage in identifying and solving the problem.

When items come back damaged or discolored, I try to identify where the abuse took place. I inspect the facility before approaching the client; the worst thing you can do is point the finger at the client without inspecting your facility and processes first (I learned that the hard way).

Sometimes during this process, I’ll even go so far as to climb into each of my machines to identify potential issues with the washing and drying process. I also try to identify if handling by employees is causing the abuse. If facility employees are causing the abuse, I spend time talking about how to prevent abuse, and I always make a point to share the item price. Once the employees understand what it would cost them to replace the damaged item, the carelessness stops.

Another way to identify potential problems is to witness item delivery. I ride along with my route personnel weekly to try to identify if improvements can be made to prevent products from being damaged during distribution. I watch them load their route trucks to see how they treat all products, and I try to identify other contributing factors. I have been able to find and make repairs to trucks that had sharp edges and to screws that were tearing goods or had that potential.

If it turns out to be an issue on the client’s end, we typically use the main rule of baseball: three strikes and you’re out. This doesn’t mean that we stop servicing the account after three strikes. It just means we find a different way of getting the point across.

First, we send back the damaged item with a sticker indicating the item’s intended use and what we believe to be the inappropriate use. When it comes back abused a second time, one of our managers personally visits the client and reiterates that training is needed to prevent the product damage from continuing to happen. Last, we charge a replacement fee if/when it happens a third time.

Depending on how the bad the items are, sometimes we skip the three-strike rule and charge for the linen immediately. Because we operating a weekly linen rental business, we have to make sure the customer understands that there are financial consequences for recurring linen abuse.

Remember, it’s all about getting back to the basics and training. Always give your employees and customers the proper tools and information to be successful.

MEMBER AT LARGE: DOUGLAS STORY, SWISHER HYGIENE

douglas story Knowledge is king! The more a customer knows about the cost of linen and what happens when the linen is damaged or lost, the more likely they will be tuned in to the need to protect this asset.

We are in a service industry, and part of our regularly scheduled service program should be to train the customer on how they can control costs via efficient use of linens; protecting their linen from abuse and loss should be part of that program. Training should include:

Identifying sources of abuse (chemicals reputed to stain or damage linens; bleach, acids or mechanical devices that can cut linens or cause them to tear; etc.)
Physical samples of abused linen from the same or similar facility
Actual breakdown of what it costs to replace a damaged or lost item
The presence of upper management and “direct contact” workers

When linen is found to have abuse stains or damage, the items should be taken to the facility and become part of the training and education process. The sooner this is accomplished within a customer service contract, the quicker the abuse can be minimized. Allowing prolonged abuse only creates a situation in which abuse becomes a hard-to-break habit.

About the possibility that you’re abusing the linen during processing and/or distribution, the answer is yes. The same training program used for customers should be implemented with staff and employees of the laundry operation.

Floor drags and drops, equipment tears, caster stains, mildew stains, etc., are just a few of the abuse issues that can occur if laundry operations are not following proper procedures or the plant is using malfunctioning equipment.

Enhanced quality control programs in which everyone is trained will aid to minimize linen abuse in a facility.

Check back Tuesday for the third and final part!

July 19, 2012

Hallak Cleaners Launches New Linen Services Company

HACKENSACK, N.J. — Well-known couture cleaner expands into linen services

HACKENSACK, N.J. — Hallak Couture Cleaners says it has launched Bergen Linen, a new service for the restaurant, airline, hospitality, country club and spa industries in a newly acquired 10,000-square-foot facility.

A full range of laundry, dry cleaning, tailoring and embroidery services are now available, along with comprehensive care for interiors, including carpets, upholstery, walls, lampshades, locker-room tile and grout cleaning, Hallak says. Rentals, including but not limited to table and bed linens, aprons, chef apparel and uniforms, will also be offered.

Bergen Linen offers complimentary pickup and delivery six days a week in the Bergen County area and provides customized billing to work within any business infrastructure.

In addition, with state-of-the-art technology, unexpected emergencies such as water extraction, smoke or fire damage, and mold remediation can be mitigated, Hallak says.

Hallak Cleaners is a family-owned company that has been providing quality fabricare for discerning clientele in the New York metro area for nearly 50 years.

June 13, 2012

Guy Fieri-Owned Restaurants Re-Sign with Mission Linen Supply

SANTA BARBARA, Calif. — Tex Wasabi’s and Johnny Garlic’s have been clients for 14 years

SANTA BARBARA, Calif. — Mission Linen Supply reports that it has renewed and expanded its contract with Tex Wasabi’s and Johnny Garlic’s, the two multi-location restaurants owned by The Food Network’s Guy Fieri.

Mission Linen will be the sole provider of table linens, napkins, floor mats, aprons and towels for all seven restaurant locations, including the recently opened Johnny Garlic’s location in San Jose, Calif.

Johnny Garlic’s and Tex Wasabi are both owned by Fieri, the host of the wildly popular Diners, Drive-ins and Dives, as well as the special series Tailgate Warriors, both on The Food Network. The restaurants first partnered with Mission Linen Supply in 1998 and have relied on the company for tableware and floor care needs ever since. The seven California locations are serviced by Mission Linen’s facilities in Salinas and Sacramento.

“The level of service and quality that Mission Linen has provided over the past 14 years is what convinced us to renew our contract,” says Brett Hutchison, COO, Johnny Garlic’s and Tex Wasabi’s - Guy Fieri Signature Restaurants. “The entire operation is professional, from the front office to their dependable and personable drivers. There was no question we would continue to partner with them when it came time to open our new location in San Jose.”

January 24, 2012

2012 Panel of Experts Ready to Answer Industry Questions (Part 3 of 4)

Textiles: Tom Langdon, Encompass Group

I am vice president of sourcing and purchasing for Encompass Group. I have spent the past 30 years in a variety of roles and responsibilities in the textile industry.

For the last 20-plus, I have traveled the globe, extensively developing and sourcing all types of textile products. My product experience spans from retail home fashions, to protective and military apparel, and into the medical textile products area. I am experienced in woven, non-woven, and knit manufacturing techniques along with all aspects of printing, dyeing and finishing.

tom langdon My educational credentials include a Bachelor of Science degree from the Stetson School of Business at Mercer University, along with various continuing education certificates in customs, compliance, CTPAT, supply chain management, and ISO 9000 registration. I sit on the Techtextil North America 2012 Symposium Advisory Council and chair the Medical Educational Section. I see my role on the panel as giving readers the layman’s perspective on each monthly topic and how obtaining the actual textile items is affected.

Two of our biggest challenges in 2011 were the unprecedented run-up in raw-material costs and mitigating the impact to our customers. We also were faced with some historic geopolitical changes in the world, of which the unrest in Egypt created some specific obstacles to our industry.

I was already scheduled to visit Egypt at the end of January 2011, the week before the Mubarak regime fell. I remember spending the first half of the Super Bowl on the phone with my travel agent rearranging my itinerary to cancel the Egypt portion of my trip. Later, I found out that the head of the largest government-owned textile mill in Egypt was removed from his post and arrested.

Probably our greatest accomplishment realized was in educating our customers and others in the industry on market conditions. This entailed explaining how contributing factors such as the price of cotton, energy, and currency exchange rates affect the price, quality, and availability of laundry textile products.

Encompass benefited from an intercompany market update I published monthly, which helped our sales force reach out to all of our customers as well. The price of cotton became such a hot topic at one point that it even made it on to NBC’s The Today Show.

Let’s all hope we have a much calmer and more stable 2012. I look forward to participating on this panel and appreciate being selected.

Linen Supply: Stephen Marcq, General Linen Service

I’m the director of business development for General Linen, with corporate offices and the processing plant located in Somersworth N.H. I’ve been with the company for approximately 22 years, starting as a production manager. I worked as a production and depot manager for several other companies before returning in 1992.

stephen marcq While most of my time with General has been on the service side of the business, I’ve done everything from load diapers (remember those?) to running the service department and then the sales department, which has given me a well-rounded background that has served me well.

Today, I work extensively with the sales and service teams to manage, retain and expand our business presence with large corporate accounts, and especially with a variety of multi-site operations, both healthcare and hospitality. Setting up various customized programs designed to appeal to the particular needs of off-site management or ownership is an accomplishment I am particularly proud of.

We have 3,800 customers in four states, serviced from our main plant and two additional service centers in New Hampshire and Maine. Our plant mix consists mostly of hospitality and healthcare business, with lesser amounts of industrial and dust control.

With both of those areas affected by the economic downturn over the last few years, and healthcare especially hit hard in the last 6-12 months, a major challenge right now is in maintaining margins and sales increases while retaining customers in an increasingly competitive, cost-conscious environment.

We have implemented route optimization software to reduce distribution and delivery expense, installed a stack economizer to reclaim waste heat, increased our sales team, set up a key/multi-site customer and corporate visit program, and have many other projects in progress or in the works.

Our mixed-plant status can be, at times, both an asset and a liability. When one segment is down, we have historically grown in another and been able to protect jobs and revenue. But gaining maximum production and delivery efficiencies can be harder for a mixed plant as well, something that we are doing our best to address.

I am honored to have been selected to serve on the panel, and I am looking forward to contributing during 2012.

Hotel/Motel/Resort Laundry: JR Norris, Delta Linen

I’m the operations manager for Delta Uniform and Linen, the largest family-owned and operated commercial laundry in Albuquerque. I am honored to have been chosen for this panel.

jr norris The Randall family established Delta Linen in 1948 as a small drycleaning business. The decision was made to take the business into industrial linen rental, and Delta Linen has since flourished. It now services more than 300 restaurants, casinos and fine hotels, and is growing daily. Delivering clean and wrinkle-free linen and hospitality wear with 24-hour-a-day customer service has contributing greatly to our success.

I worked as a general manager in the restaurant business for almost 20 years, sitting on the other side of the table in dealings with linen companies. This experience has helped me greatly with my transition from restaurants to linen service and having the ability to under a restaurant’s needs. It encourages me daily that Delta Linen has had the same beliefs and integrity for more than 60 years!

I have faced several challenges after diving headfirst into the linen business, but that’s been the fun part. The biggest has been working with and understanding the quality and maintenance aspects of hotel linens.

I have seen sub-par cotton quality coming from many manufacturers over the past 18 months. We have had to change several processes, including how we order and wash, to ensure the longevity of the textiles. Because of this, production has almost been more challenging than the cleaning of the products themselves.

We were blessed with continued growth this past year despite the hard economic times the country faced. We have taken on several new, large accounts, along with a new contract with a resort. And we recently renewed our contract with the largest casino in New Mexico.

We continue to strive for the best every day, with the mind-set and commitment that our service is our contract and it is as good, if not better, than a golden handshake. I intend to see that Delta Linen maintains this philosophy for many years to come.

Tomorrow: Introductions to representatives from the equipment manufacturing and chemical suppy sectors, plus a member at large...
Click here for Part 1.
Click here for Part 2.

October 19, 2011

Madonna Inn Makes Room for Mission Linen Supply

SANTA BARBARA, Calif. — Mission Linen Supply has been awarded a contract by the Madonna Inn in San Luis Obispo, Calif., to be the sole provider of uniforms, linens, mats and mops for the Inn’s guestrooms, steak house and coffee shop.

The Madonna Inn is situated on approximately 2,200 acres and has been one of California’s landmark attractions since it opened 50 years ago, Mission Linen says. In addition to the main inn, the property incorporates a wine cellar, bakery, coffee shop, dining room, gift shops, a full-service resort day spa, pool and fitness room, several banquet rooms, and the largest convention center on the Central Coast.

Mission Linen’s Morro Bay and Santa Maria facilities will service the inn, spa, steak house and coffee shop.

The fact that both are family-owned businesses played an important part in the Inn’s decision to select Mission Linen, says Mat Tornquist, Madonna Inn special projects manager.

“We were impressed with Mission Linen’s ability to manage the various needs of our resort,” Tornquist says. “The fact that they are local and had two processing plants nearby was another contributing factor. In the end, though, we felt that our two companies share a similar outlook, and that’s what ultimately gave us the comfort we were looking for.”

September 22, 2011

Panel of Experts: The Lowdown on High-Thread-Count Linens (Part 3 of 3)

“Our resort has upgraded its linens everywhere, from the guestrooms to the pool to the five-star restaurant. So, the pressure is on to clean, handle and store these goods so they give us the longest useful life possible. What advice can you give me about processing high-thread-count linens?”

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

The best advice that I can offer is to follow the manufacturer’s guidelines. The next best source of assistance would probably be your chemical supplier. It should be able to offer the appropriate details for the wash and dry cycles with an eye toward cleanliness as well as life expectancy.

rick rone In general, as the thread count goes up, you usually need a higher water temperature to open the fibers and release any soil or stains. Some people believe that you can accomplish the same thing with raising the pH level. I am not a big fan of this method, because I believe it contributes to a shorter life cycle. I am not saying it doesn’t work, but there are better ways to accomplish the same goal.

I will presume that you know the four parts of the washing equation. If available, you might try a longer formula or hotter water. We always try to use the minimum amount of chemicals, but not just due to the cost. Since we process only customer-owned goods (COG), we believe that part of our responsibility is to help our customers get the longest life expectancy (number of wash cycles) from their bed and bath linens.

The next area to review would be the extract cycle. Whether your machinery utilizes centrifugal extraction or the press method, faster or greater pressure is not necessarily best. You need to be ready to admit to yourself, as well as your supervisor, that this new material is going to take longer, and therefore cost more, to correctly process than the old (lower thread count) linens.

Higher-thread-count linens will usually finish better if sent to the iron with higher moisture content. Since the question is specifically about higher-thread-count linens, I will address the flat goods only.

Ironing of your new linens can and probably will be a whole new ballgame. Let’s review the factors that affect output and quality: ironing temperature, speed of line, roll pressure, type of pad, adjustment of each roll speed, type of tape being used, and, finally, folding method (air blast or blade). Since the moisture level might be higher, you can either run the iron more slowly or turn up the temperature and maintain current speed. I support the theory that slower is better. We would rather lose production than compromise quality.

Next, I would look at roll pressure. Generally, the higher the pressure, the shorter the life of the pad/pads. This can be balanced with the correct pad thickness as well as proper material. If your iron is a multi-roll unit, and if each roll is inverter-driven, you should properly synchronize the speed of each roll individually so as to obtain the correct pull of each roll away from the previous one.

There are many types of iron tape available. Based on your choice of pad material, roll pressure and roll-speed synchronization, the tape you use will not leave unnecessary tape marks or pucker lines in your higher-thread-count linens.

I prefer the air-blast method of folding. Unfortunately, as the thread count—and therefore weight and thickness—increases, so to does the need for a blade to assist in the proper folding. As long as the blade is properly maintained, it will be a valuable tool.

Be prepared to accept that the whole process will take longer and cost a little more, but the finished product will be better and should last longer.

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

Managers new to processing high-thread-count linens must first understand that high thread count does not equate to more durability. In fact, the opposite is true.

chuck anderson Thread count is simply the number of threads per square inch of fabric. These consist of vertical threads (warp) and horizontal threads (weft) woven together. To achieve a higher thread count, thinner threads are packed into the same square inch of fabric with a tighter weave. These smaller threads with a tighter, less flexible weave produce a more delicate fabric.

The most important step after purchasing new linens is to wash them thoroughly to remove vat dyes and sizing used in the manufacturing processes. If these chemicals are not removed before finishing, yellowing can occur, which will take several rewashes to remove (in some cases). These chemicals can also produce allergic reactions in some guests.

High-thread-count linens are expensive, and you want to make sure ownership has provided you with enough product. Resorts should have a minimum of three pars: one par in the room, one par being processed, and one par on the shelf. It is important that linen “rest” on shelves for 24 hours after laundering, because many types of linens are more easily damaged right after washing; this also enhances the flat-dry appearance.

Take a look at your equipment. If processing with a tunnel washer, you will need to add a program to your press for these more delicate fabrics. Specifically, to prevent hydro-burst in sheets, the press should be set to ramp to a membrane pressure of no more than 15-20 bars.

Adjust washer cylinder speeds, water levels, chemical concentrations, temperatures and process times to achieve high quality with reduced mechanical damage and chemical degradation.

Check inside of wash cylinders and around doors for snags. One method is to run an old pair of pantyhose along the inside. The material will snag on any burrs or imperfections.

For good mechanical action when washing napery, load the wash wheel to this capacity, depending on type: full drop — 90%, split pocket — 75%, Y-pocket — 65%.

Dryers should be in top shape and preferably have humidity controls. Make sure to set adequate cool-down time, and do not over-dry.

Check speed and tension on spreader-feeders using one sample test sheet; do not destroy multiple sheets before you realize you have an issue. Replace ironer padding and roll covers if worn or ripped to reduce mechanical abrasion. Make sure cleaning/waxing is on a routine schedule. Control chest temperature at 310-325 F. These heavier, larger linens are going to require slower processing.

It is important to educate banquet staff, pool attendees, servers, housekeeping and any other resort personnel who come into contact with these high-end linens about their cost and proper handling.

Each department should have proper soil carts or bins so that linen does not sit on the floor. These carts should be cleaned regularly and checked frequently for protrusions that could snag or tear linen. Besides sorting linen into normal classifications such as towels, sheets, pillowcases, etc., goods should be sorted by degree of soiling. This will eliminate over-processing and prevent unnecessary wear.

Click here for Part 1.
Click here for Part 2.

September 20, 2011

Panel of Experts: The Lowdown on High-Thread-Count Linens (Part 1 of 3)

Textiles: Elizabeth Easter, Ph.D, University of Kentucky, Lexington, Ky.

High-thread-count linens, especially cotton sheets, were introduced to consumers in the ’90s. In the past five years, the hospitality industry has begun offering these so-called “luxury linens” to their elizabeth easter customers. Thread counts that traditionally averaged 180-200 have been replaced with thread counts up to 1,500.

There are some misunderstandings about what they actually are. Most people believe that quality, softness and durability increase in a linear way with increasing thread count number. This is not necessarily true. The truth is that it’s just not that simple. Thread count is only one measurement to examine when considering luxury linens.

What are the quality indicators of high-thread-count linens?

Fiber Quality — 100% cotton sheets are by far the most popular among high-thread sheets. The highest-quality cotton is long staple. Staple refers to the length of the cotton fiber: the longer the fiber, the better. It creates stronger and finer yarns. Among long-staple cottons, the longest are Egyptian extra-long staple and Pima (Supima).
Yarn Size — This is a measure of the fineness of each yarn: the higher the yarn number, the finer the yarn. The yarn size in sheets is typically between 40 and 100. The size will determine how many yarns can be woven in a square inch. Higher thread counts are created with finer yarns, as more of them can be woven into a square inch. Also, super-fine yarns can be twisted, creating two-ply yarns that can then be woven into sheeting.
Thread Count (Yarn Count) and Construction — Thread count is the number of yarns per square inch of fabric, i.e. add the number of warp and weft yarns. Construction refers to how the thread count is achieved (number of warp and weft yarns, number of picks in the weft, use of two-ply yarns, etc.) To achieve higher thread counts, sometimes two-ply yarns are used, and sometimes multiple yarns (picks) are inserted into the weft.

Chemicals Supply: Carrie Armstrong, Ecolab, Eagan, Minn.

The upgrade of linens throughout the facility creates an opportunity to develop a partnership with each department. Training the end-user on the linens, development of quality standards, par levels, and linen-abuse potential will assist in linen management. Written procedures and standards that are specific to each department for handling the upgraded linens can then be established and practiced.

carrie armstrong Processing high-thread-count linens in the laundry has its challenges. High thread counts provide for luxurious linens and often require specific guidelines for processing. It is important to consult the manufacturer and/or read the care labels before laundering and processing. The manufacturer and/or labels will provide guidelines for processing based on the thread count, fabric type, color and manufacture.

Upgrading to high-thread-count linen does not indicate an increase in industrial wash durability. More often, these linens are more delicate due to the nature of the manufacturing of the cotton, the yarn size, and production of the thread count.

Here are items to review and document when upgrading linen, with a goal of reducing mechanical, chemical and stain damage in processing:

All linen type specifications
Wash formulas — revise per manufacturer’s recommendations
Wash processes — water levels, chemical concentrations, temperatures, wash/rinse/extract speeds and times
Load weights — do not overload or underload
Dryer temperatures — do not over-dry
Spreader/feeder tensions
Ironer cleanliness and temperatures
Stain program
Sorting procedure
Quality assurance program
Par levels
Storage space
All equipment maintenance — no rough edges, clean
Test-wash all linens multiple times

After this review, put written procedures and standards into place and begin monitoring. Continued training and education for laundry personnel, as well as the various departments, is necessary. Soon, processing the upgraded linens will be routine, and you’ll be prepared for the challenges of optimizing the life of your high-thread-count linens.

Textile/Uniform Rental: John Shoemaker, General Linen & Uniform Service, Detroit, Mich.

Marriott in New Jersey has a large laundry. Per its policy, processed linens are allowed to “rest” for a 24-hour period. In order to make linens last, be sure to maintain plenty of par and avoid quick wash turnarounds.

john shoemaker Likewise, it would be a wonderful time to have the chemical company visit and do titrations with increased regularity.

Full checks should be done. All four pieces of the “washroom pie”—time, temperature, mechanical action and chemical action—should be addressed to assure longevity of life.

Are the washers being under-loaded, resulting in too much chemical action? Is the temperature too hot? Is the run time correct for the upgraded products? Check and recheck all washroom elements to assure the maximum longevity of your textile products.

Tomorrow: In many ways, cotton is easier to wash, but finishing is another issue …

June 20, 2011

How to Reduce Linen-Replacement Costs (Part 2 of 2)

ROANOKE, Va. — The escalating cost of textile products is causing many organizations to refocus on reducing linen-replacement costs.

During my years in this industry, both as a laundry manager and as a laundry consultant, the challenge of reducing linen-replacement costs has been a recurring theme. Some years ago, I had the pleasure of working with a major hospital on a linen-cost-containment program.

The immediate goal was to lower the hospital’s annual expenditures on linens; the hospital had been trying to accomplish this for several years. It was making the same mistakes that many U.S. healthcare facilities make: It was looking for a quick and easy solution.

There is no such quick fix available. But it is interesting and educational to review the efforts of this hospital and compare them with the eventual solutions. In order to save money on the purchase of replacement textiles, this hospital began an aggressive purchasing program designed to:

June 16, 2011

How to Reduce Linen-Replacement Costs (Part 1 of 2)

ROANOKE, Va. — The escalating cost of textile products is causing many organizations to refocus on reducing linen-replacement costs.

Limit the amount of new linen stored at the hospital.
Obtain the lowest cost per item based on purchase price.
Reduce the number of linen items in circulation.
Educate the linen users on the cost associated with linen service.

Goal One: Reduce Stored Supplies

This can be done simply by not ordering more linen until the current stock has been put into circulation. The catch then becomes having new linen available when it is needed. This requires an understanding of the hospital’s linen system and its seasonal fluctuations, knowledge beyond that possessed by most purchasing agents.

Often the linen vendors will attempt to assist the hospitals in understanding their linen system. There are many linen “control” systems on the market, but the majority of them are little more than advance-order systems for the vendors.

This particular hospital made the mistake of becoming overly dependent on the textile vendor’s promised one-week delivery on all linen items. The vendor was able to meet most of the orders for the first couple of months, but then the sporadic ordering (no towels one month, then triple the monthly order the next) caused delivery times to stretch out until two and three weeks became the norm.

The hospital was ill prepared to cope with projecting its needs in advance and routinely ordering predictable amounts of textiles, especially when it had been promised one-week delivery. The natural result was periodic linen shortages that made patients and staff unhappy. These problems caused the administration to return to the former policy of stocking linen items in the storeroom in an effort to ensure an ample supply at all times.

Goal Two: Reduce Per-Item Costs

The hospital adopted the philosophy of buying on purchase price instead of cost per use. It began to purchase muslin (T128) sheets instead of percale (T180), and the textile vendor assured the purchasing agent that patients and staff would never know the difference.

The hospital entered into a period of buying lower-quality items that were “just as good, only less expensive” than what it had been purchasing. There were some short-term savings by doing this, but the test of any good purchasing program is the test of time. Problems began to develop within the first year.

Gowns that had so nicely covered the patients no longer performed in the same manner. There was less material per gown, so IV’s were harder to handle, resulting in increased cutting of sleeves. Ambulatory patients began to wear two gowns, one on the front and one on the back. This practice almost doubled the usage. Net result was a cost increase on this linen item.
The muslin sheet—that had seemed to be such a good buy—wore out more quickly than the percale. The greatest concern was the speed with which the cotton disappeared from the 50/50 blend. The majority of the cotton was worn out of the sheet during the first year, leaving a coarse 100% polyester sheet.

The nursing staff found these sheets unacceptable and therefore took it upon itself to rag them out. The muslin sheets weighed more than the percale sheets and cost more to process. Net result of the economizing effort was to increase the monthly input of sheets, increase poundage in the laundry and decrease user satisfaction.
The washcloth was another item affected by the attempt to lower costs. This certainly seemed like a prime target for a lesser-quality product, especially because of the high replacement rate. The hospital began to purchase a lighter-weight washcloth but stayed with the usual 12x12 size. It was not long before complaints began to come in from the nursing floors.

The new washcloth was shrinking a lot more than the others. After three or four washings, the washcloth became closer to an 8x8 size. The net result of this change was an increase in utilization. Respect for the product dropped and its abuse increased. The replacement rate more than doubled.

Next page: Reducing the number of items in your inventory...

April 7, 2011

Buy Best-Quality Textiles; Thwart Costly Abuse (Part 2 of 3)

“Cotton prices are incredibly high, and our textile suppliers are warning that they’ll continue to go up. Can you suggest some ways we can extend the life expectancy of the textiles that we process without completely sacrificing quality?”

Uniforms: Barb Herman, SanMar Corp., Issaquah, Wash.

March 31, 2011

Buy Best-Quality Textiles; Thwart Costly Abuse (Part 1 of 3)

Textiles: Elizabeth Easter, Ph.D., University of Kentucky, Lexington, Ky.

March 23, 2011

Cotton-Supply Shortfall, Rising Demand Send Prices Soaring

CHICAGO — Soaring demand amid low supply levels has pushed cotton prices to record heights in recent months, and the costs of finished goods have risen in turn.

Textile manufacturers are working feverishly to maintain their raw-materials supplies while providing their customers with finished goods that won’t break their linen or uniform budgets.

On the laundry side, linen conservation has never been hotter. The manager who can extend linen life without sacrificing product quality will see his or her value rise, too.

November 17, 2010

Dyeing, Mending Useful Tools in Formula to Extend Textile Life

CHICAGO — The formula to control textile replacement and keep those costs down is really pretty simple—the longer that a laundry service can keep a reusable item in circulating inventory, the less expensive it becomes based on its useful life.

But things that happen during the course of wear or use—severe staining or fading, or a significant tear—can render a towel, garment, mat or other textile unusable.

August 26, 2010

Insufficient Inventory Can Put You Out of Business (Part 2 of 3)

“What aspects of inventorying and securing textiles pose the biggest challenge? What percentage of losses would you consider to be acceptable if the proper controls were in place? And how could an insufficient inventory impact the rest of my operation?”

Hotel/Motel/Resort Laundry — Charles Loelius, The Pierre New York, New York, N.Y.

Abraham Lincoln once said, “You can’t do business from an empty wagon.”

May 6, 2010

All Textile Products Are Not Created Equal (Part 2 of 3)

“How can we tell if we’re getting our money’s worth from the textiles we’re using? What are the characteristics of a high-quality textile after it has been processed a dozen times, 50 times, or more? And can item type — flatwork or garment — actually influence textile durability?”

Long-Term-Care Laundry — Gary Clifford, Pines of Sarasota, Sarasota, Fla.

September 9, 2009

Linen Managers Strive For Quality, Controlling Costs

Linen managers are becoming increasingly important in this struggling economy. Many healthcare providers are looking for ways to reduce costs without affecting the quality of patient care. Proper linen utilization is becoming a key area of concern. Therefore, it’s time again to review the linen manager’s important role in an organization.

July 29, 2009

Wiping Cloth Company President Suggests Ragged-Out Textiles Still Hold Value

There were many excellent points brought up by your Panel of Experts. I feel that you missed an opportunity to suggest to your readers that they should consider selling their discards to a reputable wiping cloth company. Next time you run a story on this subject, I would be pleased

I read with interest your article in the June 2009 issue of American Laundry News titled Define criteria for ragging out linen, then train staff to recognize signs, take action. There were many excellent points brought up by your Panel of Experts.

I feel that you missed an opportunity to suggest to your readers that they should consider selling their discards to a reputable wiping cloth company.

June 26, 2009

Define Criteria for Ragging out Linen, Train Staff to Take Action (Part 2 of 2)

“What criteria should I establish to rag out or discard linen? Also, do you recommend a multistep process to make this determination, or should one pass per item be enough to decide whether it stays or goes?”

Consulting: Tom Mara, Victor Kramer Co., Oceanport, N.J.

June 24, 2009

Define Criteria for Ragging out Linen, Train Staff to Take Action (Part 1 of 2)

Textiles: Elizabeth Easter, Ph.D., University of Kentucky, Lexington, Ky.

Serviceability of a textile product in the institutional environment depends on meeting five major factors or requirements:

April 22, 2009

Adjusting Work Schedule, Plugging Leaks Among Ways to Corral Dollars (Part 2 of 3)

“My budget has been cut, and I’ve got to find ways to keep my costs down. Can you suggest operational changes I can make to cut or at least control costs without having to purchase anything or cause a major upheaval in my laundry?”

Long-Term Care Laundering: Albert J. Raymond, Healthcare Services Group, Bensalem, Pa.

October 31, 2008

Tracking, Control Are Keys to Merchandise Control (Part 2 of 2)

“Our facility’s linen and uniform losses are becoming a real issue, and I need to develop a strategy to improve security. Where do you suggest I begin? Item tracking, surveillance, keep it all under lock and key? How far should I go?”

Technical Support: Jim Mitchell, Ecolab, Eagan, Minn.

Although you’ll probably never solve all of your linen loss issues, awareness will go a long way in reducing losses.

March 14, 2008

How to Identify Linen Abuse and Stop It (Part 5 of 5)

In order for my customers to be responsible for linens and garments, I suppose they need to be instructed or reminded about abuse. What steps can my operation take to train them and minimize these occurrences? Is it possible that we’re abusing the linen during processing and/or distribution?

March 12, 2008

How to Identify Linen Abuse and Stop It (Part 4 of 5)