The chances of finding a totally comprehensive guidebook to equipment for on-premises laundries on a shelf somewhere are likely to be nil. Even if such a volume existed it would be huge, probably difficult to read, and quickly out of date.
The lack of an all-embracing guide is due to the myriad forms the OPL takes. There are huge variations evident through comparison of individual laundries in any of the OPL market segments.
An OPL can be anything from a facility having two small washer-extractors and appropriately sized dryers to a miniature commercial-style laundry complete with high production ironer with, two 800mm rolls.
Indeed, some larger OPLs, finding that there is spare capacity, create a revenue stream by processing “outside” work.
Textile care consultants and equipment manufacturers and suppliers recommend that, whatever size of OPL is being considered, there are some basic rules to observe concerning the provision of equipment.
Every aspect of what the OPL is expected to achieve must be carefully analysed. Types of classifications to be processed, current work volumes, peaks of work volumes and expected changes in demands in both the medium and long term, must be taken into account.
A 15-bedroom luxury hotel, providing guests with bathrobes, an assortment of towels, bath mats, bedside mats and so on, may generate more laundry volume than a 50-bedroom “budget” establishment.
An OPL handling work from a health and fitness centre will need washer-extractor and dryer capacity to deal with large volumes of towels, often on a fast-turnaround basis. The ability to process and crisply iron garments such as therapists’ uniforms may also be a requirement.
The location of the OPL within a building has to be taken into consideration when equipment is being chosen. Quiet-running, low-vibration equipment may be essential where there is the possibility of noise transmission.
Practical guide
General, all-embracing guidebooks about OPL equipment may be unavailable, but some closely focused books and guidance notes have been produced.
In a highly useful book titled “In-House Care Home Laundry Systems – A Practical Guide”, John Mitchell of Mitchell Associates pays particular attention to the processing of fouled classifications. High-spec washer-extractors are required and these should incorporate a sluice cycle, a heating boost arrangement to meet higher temperature stipulations, a temperature gauge, wash programs providing thermal disinfection, and normal wash programs.
Mr Mitchell recommends that the care home laundry is located at ground floor level. Basement installations are not advocated because acceptable levels of ventilation are often difficult to achieve, the handling of work is difficult unless a chute or lift linking the OPL with all floors is provided, and a pump system for drainage can be expensive.
Textile care consultants around the world point to how regulations affecting the installation and use of OPL equipment vary. When a new on-premises facility is being planned, or an existing one upgraded, they recommend seeking advice from an independent expert who is well versed not only in legal requirements and guideline recommendations, but also the latest types of equipment and what these can offer.
OPL production can be even more vulnerable than that of the commercial laundry. If one machine in an OPL is out of action the impact on production can be immense, especially if the problem occurs at a peak processing time. OPLs handling flatwork generally tend, because of their size, to have only one ironer and a nightmare situation can rapidly develop if this is not running. Fortunately, ironers which are carefully chosen for the job to which they are to be put and which are regularly maintained, are reliable – but problems do, inevitably, occur. Having engineering expertise that can be called on to give prompt assistance in an emergency is absolutely vital.
In some remote regions, it can be prudent to choose basic machines – even if the budget exists for purchasing the more expensive and technically complicated models. If a machine cannot be fixed by a local, general engineer then a very long downtime may be faced. While it may be disappointing to have to opt for a less “advanced” washer, dryer or ironer, there is some consolation in that the performance profiles of even basic machines today are impressive.
Microprocessor controls have been a boon for many items of textile care equipment. For washer-extractors, such controls deliver efficiency with automatic chemical dosing, maintenance of optimum processing conditions and measured cool-down.
Operational data instantly fed back from the machine can be useful for OPL personnel, for management reports, and for consideration by technicians when making service need judgements. Use of the internet allows machines’ performance profiles to be checked from anywhere.
Exact replication
Computerisation has significantly improved the way in which washer-extractors are programmed. Advances have facilitated the exact replication of a proved program in any number of machines through simple and quick downloading. Program transfer can be effortlessly accomplished from a laptop computer. In some instances, cards with embedded chips can be to transfer a program to a machine easily.
High-speed extraction is now often a necessity rather than a luxury. Fast extraction is a must for classifications such as terry towels – the aim is to quickly and efficiently lower the moisture retention during the extract phase. If extraction is not adequate, work bottlenecks can occur at the dryers and the OPL’s total drying cost is likely to become unacceptable.
Seen as efficient workhorses in larger OPLs are washer-extractors having a single motor drive with frequency converter. Infinitely variable drum spin speed is provided, and 300G or more exerted in the extract phase.
At recent textile care exhibitions, visitors’ attention has been drawn to the improved suspension systems in many ranges of washer-extractors. Different approaches have been taken to introduce effective dampening to machines but there has been unity in the aim – to reduce vibration. Lower vibration levels increase the siting options for equipment, improve a machine’s reliability and extend its working life.
In some arid areas, the concerns for minimal water consumption are considerable. Machine manufacturers have striven to improve processing action and ensure the water consumption level for optimum processing is not exceeded. However, in some regions, this may not be enough to allay worries. Where water conservation is a major issue, water recycling systems for all sizes of washer-extractors may have to be introduced.
Water recycling can be viewed as a benefit not just in dry regions but also in areas where water is plentiful. Lower water consumption generally means reduced water supply and effluent charges. Additionally, the utilisation of recycled, conditioned water for the main wash stage in the washer-extractor’s process cycle will probably cut down the volume of detergent and other chemicals required.
Ironer specification will be dictated not just by predicted throughput volumes but also by quality expectations, the type and size of flatwork being handled and any need for starching.
Small and medium-sized OPLs having moderate ironing requirements tend to opt for a return-feed, drying ironer which has a compact footprint and which is usefully labour saving.
Electrically heated/driven ironers are popular in small OPLs, and for some facilities a gas-heated machine may be the preferred option. For an OPL with a larger output and access to a steam supply, the use of steam for heating the ironer will assist in keeping down the overall costs of the laundering operation.
It is advised that expert advice is sought if any gas-heated equipment is to be used in an area where drycleaning takes place.
Teaming high-speed washer-extractors with a drying ironer can achieve excellent efficiency levels.
Flatwork having a moisture retention level of up to 55%, or thereabouts, can be unloaded from the rapid-spin washer and taken without delay to the ironer. First rate results, in quality and quantity terms, should be maintained with the ironer running at a temperature of 170C and at optimum speed. Through being able to avoid a drying stage, the flatwork turnaround time is enhanced and a cost saving is made.
Where large flatwork volumes are handled, degrees of automation in item feeding to the ironer can be considered. Feeding assistance/automation is available on larger, specialised OPL ironers, some of which can return large flatwork items folded, stacked and counted.
Drying can be an expensive business, so whenever a new dryer or dryers are being selected, it is extremely important to check out energy consumption figures, examining what levels of efficiency are offered. Skimping on capacity must be avoided – high performance air flow systems will have their action impeded if too much work is crammed into the drum. If a washer-extractor and a dryer are viewed as an equipment team, the latter should have a capacity 15% greater than that of the former.
Heating efficiency
Using gas – supplied either through the mains or by a tank system – is generally regarded as the way to achieve best heating efficiency with dryers. One manufacturer has been underlining how a heat recovery system can cut energy consumption by as much as a quarter, and reduce drying time by up to 10%.
Computerisation has afforded greater levels of precision and flexibility with drying parameters such as temperature, time, cool down, drum reversing, and moisture level control. The chosen temperature for a given load can now be maintained with a great degree of accuracy.
Merits of axial airflow have been put forward as have the benefits of in-drum moisture retention sensing – through measurement of electrical resistance, a classification type can be dried only up to the point set for ideal dryness.
In conclusion, equipment for the OPL must be chosen so that expected future work demands, as well as current ones, can be fully met. All relevant regulations must be adhered to, and equipment must not detract from the facility’s working environment though generation of excess heat or noise. Furthermore, the engineering soundness of the equipment must be unquestionable, and there must be an engineering service readily available – in-house or external – to deal with routine maintenance and handle machine breakdowns.
