Implementing cost-effective laundry operations

There are many ways hotels can save money on laundry operations.  Sometimes the simplest solutions – like sorting linens at the guest room level – can save time and money.  Other times, the solutions are more technical, like a laundry data retrieval system that can be likened to the black box on airplanes – it collects that much information.  And sometimes it’s just a case of paying attention to staffing, equipment and procedures.

More efficient operations

Terry Satchwell of Pellerin Milnor says an efficient on-premise laundry begins with a professional approach to space planning, work flow analysis and equipment selection.  “Validating and optimizing wash formulas and dry modes on a continual basis is a key factor is reducing laundry operating costs.  There is a careful balance between water, chemicals, temperature, time and mechanical action,” he adds.

Terry Satchwell

Alliance Laundry Systems of Ripon, Wisconsin is a leading manufacturer of commercial laundry equipment. “As a result, our brands — UniMac, Huebsch, IPSO and Cissell — are at the forefront of developing products that reduce operating costs,” says Alliance spokesperson Randy Radtke. “Customers look to us for features such as cutting-edge controls that help operations reduce their water and utility use as well as maximize staffing efficiency.”

Manny Sandhu, technical representative for Harco Co. Ltd, which supplies top of the line washers, dryers ironing and folding equipment, suggests laundry layout should ensure there of no backflow of product during the process.

“Dirty linen should not cross the path of clean linen. The correct equipment is needed based on the wash, dry and fold requirements of the laundry while taking hours of operation into account. It is important to have the correct production capacity in order to process linen in a timely manner and  deliver it to housekeeping on time,” Sandhu says.
At Coinamatic Commercial Laundry, which recently changed its name from OPLS – On Premise Laundry Systems – customization is key. “We ensure that our clients receive a properly designed and implemented commercial laundry system with the ideal equipment installed based on the type of facility and specific laundry requirements, ensuring extraordinary throughput, keeping operations running at full capacity while saving utility costs and staff time,” says Susan Reynolds, director of business services for the Mississauga, ON-based company.

“We work closely with laundry staff, maintenance engineers and chemical suppliers to ensure cycles, procedures and products provide optimal results at the lowest possible cost.”

Wascomat’s Clarus control and Compass control can keep track of every wash load used by individual wash programs over a monthly period, says Dan Goldman of Wascomat Laundry Equipment. “Water levels can be set to the exact gallon, inch and bath temperature. Wash and extract speeds can be set for the exact RPM and the chemical dosages to the exact ounce of product. Electromechanical timers, card control and fixed programmers may be cheaper to buy but far more expensive in the long haul.”

Wascomat also offers the CMIS system which can be networked with washers, dryers and flatwork ironers to print out daily reports on everything that should be monitored in a well run laundry. Excessive water costs, cycle times, erratic bath temperatures plus production figures are all logged and available for evaluation and correction.

Saving on staffing costs

For Alliance, the first step to staffing efficiency is knowing the present state of your laundry and understanding that small tweaks can reduce the number of loads processed and also help reduce staff time.

“Something as simple as making sure staff is using the full capacity of each washer and dryer can help reduce the total number of loads processed daily,” says Radtke.

“Managers should take a look at their washer-extractors and make sure they are using super high G-force. These high spin speeds remove more water from loads than medium and low speed models and cut drying times significantly, which in turn reduces processing times.

“Controls with a delayed-start option also help manage staff. Washer-extractors can be loaded before staff leaves for the day and programmed to start an hour before the first employees arrive the next day. From there, the morning shift can transfer clean loads to the dryers. A second group of employees then could be scheduled to arrive just prior to the first drying cycles being completed.”

Harco’s Sandhu says that where possible, laundry processes should be automated to increase production per person hour.

“There are obvious advantages to automation such as reduction in operating hours, reduction in staffing requirements and therefore a reduction in operating cost,”
Sandhu said.

EnvirO3matic, the new laundry oxidation system from Coinamatic helps shorten cycle times which means production is higher on a shift, deferring or eliminating staff requirements, says Reynolds. Coinamatic service and full service rental agreements have preventive maintenance programs that help eliminate equipment downtime keeping employees performance at a maximum.

Pellerin Milnor’s Satchwell suggests implementing a soiled linen collection procedure at the guest room which keeps terry towels separated from the bed linen.

“Hotels that use a three-bag soiled collection cart enjoy a significant labour savings as sorting in the laundry room is eliminated – one bag for terry towels, one bag for sheets/pillowcases and the third for trash. Having a houseman or linen runner strip the soiled linen and garbage out of the room ahead of the maid gets the dirty laundry off the maid’s cart and to the laundry room faster and pre-sorted. This procedure allows the maids to clean more rooms, saves space in the laundry room and reduces the weight and overloaded maids cart to handle only clean linens and cleaning supplies.”

Energy efficient equipment

Vancouver-based Haddon Equipment’s Continental high performance washers use up to 57 per cent water, according to equipment manager Shane Bichin.  The washers also decrease drying time by 40 per cent, cutting gas consumption and reducing labour costs.  The machines also dramatically cut hot water and waste water usage, and are manufactured in a factory that is certified to the ISO 14001 environmental management systems standard.

Ontario Laundry Systems is now the exclusive agent for Electrolux Professional Laundry equipment for the entire province of Ontario, says Wascomat’s Dan Goldman. “Now, they not only have access to the Wascomat line but they can also offer their customers the more advanced and innovative products that only Electrolux with its engineering might can deliver,” he says.

“The CMIS system which is the key behind effective laundering is the only true data retrieval system designed solely for our industry,” says Goldman.

“Think of it as the "Black Box" that is mounted in every passenger jet recording all information of all operations of flight and you will have a good idea of how Ontario Laundry systems push the envelope regarding effective laundering. Imagine being able to print out a report on a particular load and being able to evaluate everything from the dosages of the soap pumps to the temperature of the water in the last rinse to the drying time in the third tumbler to the temperature and roll speed of the flatwork ironer. Effective laundering begins with the ability to measure performance in all aspects of the laundry room process.”

Alliance’s Radtke says that since drying accounts for roughly 70 per cent of utility consumption in the laundry, managers should do all they can to reduce drying time.

“Obviously, that starts with dryers that are extremely efficient, balancing the key elements of drying — heat, airflow and tumble action. Equally important are washer-extractors that have super-high G-force extraction to remove more water from loads. Super-high extract speeds of 300 G-force and higher remove significantly more water from loads than an 86 G-force machine. The end result translates into great reductions in drying times, as much as 30 percent less.”

For hotels planning to follow the industry trend of upgrading from cotton/poly blends to higher thread count, 100 percent cotton bed linens, high G-force and efficient
dryers will be necessities, Radtke states. “Working without these elements likely will contribute to increased labour costs.”

Radtke also recommends that laundry staffs avoid over-drying by using dryers with an auto-dry cycle, and that managers should also look at the efficiency of the hot water heating system and, where possible, use hot water only for steps that require it.

Milnor washers featuring RinSave technology eliminate up to two high level rinses and saves the cost of water, sewer and the energy to heat the water, says Satchwell.  There are also significant time savings which means more loads per day, week and year. 

“Milnor dryers are known for their quick dry times because of increased air flow through the dryer basket to ensure the heat penetrates the fabric being dried, while their standard Fire Suppression System (FSS) reduces the risk of fire in the laundry department,” he adds.

Sandhu said newer equipment features, such as high extract speeds, means reduced water retention in washed linen, which reduces drying time and therefore utility bills.

Coinamatic Commercial Laundry carries state-of-the-art equipment from major manufacturers and is the National Distributor of IPSO laundry equipment in Canada. 

“It is important to use quality commercial equipment that is designed to handle heavy loads and round-the-clock use with minimal maintenance or downtime,” says Reynolds.  “Equipment must be considered based on the specific laundry requirements to take advantage of ideal wash programs and high speed extract cycles that help save drying time.”

Coinamatic believes that ozone is the key to more efficient laundry operations. The company has a new product called EnvirO3matic, an advanced laundry oxidation system that brings the superior disinfection power of ozone and oxygen to laundry while reducing operating costs and environmental impact.  Not only does use of ozone cut laundry operational costs by up to 50 per cent, but the new system enhances the performance of chemicals and shortens the traditional wash cycle. 

“Using cold water instead of hot, a typical laundry facility can generate cost savings and achieve a full return on investment within 9 to 18 months.  On full rental agreements, the return on investment is immediate,” says Reynolds.

Coinamatic says that ozone cleans and disinfects better than traditional wash thermal cycles, killing or disabling bacteria and viruses, including MRSA and C-Difficile, many times faster than conventional practices.  Fibres are also lifted during cleaning producing a softer fluffier feel to towels and linens.

Sandhu at Harco Co. Ltd, says laundry is one of the key areas of a hotel that can be fairly easily structured to attain maximum efficiencies.

“A direct benefit is reduced cost per pound of linen processed,” he says.

The company uses ‘green technology’ in its ozone wash assist systems. “This technology enables linen to be washed in cold water and eliminates the need for chlorination. Wash times are reduced as certain cycles are not needed.”

Ozone wash assist reduces utility costs by up to 35 per cent, as the water does not have to be heated. Chemical costs are also reduced by up to 20 per cent ROI on these systems is typically 12 months, Sandhu says.

Saving on chemical costs

Coinamatic’s dosing systems help control chemical consumption and provide consumption reports, and cycle reports to assist in monitoring and ensuring proper chemical usage, helping hotel laundry operations save on chemical costs.

Satchwell recommends washer controls designed to handle the timing function of chemical injection.

These controls require no maintenance as the chemical dispenser doesn't require a timing control module.

“Chemicals should be safely injected into the washer with a hot water flush to dilute the detergents and bleach prior to entering the washer,” says Satchwell. “The connection point should be on the rear console of the washer and not on the front or side of the washer where operators can be come in contact with them.  Laundry chemicals need to be introduced below the water line, in the sump, prior to coming in contact with the linens.  This is why all washers should have a sump designed into the shell of the washer.”

Improper injection and dilution leads to increased chemical costs as well as linen damage, Satchwell states.  Pellerin Milnor recommends that each washer should have a minimum of six chemical inlet connections to provide the greatest flexibility. High quality linens in many hotels require the use of both oxygen and chlorine bleach.

Saving power and greening laundry

Pellerin Milnor’s Satchwell suggests reducing the hours of operation to save on power costs.

“Often laundries are undersized in capacity of washers and dryers, which requires extended hours of operation.  For example the difference in electrical consumption of a 60 lb washer and 80 lb washer is minimal (3.5 running amps vs. 4.5 running amps) compared to a 34 per cent increase in productive output. Dryers with an auto-dry feature and microprocessor controls reduce gas costs.”

“The laundry operation of a large hotel can sometimes exceed 16 hours a day, which means water, gas and electricity are being consumed for most of the day,” says Coinamatic’s Reynolds. “Laundry products account for large portions of chemical ingredients which ultimately are released by laundries as waste water into the environment. In order to measure the environmental impact of a laundry operation, a number of factors should be considered including the amount of electricity, water and chemicals consumed per day.”

Coinamatic recommends switching to improved detergents that include lower toxicity, more rapid biodegradation and less toxic byproducts, as well common-sense practices such as using low-temperature water for washing, only washing full loads and reusing linens for guests who are staying more than one night.

Modern washers take into account the careful balance of water, chemicals, temperature, time and mechanical action of the washer itself, according to Pellerin Milnor’s Satchwell.
Laundry managers know that four of these five elements (water, chemicals, temperature and time) can be altered in each and every wash formula to obtain proper soil remove, rinsing and finishing the linens prior to drying or ironing operations. 

“The factor that cannot be changed is the amount of mechanical action factor (MAF) which is integral part of the washer cylinder’s design. The larger the diameter of the wash cylinder and height of the ribs inside the cylinder the better lift and prop action.  This feature should be carefully reviewed prior to purchase of any washer be it a commercial or industrial machine.

The MAF has a direct effect on the amount of water, energy (temperature) and chemicals that must be used.  Yet this feature perhaps is the least understood by some on-premise laundry operations.  Satchwell suggests careful review of the design of the washer cylinder including the size and quantity of cylinder perforations which aid in the washing and rinsing action of the machine.

Being green is about employing highly efficient equipment with variety of energy and water saving features and looking closely at wash cycles to identify efficiencies, says Alliance’s Radtke.

“It’s extremely important to work with a full-service distributor and one who is tuned in to the specific current and future needs of your operation. A greener laundry doesn’t just happen; it’s the result of an in-depth review of current practices and equipment, coupled with a focused approach. Managers should have clearly defined goals in mind but shouldn’t be averse to thinking outside the box.”