Content about chemical

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

We have chosen to address three common stubborn stains that can best be managed with procedure, machine programs and chemistry. We will outline procedures important to all stain removal and then address specifics for each stain category.

In all cases, it is important to either pre-treat the stain, or begin the laundering process, as soon as possible after staining. The sooner that stains are removed from the fabric, the less aggressive the program required for removal and the greater the possibility for success.

With a few exceptions, it is important to treat stain removal with the warmest temperature appropriate for the fabric and color blends. Chemical activity increases with elevated temperature and stain removal is generally enhanced with higher temperatures. Exceptions to the “higher the better” are situations involving color fading/bleeding, fabric shrinking, protein or blood “setting,” or exceeding temperatures recommended for enzyme products.           

Medicinal Stains — There are a number of medicinal preparations that can be irreversibly set with chlorine bleach if not thoroughly removed prior to bleach process. Chlorhexidine gluconate and iodine preparations must be thoroughly rinsed prior to standard wash cycles. Education of healthcare staff regarding possibility of irreversible staining, vigilance by laundry staff for particular laundry categories, and possible replacements of non-staining materials can provide solutions. Salves and skin-protection preparations compounded with oils may need special attention and are best removed with selective surfactant products.

Food Stains — Food stains are common to healthcare and hospitality linens. Conventional chemistry with increased alkali and detergent usually provides satisfactory results for greasy soils. Protein stains can be removed with a bleach program step if fabric dyes are compatible. There are a number of enzyme detergents and enzyme presoak products that provide good removal of protein and/or greasy stains if soak time is available. Be sure to match specific enzyme product to type of food stain.

Athletic Uniforms — School and professional athletic colors have never been selected for laundry compatibility! Before beginning any aggressive stain-removal program, make sure that both uniform materials of construction and colors can withstand temperatures and chemistry chosen. Always consult manufacturer’s care tags. Temperature and chlorine bleach are two often-exceeded treatments that can do irreversible damage to fabric finish, fading/bleeding of incompatible colors, and overall irreversible color deposition. There are also a small number of hazardous chemistries that are used to strip dyes and field marking colors. These should be avoided by using an enzyme presoak program if team schedules allow.

It is important to identify impact-generated (helmet and plastic padding) stains that are a result of fabric and protective gear colors being physically transferred into the opposing team’s uniform fabric. Impact transfer is usually an irreversible situation.

COMMERCIAL LAUNDRY: TOM GILDRED, EMERALD TEXTILES, SAN DIEGO, CALIF.

From the perspective of an industrial healthcare linen services provider, the most stubborn stains regularly encountered include bodily fluids, metal and rust stains, tape residue and finally medicinal chemical stains.

We address these difficult stains through a multi-tiered approach, designed to address each particular type of stain. Time, temperature, chemical action and mechanical action are the keys to effective stain removal, and can be adjusted as each case requires. 

As a first step, we work closely with our chemical company to create the proper formulation, or “chemical cocktail,” to remove specific types of stains. Heavily stained linens are identified during soil sort and separated for special treatment.

After the appropriate treatment has been determined, we pre-wash the heavily stained items to remove the first level of soil in our heavy-duty single-batch washers. Hand inspection is employed throughout the process to determine what the next steps are, as well as to ensure quality control. A stringent quality-control program ensures that we effectively launder items until the stains are eradicated.

Because of the intense nature of healthcare laundry stains, there are instances in which items are destroyed in the process of stain removal and those pieces are placed in our linen recycling program. By continually evolving our processes, and working with our chemical vendor, we successfully remove a large number of stains.

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

Not having had much experience with this topic, I sought the advice of a few long-time laundry professionals. What I found was a little surprising. While most agreed about which substances were the most difficult to treat and remove, their approaches to accomplish this task were completely different.

One approach is stain avoidance. The process starts with sorting the soiled linen from least stained to most stained, or light, medium or heavy soil. By isolating the dirtiest linen, the launderer reduces the chance of contaminating the rest. They also sort by soil factor (whether the stains are protein- or oil-based), as this will determine what wash formula should be used to process the linen. Using this approach, most of the cleaner linen can run through the normal process and be cleaned satisfactorily. They then save the “blood load” to be processed at the end of the shift when the wash formula, along with temperature and process time, can be adjusted.

On the other end of the spectrum is the “one wash” method. Using this approach, the laundry does not segregate its linen because it has optimized its process and system to yield the best overall cleaning results. Of course, if an item that is obviously heavily soiled turns up, they would not process it, preferring instead to rag it out. As stains are the enemy of efficiency, this method works to minimize their disruption on the process.

Stains, after all, are a big problem. Some operators advise that they incur more loss due to stains than to wearing out product through processing. Up to three times more product is “ragged out” because of stains than from actually being worn out.

Regardless of the approach, most operators agree that, in the healthcare setting, Hibiclens, or chlorhexidine gluconate/isopropanol, is the toughest stain to get out. This antiseptic liquid is applied directly to a patient’s skin at the incision site prior to surgery. Its normal state is a clear pink liquid. After being transferred to a textile article and exposed to chlorine bleach during processing, it turns orange-brown and is a difficult stain to remove.

The products themselves play a part in the challenge of dealing with stains. Results from my research rank incontinence products, patient apparel and bath items as the products that experience the most stains. Fabric type is also a factor in stain resistance and stain removal.

Due to advances in finishing chemistry and applications, polyester-rich products actually fare better than cotton-rich items, even though in its natural state polyester has an affinity for oil. These predominantly synthetic-rich products also last longer, which is a plus when exposing them to additional mechanical action and stronger wash formulas that can accelerate the breakdown of cotton-rich fabrics.

Stain treatments are changing. Historically, stain-release treatments were based on C8 fluorocarbon chemistry that has been identified as being harmful to the environment and bio-accumulative. The Environmental Protection Agency (EPA) has requested a voluntary elimination of this chemistry by 2015; manufacturers of these products have been working toward alternatives since 2000. As with most developments, the alternative technologies are more expensive to produce. Some estimates predict as much as a double-digit increase in the cost of stain removal with the new technology as compared to current options.

Regardless of which method you use to process your tough stains, one thing is clear. Stains are here to stay and will become more challenging to treat as the demands for environmentally friendly chemistry becomes the norm.

Check back tomorrow for Part 2!

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 manager’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 categories: 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.

Energy — 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.

Healthcare Laundry: Scott Beaton, Kaiser Permanente Northern California

There are two major differences between institutional and commercial rental laundry plants regarding laundry processing equipment and operational procedures. The overarching difference is that each must serve a different master.

One is customer-based, high-volume, and driven to make a profit, while the other exists to provide a service for a captive audience. Due to these differences, the degree of necessary automation varies substantially.

The other major difference is that commercial/rental plants wash and process linen to meet the needs of both regulatory and customer-based demands. They deliver linen in a manner that guarantees and produces a positive net operating margin. This is driven by the fact that they are in business to make a profit.

Rental laundries typically spend more on their equipment, training and education of their workforce than an institutional facility. Pounds per operator hour, or PPOH, become the mantra. The old adage “time is money and money is time” comes to mind. These large, high-volume shared-service laundries and commercial plants tend to be highly automated, with batch washers, shuttle conveyors and pass-through dryers greatly reducing manual-labor requirements.

Commercial rental operations realize quickly in this competitive, price-point-driven market that financial investment and reinvestment is key in both manpower and equipment. This must take place to be competitive and sustainable in an ever-changing business climate.

A rental plant usually realizes that it takes a financial investment to achieve an efficient operation and, as a result, spends money to make money. Institutional laundries would benefit greatly if they would also utilize this model and invest in their infrastructure to best serve their internal customers.

Chemicals Supply: Marlene Williams, Anderson Chemical Co.

As a chemical formulator, my comments will focus on procedural differences between institutional and industrial laundries. Institutional and industrial facilities both launder linen, but the purpose and focus of each is in response to different expectations.

Institutional laundries provide a service within organizations. Industrial laundries are typically focused as independent businesses. This results in different orientations, chemical programs and procedures.

Major concerns for commercial laundries include optimization of production orientation. This would include labor and labor cost as a percent of revenue, utilities, water and chemical costs, production cost per machine, and overall profitability.

Formula times and rewash numbers can be well balanced to provide optimum profit. Hot water, high alkali, and bleach can provide lower pounds of rewash, but at the expense of linen integrity.

Major concerns for institutional laundries include: maintaining facility par, quality of results depending on potentially lower water temperatures, machine programmability, correct choice of program, and chemistry.

While most institutional facilities have well-trained staff, problems can arise when machines and chemical supply malfunction if a staff person does not make timely corrections. Because of a lesser focus on cost per piece, spotting and special pretreatments or machine formulas may be utilized. The luxury of time for rework and special formulas can result in higher volumes of good quality work without the expense of fabric damage.

Linen Supply: Stephen Marcq, General Linen Service

I see substantial differences between equipment and procedures in commercial vs. institutional plants. In commercial plants, for example, it is common to see newer, larger, more energy- and water-efficient machinery, i.e. continuous batch washers vs. smaller washer-extractors, six-roll ironers vs. one-roll, and so forth.

It is more common to see things like heat reclamation and water treatment equipment, as well as use of steam vs. thermal oil, electric and so forth on ironers. The reason is likely because the commercial plant can typically gain economies of scale, lower the per-unit production costs and thus generate a sufficient return on investment on the large up-front expense, although available space also has something to do with it.

The biggest procedural difference I see is that many institutional plants, by their nature, do a larger number of small loads, turning product sometimes several times per day, whereas a commercial plant may have one machine dedicated to a specific item operating eight hours or more daily.

The institutional plant often can customize the finishing procedures and requirements to the exact specification required, whereas the commercial plant has to find some middle ground to suit its mix of customers.

Commercial Laundry: Tom Gildred, Emerald Textiles

Differences in equipment and procedures between a commercial laundry plant and an institution-based laundry are substantial and exist for a variety of reasons.

The equipment in a commercial/rental plant is usually larger in scale and capable of processing huge amounts of volume (pounds) per hour. In newer facilities, or those that invest in newer equipment, tremendous energy efficiencies are achieved that result in energy and water savings. This positively impacts the environment and reduces operating costs.

Equipment in an institution-based laundry is smaller in scale and handles wash loads of lesser volume. In-house laundry facilities sometimes occupy revenue-generating space that might otherwise be used for additional operations within the organization.

Processes and procedures in a commercial plant are typically more automated, so less labor is required to process the laundry. This improves efficiency and decreases the risk of strain and injury to employees. Another difference in a commercial facility is rental pool linen. Large rental pools require fewer linen purchases on a regular basis and offer a consistent, flexible supply of product to all customers as needed.

The chemical mix in a commercial plant is also handled differently because of the opportunity to use each pocket in a continuous batch washer for specific purposes with specialized chemicals. This allows the precise timing, titration and temperature required to achieve the highest levels of cleanliness.

Handling larger wash loads also allows for the production team to run the same products through folding or ironing consistently, which improves efficiencies lost when switching the products that are being processed.

Finally, the focus in a commercial laundry operation is generally specialized and, because of its scale, designed to comply with OSHA, Title 22, and state and federal regulations.

In an institution-based laundry facility, processes are typically labor-intensive, and require more employees, because they are less automated and staff may or may not be assigned exclusively to the laundry function. Since the task of laundry is usually just one aspect of operations in the organization, it may be more difficult to be focused on compliance, efficiency and quality control.

In part, some of the reasons for these differences exist because of specialization as well as the scale and volume of each type of laundry facility. There are economies of scale realized when a commercial plant is focused on processing linen for multiple large healthcare or hospitality customers, vs. operating a laundry department in-house to process only the linens needed by that organization.

Uniforms/Workwear Manufacturing: Steve Kallenbach, American Dawn

Typically, the equipment and procedures in processing textiles is about the same—whether in a rental laundry or an OPL (on-premise) hospitality or healthcare laundry—but does depend on the volume/poundage of each facility. When it comes to boilers, heaters, reclaimers, sewage treatment, washers, dryers, tunnels, ironers or presses, the equipment manufacturers supply our industry as one. And the chemical companies typically use formulation based on textile/application/poundage vs. market.

While one would think that the processes for these two business channels are equally alike, there are many different practices, based mostly on profitability and/or quality expectations.

The rental channel always has two common goals: growth and profitability. They are sometimes in opposite order, but always present together. This becomes a delicate balance between efficiency and quality. To illustrate, let's look at linen napkins.

A rental laundry typically wants to achieve acceptable market standard quality at the lowest cost. It’s in the business of making profits through textile rental, and therefore measures every microbe of wear life, processing cost, merchandise field recovery, and total merchandise costs (including acquisition) all the way to electricity and building costs.

In comparison, an OPL must maintain the internal (typically single-department customer) quality standard, and is part of a much bigger picture (a small department of a large enterprise). Its building, energy and overhead costs may be charged by estimate or calculation to the whole. Additionally, its quality standards are typically set by one of the other departments that it serves, are not negotiable, and are expected to be maintained, without as much weight given to cost.

The sheer difference in service dynamics and accounting in an OPL drive fairly significant differences in labor management, water/energy/chemical management, textile selection, and inventory management (which typically doesn’t fall under the control of the OPL), all the way to formula times, pressing speeds, and water temperature/steam use.

Additionally, because the perceived quality of OPL customers (key departments) is allowed to be as high as requested, much more finishing (such as pressing vs. tunneling) occurs.

Material handling and delivery also differs between the two types. An OPL typically delivers the goods to another on-premise department (i.e. Guest Services) using carts, rails and perhaps a small vehicle — and goods are many times picked up by the department being serviced. A rental laundry has many more carts (for separation by route/customer) as well as sort railing and numerous route trucks for delivery within a large geographical area.

Numbers will tell a big story here, and both have their place in the textile services markets. Cases can be made in either direction as to what is most efficient and profitable for the enterprise.

Tomorrow: Answers from the textile/uniform rental, consulting services, and equipment manufacturing sectors...

ALBANY, Ga. — Equinox Chemicals has announced that it has acquired Adco Cleaning Products, based in Sedalia, Mo. Terms of the acquisition were not announced.

Equinox will move Adco’s manufacturing operations to its state-of-the-art manufacturing plant in Albany, according to Yalda Harris, Equinox’s executive vice president for Global Product Management.

Dr. Jim Schreiner, Adco’s chief product technology officer, will also be relocating, she says.

Customer-service and order-taking staff will remain in Sedalia, and there will be no changes to the way customers or distributors order from Adco, Harris adds. The national sales team will remain the same.

Equinox is a specialty chemical manufacturer with specialty research, innovation, product development and commercialization capabilities that reach markets spanning the globe, the company says.

Adco manufactures a comprehensive line of specialty cleaning chemicals and detergents used in dry cleaning, commercial laundry, and janitorial and institutional cleaning applications. It offers more than 300 proprietary products through the Adco and Laidlaw brands.

“This latest acquisition will continue our aggressive strategy to revolutionize and revitalize the laundry, dry cleaning and cleaning chemical industry,” says Mark Grimaldi, CEO of Equinox Chemicals.

Mentor Partners had owned Adco since 2007.

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

Chemicals Supply: Carrie Armstrong, Ecolab Eagan, Minn.

Optimizing the laundry processes and following the recommendations will help with the reduction of higher-than-necessary utility costs. The following are common errors in laundries leading to additional costs; these are in the order of processing, not necessarily in order of magnitude.

• Incorrect Sorting, or No Sorting, of Soiled Linen by Soil Content, Soil Level and Linen Type — Not sorting will result in all loads washed in heavier formulas than necessary, which generally requires higher temperatures and more water exchanges and leads to reduced linen life. If heavy-soil contents are washed on a regular soil formula, rewash/stain percentage will increase. This results in additional rewash/stain loads processed, some of which would not be necessary if properly sorted. Reclaim formulas generally feature higher temperature and extended wash times, resulting in added utility costs.

• Not Loading to Optimal Capacity — Under-loading and overloading results in additional washes. Under-loading does not utilize the capacity of the machine, thus wasting utilities. Overloading results in additional rewash due to inadequate soil removal (which can also be the result of under-loading).

• Incorrect Wash-Formula Selection — Wash formulas are developed for the soil types, soil levels and fabrics for optimal soil removal. Each is specific in time, temperatures, water and chemicals for each classification. Not selecting the correct wash formula is similar to incorrect soil sorting.

Selecting a heavy-soil formula for a light-soil classification results in increased utilities, as these formulas generally include higher temperatures, additional water exchanges and extended wash times. Selecting a light-soil formula for heavy soil will result in added rewash.

• Wash-Formula Structures — The formula structure and programming of the wash machines are critical for cost control and require optimization. Times, temperatures and water exchanges may be reduced given the textile types and soil levels being processed. An extensive review of wash formulas may result in changes in flushes, rinses, time or temperature. Additionally, ensuring that all machines are programmed identically will result in more consistent results.

• Incorrect Extract Times — Too-short extract time results in the textile being too wet, thus requiring extended dry times. Extract times that are too long use energy unnecessarily.

• Incorrect Dryer Formulas and Loading — As with incorrect washer loading and formula selection resulting in added utility costs, this same concept carries over to the use of the dryers. Overloading will result in extending the dry times, adding to energy costs, plus it shortens linen life.

• Rewash and Stain Reclamation — Not having an established rewash and stain reclaim program results in increase of utilities. Rewash encompasses textiles that have fallen on the floor, mis-feeds through folder/ironer, are still dirty, etc. Stain reclamation is the category for which the wash formula has not been adequate to remove the stain. A reclaim formula generally requires higher temperatures and extended times.

• Postponed Equipment Maintenance — Leaking drains, water valves, steam valves, etc. result in added utility costs.

• Chemical Program — New technologies and laundry product programs are available that can offer customized solutions to reduce water and energy costs. Lower-temperature washing, sanitizing and disinfecting products can shorten processing times.

At each point of the laundry process, errors occur that can increase utilities cost. Continued monitoring and training of personnel will help keep these in control. In addition, your chemical supply representative can consult on ways to help with laundry efficiency.

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

From my experience, the single most wasteful error is the improper loading of washers and dryers. If you run your machines under-loaded, you will waste not only energy, fuel and water but also chemicals and time.

It doesn’t take any more time or effort to load at the proper levels if you just do it! I realize that everyone wants to be busy, or at least look busy at all times. However, it is clearly beneficial to accumulate and process the correct size loads. The time spent waiting can then be appropriated to wherever you need it.

As an example, the first time I did a late-hour check on laundry at my first OPL in healthcare, the night washer was not sorting everything, just throwing whatever was in the bags in the washers and washing them on the setting for heavily soiled linen. He figured he could eliminate a step that way and save himself a lot of work.

Maybe he did save time and effort, but what a terrible waste of chemicals and utilities. After the proper sorting and loading procedures were reviewed with him, along with the reasoning behind them, it was never a problem again and our chemical expense dropped noticeably.

For those of you working at long-term healthcare facilities, make sure you have adequate washes for heavily soiled linens. A separate setting for this is essential in eliminating rewashes and quality-control problems. Even if you have to hold heavily soiled linen in the sorting cart for a while to get a full load, you can certainly save a lot by doing so.

You will also find it helpful to schedule a recovery load for trying to save badly stained linens prior to taking them out of circulation. Even if you only save half a load, it is linen you may normally would have thrown out.

It is also important not to overload the washers or you will waste your chemicals and utilities on rewashing. It is a bit of a balancing act, but one that can be easily accomplished with education, cooperation and teamwork.

Be sure that you do not ignore proper loading and temperature settings on your dryers. Over-loaded and under-loaded dryers waste a lot of energy and fuel and can also lead to lost time and excessive wear of your linens. And be sure your temperature settings are correct for the loads you do. Too much heat is as bad as too little heat for your linens and is extremely wasteful. Today’s dryers feature multiple settings, so be sure to use them correctly.

Involve your representatives from your laundry chemical, linen and equipment companies to help you fine-tune everything to get the best, most efficient results for your investment. They will be glad to help with this important task. With their help and your attention to the details, you can be sure you are not wasting energy, fuel or water.

Tomorrow: Answers from the commercial laundry and equipment manufacturing sectors.
Click here for Part 1.
Click here for Part 2.

Chicago Dryer Co. Hires Anderson as Regional Sales Director

CHICAGO — Chicago Dryer Co. (Chicago®) has hired Chuck Anderson as sales director for the company’s Western U.S. region.

Anderson has been in the laundry industry for more than 23 years, most recently with Ellis Corp. He will work with Chicago®’s established distributor network to increase sales and provide additional customer support services. Anderson was a contributing member to the American Laundry News Panel of Experts in 2011.

“We feel that Chuck’s extensive experience on the equipment specification/sales, chemical, and service sides in a wide variety of laundry environments will be of great value to our commercial, industrial and on-premise laundry customers,” says Tom Egebrecht, Chicago®’s sales director.

Alliance Promotes Brooks to UniMac National Sales Manager

RIPON, Wis. — Alliance Laundry Systems has promoted Bill Brooks to national sales manager of UniMac, the company reports.

Brooks will be responsible for overseeing sales of the UniMac brand of heavy-duty commercial laundry equipment in the United States and Canada.

He joined Alliance in 1990 and has held several positions during his tenure. He most recently was the national accounts sales manager. He is an expert in the OPL industry and has provided counsel to many national hotel and healthcare chains on issues that impact a laundry’s operating costs, Alliance says.

“Bill’s track record of success with Alliance made him an ideal candidate to lead UniMac,” says Jeff Brothers, Alliance’s senior vice president of sales, North America. “We look forward to his continued success and congratulate him on his new venture.”

“I look forward to continuing and strengthening existing relationships with our distributors and establishing new connections,” says Brooks. “I’m excited to be part of a brand that is known for its quality equipment and expertise in the on-premises market.”

Brooks has a bachelor’s degree in business administration (minor in marketing) from Concordia College, St. Paul, Minn.

He also serves as a lieutenant with the Berlin Fire Department and Rescue Squad, where he has volunteered for 22 years.

Softrol Hires Grandy as VP of Sales and Marketing

ACWORTH, Ga. — Softrol Systems has added Tim Grandy to its staff as vice president of sales and marketing.

Grandy’s experience that will help strengthen and grow the company’s position in its core marketplace, as well as initiate penetration into markets other than textile rental and textile manufacturing, Softrol says.

He has more than 14 years of business development, product development, engineering, technical support, and sales management experience. He’s held management posts at General Electric, Siemens Energy and Automation, and Lutron Electronics.

“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.

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.

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.

COMPTON, Calif. — Infection control might be on everyone’s radar, but it is just one factor in recent changes to healthcare apparel. Peter Menaker, regional sales manager for textile manufacturer, distributor and importer American Dawn, says there are other factors driving changes in the textile industry, too.

Menaker briefed laundry processors and linen distributors during an Association for Linen Management-sponsored webinar, Changes in Healthcare Apparel.

For healthcare workers and laundry managers, infection control can be a major concern.

“As of June 2010, Centers for Medicare & Medicaid Services stopped reimbursing for the costs of hospital-acquired infections,” he says, “so it became more important for healthcare facilities to make sure there are as few hospital-acquired infections as possible.”

Most of the concentration has been on hand-washing initiatives. “That’s been a big focus,” he says, “because most such infections are transferred on the hands of the healthcare worker. I’ve seen recently initiatives … (concerning) hospital-acquired infections that occur among catheter patients and in patients with central lines.”

Another point of interest to laundry personnel is the use of antimicrobials bonded with the fabric of patient garments.

“Antimicrobial treatments are certainly starting to show up on patient apparel, bedding, cubicle curtains, room curtains, scrubs, personal protective apparel and equipment, and certainly they’ve been found in surgical gowns for some time.”

Antimicrobial Treatments

Menaker went into depth on treatments that involve metallic ions being fused permanently onto a textile product. Silver, copper and even gold are used in these technologies.

“These metallic ions combine with a membrane that increases the surface tension of fabrics that can also make them fluid-repellent yet breathable,” he says.

The ions puncture a germ’s cell membrane, rendering it incapable of replicating. These types of antimicrobial treatments, according to Menaker, are nonleaching and permanently bonded to the fabric. He warned against using any type of treatment that works by allowing the chemical to leach from the fabric.

“If the antimicrobial is leaching out of the textile, eventually it will not be effective in killing the organisms we want it to kill,” Menaker says. “Also, it’s possible that the leaching chemical could disturb the skin (of the wearer) and cause an issue. And we don’t want to be causing an allergic reaction or any problem with their skin.”

Also, a leaching type of textile creates a zone of inhibition, which leads right to a zone in which the antimicrobial treatment is only partly effective in killing off germs.

That could lead to the microbe mutating and becoming resistant to the treatment, developing into a superbug, he says.

Antimicrobial treatments can present challenges for laundry managers.

“With any of these antimicrobial agents, we want to make sure we use a chemical and a process in our laundry that will not break the bond between this molecule and the product that we want it to stay on,” Menaker says. “And the provider of the antimicrobial textile or your laundry chemical provider should be able to let you know which processes might be necessary for use with these types of products.”

There is a staining test available that can determine if the antimicrobial treatment remains on the textile product, he says.

Another potentially problematic issue for laundries arises when items such as isolation gowns or cover gowns feature a coating that can be refreshed. Each garment has a grid stamped onto the fabric or a label attached that allows the laundry to keep track of the number of times the item has been laundered.

Most treatments can withstand a limited number of washings—usually around 75. The challenge arises when a garment has been chemically refreshed, or a treatment is reapplied to the garment. How laundry personnel communicate that the garment is once again fluid-repellent is an ongoing concern.

Reapplying the treatment could also be cost-prohibitive.

Menaker says textiles are usually not involved in hospital-acquired infections, and there is a question whether treating the textiles with an antimicrobial would truly be helpful in preventing infection.

“I don’t think there have been any studies on this, and the jury is definitely still out,” he says.

Patient Satisfaction

Patient satisfaction is growing as a change motivator in the industry, Menaker says. Many healthcare facilities are using Press Ganey and other survey tools to gauge how patients perceive that institution’s commitment to care.

“In fact, textiles come into patient satisfaction quite a bit,” Menaker says, “if you realize that patients have more interaction with their hospital gown and their bedding than they really have with doctors and nurses.

“They’re exposed to their textile products 24 hours a day for every day they’re in the hospital. So, like it or not, these do make an impact on how satisfied they are with their treatment at the hospital.

“Usually the laundry hears about it when a linen item is of subpar quality or in quantity. But it can also go the other way, too. If linens are upgraded, they can actually make a patient experience more positive.”

Patient dignity is another influence on healthcare apparel decisions. Religious considerations, physical size and patient mindset all go into determining how a hospital’s apparel offerings fare in a patient’s assessment of dignity issues.

Burkas and face veils have been in the press, and obesity is a concern on many different levels, Menaker says. Patients also are more involved in their own care, and patient comfort and allowing them to focus more on the care for their illness is important, too.

“We also have smaller and smaller people coming into the hospital, too, with more premature births, and there may be some issues with garments being too big or not properly sized for the little patients,” says Menaker.

And there are standardization issues to be considered, especially as they relate to supply/processing costs and effectiveness of the laundry service.

“With so many SKUs, particularly in patient gowns,” Menaker says, “there’s some cost implications in standardizing, stocking fewer different garments, and processing them properly and distributing them to the end-user.”

Tomorrow: Laundry processors need to play a role in policy changes…

Once again this year, the most exciting and controversial new technology on the Clean Show floor is a chemical system at the Proteus booth. The system uses salt and electricity to create the alkali and reducing agents used in laundry processing.

It is of no great surprise to me that the entrenched laundry chemical companies are talking the system down and actively looking for reasons why it will not work. The potential to generate your own wash chemicals and save the environmental impacts associated with trucking chemicals and their containers warms my environmentalist heart.

Eric Frederick is director of linen services for Carilion Laundry Service, Roanoke, Va., and a two-time Association for Linen Management manager of the year.

“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?”

Equipment/Supplies Distribution: Russ Arbuckle, Wholesale Commercial Laundry Equipment SE, Southside, Ala. — A Web-Exclusive

As the cost of cotton rises, premature linen replacement becomes a larger and more expensive issue.

SPARTANBURG, S.C. — Roger Milliken, one of the last in the tradition of industrialists who built America’s manufacturing success, died Thursday at the age of 95. He was the chairman of Milliken & Co., a prominent textile and chemical manufacturer.

A memorial service to celebrate his life is scheduled for 2 p.m. today here at the Episcopal Church of the Advent.

ALEXANDRIA, Va. — The Environmental Protection Agency’s (EPA) announcement to take steps to improve the safe handling of nonylphenol ethoxylate (NPE) that stop short of banning its use in industrial laundry detergents signals the agency’s confidence in a voluntary phaseout of the detergent ingredient, the Textile Rental Services Association (TRSA) says.