The modern laundry needs to minimise its costs without compromising standards – which means achieving output at an acceptable energy cost whilst meeting the quality demanded by its customers.
According to Wim Demeyer at Lapauw, the two key issues in the market for ironers are energy consumption, and quality and service. International debate about the effects of global warming, as highlighted in the recent film “An Inconvenient Truth” by former USA vice president Al Gore, is raising public awareness on energy behaviour, says Demeyer.
“Energy cost takes increasingly larger bites out of the laundry budget,” he says. “Therefore energy consumption is the number one question posed by customers nowadays. This is one of the reasons we see the demand for gas heated ironers at an all time high.”
The most recent ironer developments in the Lapauw range are the addition of a 1,600mm diameter model and a gas-heated version of its 4000XXL. The 4000XXL was the first gas-heated ironer with 1,600mm roll diameter to enter the market – and it remains the largest 1-roll gas-heated ironer presently on the market, says Demeyer. “Gas gives laundries an opportunity for further expansion because output is independent of boiler capacity and also operational flexibility,” says Demeyer.
Lapauw’s range targets the heavy-duty sector and includes chest ironers, with roll diameters of 800, 900, 1,200 and 1,600mm, available in one-, two- and three-roll variants, and in steam and gas versions. Sister company Laco aims its range at the OPL sector with smaller one-roll machines, of 370 – 800mm diameter and working widths of 1,750 – 3,300mm, available in gas and electric versions, with two electric-only models of 300mm diameter and working widths of 1,400 and 1,800mm.
Lapauw produces five models in its 4000XXL range, plus five more in each of the Duo 1600 and Mono 1600 ranges; they are available with a roll diameter of 1,600mm, and working widths of 2,700, 3,000, 3,300, 3,500 and 4,000mm respectively. The ironers benefit from innovative technology which Lapauw describes as “smart ironing”, and features integrated energy recuperation and “smart” modulating burners.
Lapauw applied this technology for the development of its 2-roll 1,600mm diameter ironer. The first Duo 1600 ironer is already in operation in the Netherlands where the laundry processes heavy-duty work such as full cotton sheets and duvets at speeds exceeding 30m/min. Demeyer says: “The modulating gas burner with microprocessor control first of all improves the efficiency of the machine. This system reacts more quickly and precisely to changes in the ironing temperature, so gas consumption is lower.”
Lapauw believes this technology is so promising in terms of improved efficiency and maintaining constant temperatures that it plans to fit it to all gas-heated ironers.
The microprocessor enables the launderer to input up to 29 programs, optimised to the specifications of the material to be ironed and to the customers’ needs. Thanks to the large touch screen and event history log, diagnostic checks and maintenance are made a lot easier. The microprocessor can be integrated into the company network and energy consumption can be monitored, enabling the laundry to determine the precise cost.
Lapauw has also introduced an integrated “smoke gas recuperation system” on all newly developed ironers (gas heated 4000XXL, Mono and Duo 1600), where the heat of the smoke is used to preheat the thermal oil.
“Because of this system and the smart heating, we have succeeded in making the latest generation gas heated ironers 15% more efficient than the standard gas heated ironer,” says Demeyer.
Ironers smaller than 1,600mm roll diameter cannot be equipped with the integrated smoke gas recuperation. To overcome this problem Lapauw has developed the Aircup system. This is mounted on top of the rolls and reuses the heat energy of the vapours to preheat the air drawn into the rolls.
Jensen also sees rising power and energy costs accelerating the trend to low energy and water consumption. Increased travel and tourism brought about by a higher standard of living will prompt more laundries to look for equipment that provides a quality result, says Jensen. This applies especially to ironers.
Hotels and restaurants typically want high-quality ironing of bedlinen, duvet covers and table linen. This requires a design without tapes as tapes might leave marks on the linen. This demand for the best ironing quality available prompted the latest development in the range of ironers produced by Jensen, the oil and gas-heated Jenroll EXPG 2000.
According to Jensen, its steam-heated 1-roll EXPress 2000 has shown remarkable finishing results. However, a sufficient and stable steam supply is not something that can be taken for granted, says the company. When laundries plan to extend their production or when they run extra hours, the availability of energy and space plays a major role.
The Jenroll EXPG 2000 has built-in features such as automatic change to idle mode when not in production.The ironer also uses external air intake to the combustion chamber that provides the burner with fresh air to obtain a very low consumption of gas compared to the output.
The Jenroll EXPG 2000 ironer has a flexible chest that uses oil as the heating medium with an integrated gas-fired burner and heat-exchanger. Because the chests are made from high-grade carbon steel, the distribution of energy to the linen is at its optimum – the heat conduction is four times higher than that of stainless steel. Operating costs are lower as the transfer of heat via the oil medium is up to 40% higher than that of steam. The use of oil as the heating medium contributes to a higher capacity through a higher temperature, as oil can be heated up to 220C against 190C of a traditional steam installation.
The EXPG 2000 is also well suited for roller towels as, being designed without tapes, it eliminates the risk of a jam caused by narrow items becoming caught.
In addition to the Jenroll EXPG 2000 model, Jensen produces the Jenroll EXPG 800 and 1,200mm models, and Jenroll EX model with 800, 1,000 and 1,200mm rollers and fixed chest for steam or oil heating, and the steam-heated Jenroll EXPress model with 1,000, 1,200 and 2,000mm rollers, the latter without ironer tapes as it is a single roll ironer.
One company reporting growth in the OPL sector is Primus, which offers both chest-heated and cylinder-heated ironers for the sector. Primus has developed four different types of cylinder heated ironers: I, IR, IF and IFF-models.
There are two diameters, 350 and 500mm, with a width varying from 1,400 to 3,200mm.
The I-models have return feed and are available in both coin-op and OPL versions.
The IR-models are available with a diameter of 500mm and a length of 2,000mm. The IR-models are pass through and enable the operator to increase the production compared to the return feed types.
The IF-models are cylinder-heated ironers with a diameter of 500mm and a length of 2,000mm with a length-folding device.
The IFF-models are cylinder-heated ironers with a diameter of 500mm and have an integrated feeder, folder, crossfolder and stacker. The IFF ironer with built-in folding system is described as the ideal ironer to dry, iron and fold linen. The high roll-to-bed pressure of more than 300degrees allows linen with as much as 50% moisture content to be ironed efficiently.
The IF and IFF models are both equipped with Easy-fold technology as standard. This is said to give an smooth guidance of the linen from the roll to the folding device.
All ironers are available in gas-heated, electrical-heated and steam-heated versions. The cylinders are finished with a chrome coating that prevents the roll from rusting and it additionally gives a sheen to the ironed linen. Up to 20 ironing cycles can be programmed and the ironers have an easy-to-use timer.
Primus has developed its latest industrial chest-heated ironer, the model, I 40-250. The ironer has a diameter of 400mm and roller length of 2,500mm, which is ideal for medium-sized OPL sites. The chest consists of two parts connected with a hinge to provide optimum ironing results, thanks to its roll coverage of 180degrees.
The I 40-250 ironer is available in steam-, electric- or gas-heated versions, and is equipped with an electronic timer. It is the latest addition to the Primus range of chest-heated ironers, which includes the I 25 – 100, 120 and 140 with roll diameters of 250mm and working widths of 1,000, 1,200 and 1,400mm respectively; and the I 30 – 160 and 200, with roll diameters of 300mm and widths of 1,600 and 2,000mm respectively.
Danube International supplies a full range of flatwork dryer ironers (heated cylinder type), built to meet the needs of hotels, nursing homes, hospitals and OPLs.
It produces four ranges – the Micra, Delta, Maxima and Sygma – that cover cylinder diameters of 200, 320 and 500mm, and widths from 1,400mm to 3,200mm, while the Ecomina model has been developed for the budget market.
Bernard Jomard of Danube International reports a switch in demand to smaller-diameter models, with increased orders for the 325mm diameter ironers in Danube’s Delta range and away from the 500mm models found in the company’s Maxima range.
The Delta and Maxima ranges both benefit from Danube’s own automatic speed adjustment system that takes into account linen and room humidity, so allowing the linen to go from washer to ironer without any manual adjustment.
Danube’s “smart system” is based upon a stainless steel tub that measures the residual moisture of the linen at three separate points.
A mini vacuum brings the moisture in contact with a sensor, which analyse the residual moisture, room humidity and temperature. A cool down operates while the cylinder continues to rotate. The frequency inverter uses the sensor data to control the roller speed, which is automatically adjusted 100 times per second.
Electric and gas heating options are available on the Delta, and gas, electric and steam heating on both the Maxima and Sygma ironers.
Ipso is aware of the growing demand for high quality ironing. The company believes this demand, together with the view that cylinder ironers are more efficient, is responsible for the rise in popularity for cylinder ironers over chest types.
Ipso’s current range of ironers includes the CI cylinder ironers. The CI-range is mainly used for OPL-applications, except in the Belgian market, where the range is used for the coin market as well.
The models are the CI1650/325 and CI2050/325 with roll diameters of 325mm and working widths of 1,600mm and 2,000mm respectively; and the CI2050/500, CI2650/500 and CI3250/500 with a roll diameter of 500mm and working widths of 2,000, 2,600 and 3,200mm respectively.
The entire CI-range is available with gas, steam or electric heating. Ipso has also improved the burner for the gas-heated models.
A metal fibre burner is now used to limit the temperature fluctuations while improved flame control keeps heating constant.
Ipso also offers the RI-line of roller ironers. There are five models, with 30k – 60kg/h capacity and roller diameters of 250 – 300mm.
The models are the RI1000/25, RI1200/25 and RI1400/25, with roll diameters of 250mm and capacities of 25kg/h, 30kg/h and 35kg/h respectively; and the RI1600/30 and the RI2001/30AV with roll diameters of 300mm and capacities of 50kg/h and 60kg/h respectively.
The RI800/16 semi-commercial ironer is designed for processing small items, with a 16kg/h capacity and 160mm roller diameter.
The HPM heating band ironers from Kannegiesser combine high output and excellent finish with energy savings. The HPM 1,200mm diameter is available with working widths from 2,700 – 4,200mm as 1-, 2- and 3-roller machines.
The flexible heating band and long fully heated bridge provide higher output compared to conventional roll machines, allowing laundries to replace an existing 3-roll 1,200mm machine with a 2-roll HPM heating band ironer. The smaller surface area and fewer rolls result in less heat loss, reducing energy costs.
The HPM Grand heating band ironer has a diameter of 2,000mm and is available in working widths from 2,100 – 4,000mm. This high productivity table linen and small piece machine processes linen without tape marks. Both the 1,200 and 2,000mm models are available with stainless steel heating bands.
Adjusting the ironing process to the material being ironed and moisture retention also ensures efficient energy use. This temperature regulation is automatically linked to the central program control of the whole Kannegiesser ironer line.
The conventional Kannegiesser SHM ironer is available in 800, 1,000 and 1,300mm diameters and working widths of 2,700 – 4,000mm. It is available in single roll and multi-roll designs, with steam and oil-heated versions.
Kannegiesser has introduced an SHM gas-heated machine. A fluid heat SHM is combined with a gas burner and 3-pass heat exchanger, and the resulting machine allows an ironer line to operate without an external steam or oil supply. Temperature can also be adjusted to different materials.
Girbau of Spain says that for high production of flat laundry there is a tendency to work with chest ironers.
For small and medium-sized laundries, cylinder ironers are used more frequently.
The variations don’t depend so much on sectors, rather the individual requirements of production and the quality of textile finishes. A hotel or restaurant with small or medium production needs can operate perfectly well with a cylinder ironer, but in some specific cases where a better quality finish is required, such as table linen, the chest version is more suitable since it offers a better quality finish.
Girbau’s Wall Type flatwork ironer, with strap ironing system, is available with 220, 325 and 510mm cylinder diameters, with widths from 1,200 – 3,165mm, and an integrated primary folder option on the PSP-51 model.
Features include kinematic strap tensioning system and the Autospeed system that automatically adjusts the ironing speed to suit the type of linen and humidity.
The temperature is constant, ensuring even drying for all types of linen.
Girbau also has a chest flatwork ironer with a 800mm roll diameter. This is available in three operating widths (3,000, 3,300 and 3500mm) and three configurations (1, 2 or 3 rolls) in hot oil and steam.
