Cutting edge controls give greater flexibility

Reducing water and energy consumption has always been a goal for washer-extractor design. The latest generation of machines represents a streamlined approach to design without sacrificing durability and efficiency.

Jean-Marc Vandoorne, senior vice president of international sales for Alliance Laundry Systems, says that washer-extractor development is a blend of a variety of goals, each of which is a result of feedback received from customers. He says laundries have placed many additional demands on manufacturers labour-saving, water- and utility-saving features, greater flexibility and details that will help the laundry to handle the largest daily volumes possible.

“Our position has always been one born of giving customers what they need to do their job quickly and efficiently,” he says.

Steve Hieptas, national sales manager at Maytag Commercial Laundry says that commercial laundry owners are constantly looking to use less water while still obtaining great cleaning results.

“Hotels, hospitals and nursing homes are watching their purchasing dollars right now and are much more likely to repair a machine than replace it,” says Hieptas. “However, machines with more expensive repairs, perhaps costing a few thousand dollars, are generally being replaced.” He adds that textile rental companies are able to lower their bottom-line costs by purchasing equipment with higher spin speeds, which extract more water and allow for a quicker dry time.

“The pressure to save resources is a major concern; however, reducing expensive labour costs, which accounts for half the cost of running an OPL, is the main concern,” says Hieptas. “Luckily, washer-extractors produced over the last five years use substantially less water and have higher spin speeds, so they decrease drying time and help OPLs to save money.”

Using its customer feedback, Alliance has focussed on producing the next generation of washer-extractors, equipped with state-of-the-art microprocessor controls. The latest development is the new Quantum control platform for its Speed Queen range of washer-extractors. Quantum Gold enables laundry managers to fine tune the wash process with 30 programmable cycles as well as 30 programmable water levels, a feature that allows managers to adjust water levels at each step of the wash process, says Vandoorne.

Programming is simplified further as cycles can be uploaded to the machine through a handheld computer or personal digital assistant (PDA). The same infrared port also enables managers to download machine audit data for operations review.

Further developments to Alliance’s Speed Queen washer-extractor range include advanced leak detection for quickly identifying drain valve problems; a highly reliable triple-lip seal to protect the washer’s bearings; and an extraction speed of up to 140G.

Vandoorne adds that the latest development for the UniMac brand’s UW range of washer-extractors is the UniLinc control. This enables laundries to adjust cycles with 30 programmable water levels, a feature that can save hundreds of gallons of water annually.

“The control acts almost as an on-site laundry manager,” says Vandoorne. “The reporting software that UniMac has designed offers managers and general managers access to data that will help them better allocate resources and promote quality.”

According to Girbau of Spain, one of the keys to laundry savings is to make a program suitable for each type of laundry and each soil level.

The company’s Inteli control provides limitless programming possibilities that regulate wash cycle parameters phase by phase, to give significant savings in water, energy and chemicals.

A selection of graphic icons exclusive to Girbau allows any operator to program the wash processes easily. After receiving positive feedback about its latest improvements to its 6-Series of washer-extractors, Girbau has launched its large capacity machines – 25, 44, 63 and 122kg, all with the company’s Inteli control.

According to Merce Bover at Girbau, some heavy-duty laundries frequently use washing machines to tackle small quantities of laundry that can not be processed in the batch washer.

Lavandería Calandra, an industrial laundry in Barcelona, has a complete Girbau TBS-50 batch-washer system and two Girbau ironing systems. The laundry required washing machines to process small loads of sheets with specific soil stains and tablecloths. It opted for Girbau’s HS-6057 (63kg capacity) and HS-6110 (122kg capacity) washing machines to cope with the loads.

Bover adds:?“The laundry manager says that the wide programming possibilities of the Inteli control allowed him to readjust his customer’s programs and optimise the washing action.”

Girbau has also developed IMT Plus computer programming software, the next step from its Interim Manager Tool (IMT) that enables the operator to configure wash programs from any computer, save them to a memory card and use them in as many washers as needed.

As a further development in the 6-Series, both the HS-6057 (63kg) and HS-6110 (122kg) models have been equipped with an option called Easy Load to assist in loading and unloading.

With the Easy Load system, the laundry load is progressively compacted with water to allow the rest of the load to be placed in the washing machine without problems.

All Lapauw washer-extractors are prepared for future connection to a water recovery system, according to Wim Demeyer. The drain is fitted with a plug that can connect to a recuperation pump, and the machines’ PLC has its parameters set to manage the recuperation process. Lapauw can also supply its own water-recovery package consisting of recuperation pump and one or more water tanks, depending on customer requirements and the capacity of the washer-extractor.

Lapauw also has a range of 3-pocket washer-extractors, with capacities of 100 – 300kg, which is suited to handling sheets as the load is divided over three compartments rather than loaded together in one compartment.

Demeyer says the latest development from Lapauw is its line of open-pocket washers for dustmats. They go up to 400kg in capacity and are based on models in the Lapauw open pocket range. These already lend themselves to heavy duty applications such as dustmat washing because they are extremely robust, with frame sizes over 20mm thick and thick inner and outer drums.

The mat washers are modified to achieve the most efficient way to wash dustmats. These include adapted suspension to absorb the vibration, increased drum volume and modified drum construction to accommodate the dustmats.

The most efficient washing action is achieved by allowing the water to reach the whole surface, while an enlarged door opening makes loading and unloading easier.

Tolkar, one of the biggest laundry machine producers in Turkey, has also addressed the question of water resources. The company has been operating in the manufacturing sector for textiles and laundry for more than 30 years.

According to export manager Mehmet Karali, reducing water requirement also reduces the energy required for heating the water and the required amount of chemicals. Tolkar/Smartex has designed its Eco Drum system to achieve water savings of up to 35%. Washing takes place in a perforated inner drum, which is rotated in another large volume cylindrical drum.

Around 65 – 70% of the water is in the inner drum with the linen, while around 30 – 35% is between the outer and inner drums. The Eco Drum allows the water outside the inner drum to be used for both washing and rinsing processes achieving water saving of 50%.

Mehmet Karali adds that increased efficiency in chemical and energy use is delivered by the Tolkar/Smartex PolyRib drum. The drum is designed with multiple small beaters instead of four large beaters. This provides a better mechanical action, increasing the effectiveness of dirt removal. It also avoids the problem of tearing of large bed sheets when extracted at very high speeds. With the PolyRib system, the perforated surface of the drum allows water to flow through during the extraction process.

John Balman, sales director of the Ipso brand of laundry equipment, says its CW8 washer-extractor is designed for small capacity OPLs. A matching semi-commercial dryer also is offered with a stainless-steel cabinet. Balman adds that the entire CWDS 8 range now features a control that can be programmed by PDA and offers a variety of functions.

The focus on spin speeds has resulted in Ipso developing WFF cabinet hard-mount models capable of 145 to 165G and a soft-mount range delivering speeds up to 475G.

Developments also include the Cygnus control platform for laundry operators. Ipso’s Cygnus Professional enables managers to modify wash programs any time, even while the machine is running. Cygnus offers data such as temperature, water level, wash speed and soap injection times.

“It delivers helpful troubleshooting information to limit downtime and identify concerns before they become major problems,” says Balman. “Managers have access to a log of the complete history of the washer-extractor, as well as the ability to run diagnostic checks of major systems such as heating, water levels, inlet valves, outputs, wash action and drain valves.”

Schulthess Maschinen has worked closely with Büfa cleaning systems to develop new disinfection programs for its commercial and industrial laundry machines. The disinfection programs are especially suited for applications in old people’s and nursing homes, the hotel and catering trade, saunas and fitness businesses as well as in clinics, building cleaning companies, fire brigades, rescue services and other service and business enterprises.

According to Schulthess Maschinen, the disinfection programs were tested for their germ-killing effect by means of biomonitors. The tests were conducted using detergents made by established manufacturers.

Evaluation of the test results, carried out by Germany’s wfk Institute for Applied Research, could not detect any residual test germs.

Daniela Koch, head of marketing at Schulthess Maschinen says the Swiss-based manufacturer has improved the temperature control of its washing machines. “The knowledge gained in the course of these laboratory tests was taken into account and implemented by the software developers and process engineers during the development of the new disinfection programs. When used in conjunction with suitable detergents, the new programs offer security and guarantee hygienically clean and germ-free laundry.”

Pellerin Milnor has expanded its line of 18 – 72kg (40 – 160lb) capacities washer-extractors. The V-Series range offers high extraction rates, which is particularly suitable for all-cotton goods and easy-to-use controls.

The V-Series features ExactXtract high speed extraction, which maximises moisture extraction up to 300G. This option measures physical vibration of a washer-extractor in high extract. With this, the machine will proceed in extraction until 300G or a certain vibration threshold is reached. At this point, the model’s extraction speed is locked-in. This process, coupled with an efficient dryer design and superior basket area, leads to energy in the drying cycle. Other energy efficient features include larger perforations. Chemical flush and deep bath rinse shorten cycle times.

Stahl developed its range of Atoll washers and its Divimat hygiene washer-extractor to reduce water, energy and detergent consumption. The Atoll range is now available in 12 different sizes from 5.5 – 110kg.

Stahl’s latest addition to the Atoll range is the 45kg capacity Atoll 450 washer-extractor. Although capable of operating at 410G force, it runs with little noise and no vibration, even during the extraction cycle.

The six perforated scoop ribs, hydrodynamic wash system and heat insulation provide optimum wash-efficiency. The specially designed heat insulation, which is similar to that of a thermos flask, ensures heat is retained inside the outer drum. This effect is said to save about 30% of the heating energy.

Stahl’s pendulum-overflow technology tackles the problem of dirt collecting on the water surface during washing. A microprocessor adds water at regular intervals and the drum’s pendulum movement causes dirty surface water to flow off through the overflow. Resulting wash times are shorter as fewer rinses are needed and Stahl says the machine gives better wash results while reducing energy consumption.

Machine operation is made easier by means of a large loading door and through the FREEpro microprocessor control unit, which enables the operator to select and save hundreds of different wash programs.

Much of the research and development at Primus is dedicated to reducing water and energy consumption, according to marketing manager David Grendysa.

The company’s Optiload feature is available on its hygiene washer-extractors and the FS33/40/55/120 models. Linen is weighed in the drum and the water level and the accompanying soap consumption can be calculated according to the load. Optiload can reduce water consumption by up to 35%, depending on the model and the load, says Grendysa.

Primus has introduced its FS13 model with a capacity of 130litre (13kg dry linen) and a door opening of 420mm.

This year the company plans to launch its FS80 washer-extractor, with a capacity of 800litres (80kg dry linen), aimed at industrial laundries and larger OPLs.

All machines will be equipped with Super-Eco wash programs as standard.