E Book

Professional Laundry

Part 1

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CONTENT

1. Introduction & Overview of the Market

2. Chemical Types & Their Functions

3. Ozone, Thermal and Chemical Disinfection

4. Chemical Dosing & Wash Programmes

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1. Introduction & Overview of the Market

Following our recent three part series entitled A Brief History of Laundry we now turn our attention to the professional market. Similar in style to the recently published Auto Dish & Glass Washing Series, the series of 8 articles reflects the importance of the professional laundry sector to our business, both from a chemical sales and engineering services point of view. The following key topics will be covered:

1. An introduction to and an explanation of how the professional laundry market is currently structured and operates in terms of types of customer and their core requirements.

2. An understanding of the core laundry machinery capabilities and their functions.

3. An explanation of the types of chemicals used within the On Premises Laundry (OPL)

market, their properties and functions within each stage of the laundry wash process.

4. An overview of specific disinfection rules and procedures within the professional laundry with focus on thermal, chemical and ozone technology.

5. The importance of automated chemical dosing systems, devising the correct wash

formulas and programme settings for different loads and fabric types, and the importance of professional engineering services and preventative maintenance programmes.

6. A guide to the correct linen flow cycle including sorting, manual handling and storage

of dirty and washed fabrics and correct laundry safety practises.

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7. An overview of the key fabric categories, the importance/meaning of care symbols and the importance of correct drying procedures and finishing practices.

8. An examination of how to reduce re-wash rates through proper sorting, correct

formulas and effective stain treatment, and identifying the common problems associated with poor wash results.

On Premises Laundries – The OPL On-site facilities dedicated to washing fabrics that are used there are often referred to as On Premise Laundries (OPLs) and are typically found in airport facilities, hotels and leisure centres, hospitals, residential care homes and correctional institutions. In many cases, they are not purpose built so the washers, dryers, chemical storage area, and the folding/stacking/sorting benches can often be cramped into an available space.

An OPL will often use an automated liquid detergent system relying on a reputable chemical manufacturer to install and service the electronic dosing equipment and supply the appropriate type of laundry chemicals. In addition, the chemical company should assist the site to determine the correct wash formulas/programmes for the various fabric(s) categories being laundered daily. OPLs vary in size from small to very large, primarily using washer extractor machines that can vary in size from 13 kg-28kg machines in smaller OPLs to 45kg-100kg in medium/large operations. Some very large OPLs may even have washer extractor machines as large as 145-350kg or even continuous batch washers (CBWs). These types of machines are normally found in Commercial, Institutional and Industrial (CII) laundry facilities and are capable of processing huge quantities of laundry work (see later). Care Homes: In the UK, one of the biggest OPL markets is the care home sector, within which there are two distinct types of home – Residential (care) and Nursing (clinical) – each with very different laundry challenges. In a residential care home, the guests, despite their age,

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are still independent and their washing needs are not much different from any normal domestic laundry. In a nursing care home, however, residents are more likely to have high dependency requirements, often resulting in greater laundry problems – incontinence being an obvious example. Irrespective of the type of care home, the OPL will normally launder personal clothing, sheets, duvets, pillows and towels – it is just the scale of the laundry challenge that will differ. Hotels & Leisure: In the hotel or lodging sector the OPL will mostly wash chef whites and guest sheets, duvets, pillows and towels. The sport and leisure sector can be more challenging as it has grown and diversified in terms of what it now offers members. In addition to the general washing of towels used in swimming pools, there are treatment sheets, cloths and towels used within the spa or beauty treatment areas that are often heavily soiled with muds, essential oils and emollients, all of which require different wash formulas/programmes. In addition to the small to medium sized OPLs found in these sectors, we often find larger sites where the OPL has been sized and designed as a central production laundry facility, fitted out with larger washing machines and a wider variety of driers and ironers. These types of OPL laundries are usually found in central hospitals or within hotel groups where they wish to control their group’s laundry provision in-house rather than contract it out. In-House Laundry or Contract Out? The Upsides & Downsides This is an interesting debate with strong arguments for and against. It is clear that disciplined management of laundry processes is critical within an OPL, otherwise it can get out of control and standards can suffer significantly. Why, therefore, not take the easier option and gather it up and hand it over to an outsourced laundry specialist? After all, they collect it, clean it and then deliver it back to you, so it seems to be the most convenient solution. Is it, however, the best approach? At RP Adam, we do not serve the large scale commercial laundry market, so from a business point of view we can be forgiven for favouring OPL operations, but nonetheless it is a huge industry processing millions of pieces of laundry daily throughout Europe. For the smaller organisation, outsourcing to industrial scale laundry companies can be costly and there is an argument that there is little opportunity for any long-term return on investment. However, there is a significant convenience factor which must be balanced against the capital costs and the ongoing running and management costs of operating an efficient OPL. This, in turn, needs to be weighed up against the possibilities of things going wrong – for example, there may be arguments over liability of the outsourced laundry service, where failed collections and/or deliveries leave businesses high and dry with insufficient clean linen or work wear. As with many important procurement decisions, such as choosing a reputable chemicals supplier, the selection of a reputable, outsourced laundry company is crucial. When they take possession of your laundry work, there needs to be a traceable guarantee that it is treated

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carefully, cleaned in accordance with best practises and industry standards and returned in a pristine condition. Whilst a diligent cost v benefit analysis needs to be undertaken before deciding whether or not to retain your laundry requirements in-house, there are multiple benefits in taking a considered approach. There are two main objections to in-house laundry: the first objection is typically the cost and the second is related to the space required to accommodate the equipment. In assessing costs, the following rules of thumb generally apply to the breakdown of non-capital costs:

Labour: between 38% and 56% of the total costs

Linen Replacement: between 12% and 24% of total costs due to normal wear and tear, rejects, theft and damage

Energy: between 9% and 15% of total costs – covers water, sewage, gas, and electricity costs

Chemical: between 6% and 8% and covers cost of laundry detergents, destainers, softeners etc

Indirect costs: between 5% and 20% covering equipment depreciation, maintenance, lighting, heating, and cooling

Regarding the problem of space, equipment manufacturers understand the importance of space saving solutions and modern laundry equipment has become smaller and more streamlined. Now, some washer extractors can have dimensions as small as 1m x 1m and many dryers and washing machines may be stacked on top of each other. To put this into perspective, professional laundry and disinfection and tumble drying facilities can now be fitted in a space on a footprint not much bigger than a domestic washing machine. Clearly, the cost of professional laundry equipment is higher than domestic variants. Businesses often make the mistake of trying to minimise set up costs by using domestic machines, but this invariably costs more in the long run due to higher running and maintenance costs, more breakdowns/downtime and reduced warranty cover. Many professional washing machines will have a theoretical operating lifespan of over 30,000 hours; which equates to running the machine 8 hours a day, every day for over 10 years – these really are work horse machines. As your business is likely to process laundry all the time, it needs to be fitted with efficient equipment that can satisfy all your demands in the shortest possible time. For example, if you want to do a quick wash; is the machine capable of functioning quickly and efficiently whilst providing the best results? Do your machines also have additional energy-efficient features such as moisture reduction to help reduce the drying time? Can your tumble dryers switch off

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automatically when the load is dry to prevent running on unnecessarily? There are a number of additional tools to improve efficiency and effectiveness but there are no shortcuts to a well-run, cost effective OPL. Another angle on the cost argument: when you outsource your laundry operation there is little opportunity to then reduce your costs – unless, of course, you are regularly changing supplier and chasing cheaper rates, which is time consuming and complex akin to changing energy supplier. Although most professional outsourcing companies are reputable you will always be at the mercy of their pricing model, because, for them, it is a revenue stream. With your own OPL, you have the opportunity to continuously make improvements to reduce costs and improve efficiency. By choosing your equipment carefully, you can dramatically improve on the costs of outsourcing, reduce energy bills and generate long-term savings and ROI. Most importantly, you are in total control and will have a direct input into achieving and maintaining a high customer satisfaction rating. Industrial Sized, Commercial Laundry Facilities These are typically much larger facilities, purpose built and generally offer a business to business textile rental service. They offer contracted rental services to launder floor matting, staff uniforms/overalls, restaurant table cloths, bed linen and towels in much larger volumes than an OPL could handle. Rather than investing in your own OPL laundry, these types of laundries offer an alternative. The hotel or care home for example will not need to buy textiles or replace them as they wear out. Due to the massive volumes of textiles bought by these companies, they can go direct to the textile manufacturer, obtaining better prices due to economies of scale and will, in most cases, replace textiles when no longer fit for purpose. The use of these companies eliminates the need to buy or lease machinery, or incur any of the associated costs of service, maintenance, energy, water, effluent, detergents. Significantly, as it represents the largest % cost, there is no investment required in labour and the management required to run a successful laundry operation. Outsourcing also releases space. You may be a hotel wanting an additional meeting room to hire out, a care home seeking additional social/leisure space or a factory wanting larger changing room capacity or a canteen, and a professional OPL (washing, drying and storage of textiles) takes up valuable floor area which can be used for other things. An OPL, if not managed correctly, can be complicated and costly so outsourcing eliminates the need to:

Manage textiles, cleaning chemicals and equipment maintenance costs.

Choose the appropriate equipment and capacities, manage the installation project

including ongoing safety concerns related to equipment installation and use.

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Ensure the business has emergency textile capacity for unforeseen increases in

demand (called Linen Par Stock). As a guide it is accepted that a site should maintain

a “4-PAR” linen inventory which equates to four times the actual linen used in one

day.

Recruit and manage specialist staff – it is critical you have a proficient laundry manager

and an experienced engineering manager.

Ensure that infection control procedures with infected linen (in line with CFPP 01-04

guidelines) are followed rigorously in healthcare premises.

These facilities use industrial grade washing machines called Continuous Batch Washers (CBW) or tunnel washers, which are very expensive and are only found in very high volume laundries. As can be seen from the above video, tunnel washers are inherently water-efficient and are highly automated to maximise the throughput of the laundry. The tunnel washer concept was first introduced in the 1960s, a time when the laundry industry was undergoing great changes. In the UK, the idea of continuous wash production was explored by Michael Ross, of Watford Steam Laundry, who installed the Baker Perkins Streamline in 1969. The CBW is specifically designed to handle heavy loads where laundry will progress through the washer in one direction, while water and washing chemicals move through the machine in the opposite direction so that wash wear moves through pockets of progressively cleaner water and fresher chemicals. In simple terms, soiled linen is continuously fed into one end of the tunnel while clean linen emerges from the other.

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Photo Courtesy of Kannegeisser

Photo Courtesy of Girbau Laundry Review UK Edition No.2

To illustrate the sheer scale of the process, a CBW consists of separate pre-wash, wash and rinse “zones”. Fresh water is introduced into the rinse zone of the machine and is passed cascade-fashion toward the main wash zone while the laundry is transported in a counter-current direction. These steps are carried out sequentially while the wash load is transported. A CBW that can process 970 kg laundry per hour may have 16 compartments/zones (or more) of which typically:

Zones 1-4 are pre-washing compartments.

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Zones 5-10 are main washing compartments.

Zones 11-14 are rinse compartments.

Zones 15-16 are neutralising compartments. Tunnel washers or CBW’s are very different from washer extractors. As the name implies, the main structure consists of a long metal tube called a tunnel, divided into sections called “pockets”, through which runs a huge metal spiral called an “Archimedes Screw”. As the screw rotates, linen is forced from one end of the tunnel to the other, passing through the various pockets. Since the screw is of a porous design and construction, laundry can move through the washer in one direction while water and chemicals are forced through in the other. Thus, the linen moves through pockets of progressively cleaner water and fresher chemicals. Soiled linen continuously goes into one end of the tunnel while clean linen moves continuously out of the other. The first few pockets are used to pre-soak and wash fabrics in a detergent solution. The corkscrew effect moves the fabric to subsequent pockets, dedicated to rinse functions. The water moves in a counter flow direction to the laundry and is used several times before being sent to the drain. At the end of the tunnel the washed fabric is removed automatically from the machine in the form of a large compressed cake, and then fed into the line of dryers. In most industrial scale laundries, they will have systems in place to validate wash processes and linen hygiene and to provide documentary evidence of chemical/thermal disinfection. The suppliers of equipment and chemicals will provide detailed data management systems which provide process control and machine utilisation data. They will also provide fully traceable laundry services for industrial and healthcare work wear. This may include a track-and-trace system utilising barcode technology where every garment is assigned a unique bar code which is used to track the garment and catalogue a full wash history throughout its lifespan.

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2. Chemical Types & Their Functions

In chapter 2, we focus on the main types of laundry chemicals used and their functions within the wash process – whether they be for cleaning, destaining, disinfecting or finishing. With automatic chemical dosing systems, the reputable chemical supplier will strive to keep dose rates as low as possible, ensuring that the chemicals are working as an effective component within the overall wash process, whereas the more unscrupulous supplier will increase dose rates irrespective of wash type to maximise the revenue from the unsuspecting customer. It is critical that the chemical supplier understands the requirements of the laundry, so that they can set up the correct programmes for all possible wash and soil types, and prevent unnecessary and costly over consumption of detergents (See chapter 5). Firstly, let’s look at the importance of the quality of the water itself. The detergent supplier cannot influence the quality of the water (i.e. the levels of hard water salts/hard water) coming into the laundry, but has to be aware of it. Water hardness is measured by the level of calcium and magnesium salts present in the water, and this can have a detrimental effect on laundry results if untreated. Water hardness can be easily reduced by using a commercial water softener. To find out more about the effects of water hardness in general, please refer to our earlier blog post in our series on automatic dish washing. Detergent dose levels can also be adjusted to compensate for water hardness, so the reputable chemical supplier should be continuously monitoring water hardness during routine service visits.

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Professional laundry detergents are available in both powder and liquid formats and, depending on the size and/or the specific requirements of the laundry, both types may be used, sometimes in conjunction with each other. There is a common misconception that, if a recommended dosage of chemical does the job, then surely a higher dose will do it even better and faster. Similarly, if there are problems with wash results, then machine operators may be tempted to dose more chemical. This malpractice can lead to chemical damage to garments and higher costs, so automatic chemical dosing systems have become an integral part of most OPL operations. Automatic systems not only provide accurate and consistent chemical dosing, but also eliminate the need for handling potentially hazardous chemicals. Most commercial laundry machines are now pre-fitted with connections for liquid detergents to enable chemical suppliers to dose their detergents directly into the machines via external electronic dosing equipment. The amount of chemical dispensed is dependent on the size of the pump, the size (diameter) of the squeeze tube and the length of time that the pump runs. The longer the time, the more chemical that is injected into the washing machine. Most chemical companies install and service their equipment on a free-on-loan basis, provided that the laundry exclusively uses their chemical products through their equipment. We look into this in more detail in Part 5 of this series. Generally speaking, auto-dosed liquids are the preferred choice for many OPL laundries for a number of reasons :- 1) to minimise the manual handling of chemicals, 2) to control consumption, 3) to offer more flexibility in the siting of chemical drums (as products can be pumped to the machines through pipework from a secure central room or other storage area remotely located from the washing machines) thus making maximum use of the available space and 4) to reduce the incidence of pilferage, as bulk drums of chemical connected to dosing equipment are, by their nature, less accessible to staff. Powder laundry products do have a slight advantage over liquids in that they can theoretically be 100% active (compared to a liquid which is a solution diluted with water). It is for this reason that highly concentrated powders are usually more prevalent in industrial scale, commercial laundry operations. Modern Day Laundry Detergents – You Pay for Quality Modern laundry detergents are now ‘engineered’ for maximum effectiveness against all soil types. Whereas, in the past, a number of products might be required to obtain the desired results, laundries can now effectively use one main “fully built” detergent that leaves linen clean and bright and is effective against a wide range of stains. However, fully built detergents vary in quality and their price and effectiveness is determined by the extent to which the chemical manufacturer ‘builds them’.

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There can be wide unit price variations between different laundry detergent brands, and buyers should be aware that the unit price is normally a reflection of the complexity and effectiveness of the “fully built” formulation – reputable manufacturers will only offer high specifications, so it is likely that cheaper products will contain less active ingredients and will require to be dosed at significantly higher concentrations to work. Professional launderers usually understand that a compromise on the quality of the detergent is a false economy and leads to higher re-wash rates, higher consumption of chemicals and higher costs. Biological and Non-Biological Laundry Detergents: The Difference A biological detergent contains enzymes which are effective at breaking down or ‘digesting’ protein soiling such as proteins, starches and fats. Enzymes are excellent for heavy duty cleaning and also work better at lower temperatures (30-50°C) than non- biological detergents. A non-biological detergent contains no enzymes and is suitable for use where there may be a risk of irritation to sensitive skin – babies clothing for example should be washed with non-bio products. These products are more effective for stain removal when used at higher temperatures. Optical Brightening Agents (OBA’s) OBA’s (fluorescent brightening or whitening agents) are chemical compounds that absorb light in the ultraviolet and violet regions and re-emit this as brilliant white light, making fabrics look much brighter, whiter and more lively. These additives are often used to enhance the appearance of coloured fabric and also make white fabrics appear brighter. The best OBA’s are very expensive and only small amounts are added to the best laundry detergents. OBA’s basically create an optical illusion, designed to mask yellow or brown tones in fibres and make the fabric appear cleaner and brighter than it would otherwise appear to the naked eye. One of the best illustrations of this whitening effect can be seen when a UV light is used in a nightclub and all the white clothing of the dancers appears to glow bright white. If white fabrics are washed in detergents which do not contain OBA’s they will start to look grey by comparison in a short space of time. For an expert explanation on OBA properties from BASF, one of the largest chemical companies in the world click here.

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Laundry Detergents for Coloured and White Fabrics Most detergents contain a bleach-like agent which can and will over time ‘pull’ the colour out of some clothes, so specific colour safe laundry detergents which do not contain OBA’s, bleaching agents or enzymes, are used to preserve the original colour of the fabric for longer. Laundry De-Staining Products Removing stubborn stains from fabrics is probably one of the most emotive subjects for the OPL manager and in this section we take you through the most widely used types of destainers.

Oxidising Type (Hydrogen Peroxide) – A liquid bleaching agent designed to work in the hot wash at temperatures above 60°C and can be used on both coloured work and whites. It must not be used on woollen or silk items as it will degrade the fibres. Overdosing peroxy destainers on cotton towels will make them hard to the touch.

Oxidising Type (Sodium Hypochlorite) – A liquid bleaching agent designed to work at temperatures below 50°C and ideal for stain removal in the first rinse cycle where it targets those stains not removed by the hotter wash cycle. If used at too high a temperature, or over-used, hypochlorite destainers will cause severe physical damage to cotton. We would not recommend use on natural silk, wool or nylon fibres.

Reducing Type (Sodium Dithionite) – A bleach powder which works by removing a molecule of oxygen from the stain thus making it a “reducing” bleach. This is an ideal product for reversing the overall colour tinting of a batch of white items which have been accidentally affected by coloured work in the wash load.

Low Temperature Type (PAP) – A liquid bleaching agent suitable for use on all types of fabrics (white and coloured work). Effectively and safely removes stains from fabrics with little risk of chemical damage over time. Because of its use at low temperatures it is suitable for woollens too. PAP based destainers are ideally dosed into the main wash cycle at temperatures between 20-40°C. They are relatively more expensive than traditional destainers but are dosed at much lower levels, safer, more effective and better for the environment.

There has been a noticeable trend towards lower temperature washing over the last two decades and this trend points to even lower temperatures being requested by consumers. Milder and lower temperature washing conditions lengthens the life cycle of fabrics and means more efficient energy use and lower energy bills. However, it must be noted that a report by the International Scientific Forum on Hygiene warned that low temperature washing might be inadequate to kill disease-causing bugs. Professor Sally Bloomfield of the London School of Hygiene and Tropical Medicine states ‘We need to launder clothing in a way that renders them not just visually clean, but hygienically clean – the two are not the same’. Her concerns are backed by a German study on clothes contaminated with Staphylococcus Aureus (linked to skin and urinary tract infections as well as pneumonia), where researchers found the only way to eradicate the bacterium was by washing at temperatures of 40°C + along with a detergent containing bleach.

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Alkali Boosters: These are also called ‘detergent builders’ and are sometimes used in conjunction with a main wash laundry detergent to boost or enhance the wash performance by increasing the level of alkalinity of the wash liquor. They are generally only required when washing heavily soiled laundry. Laundry Emulsifiers: These are degreasers designed for the effective removal of oil, grease and some problematic wax residues on table linen. They are harmless to most fabrics and do not affect most dyes. Good quality laundry emulsifiers are also very effective in the removal of mineral deposits from polyester/cotton fabrics. Laundry Fabric Conditioners: This type of finishing or conditioning product works by coating the surface of the cloth fibre with an invisible layer of perfumed conditioner. In addition to leaving a pleasant residual fragrance, the conditioner has lubricating properties and is electrically conductive, both of which make the fibres feel softer and smoother, and prevent the build-up of static electricity. Fabric softeners/conditioners have a number of uses:

1. Imparts increased softness to pile fabrics such as towels.

2. Leaves processed laundry with a pleasant residual perfume.

3. Reduces the chances of wrinkling and pilling or bobbling”.

4. Reduces or eliminates static electricity within the ironing process.

5. Increases flatwork ironing efficiency by lubricating the surface of the fabric and “iron glide”.

6. Effective at minimising the build-up of lint. Lint is the common name for visible

accumulations of textile fibres found on and around clothing. Certain materials used in the manufacture of clothing, such as cotton, linen, and wool, contain numerous very short fibres bundled together. During the course of normal wear, these fibres may either detach or be jostled out of the weave of which they are part.

It is worth noting that the over-use/over-dosing of fabric softeners can also cause some serious problems within the laundry. If too much is used on sheets prior to ironing, the flatbed ironer rollers can slip, leading to wrinkled sheets and poor folding. N.B. There are two commonly used fabric types where fabric conditioners should never be used: 1) Bed Pads or Kylies These are bed sized washable pads used to protect the bed sheet and mattress from incontinence events. With a quilted absorbent upper layer and a waterproof backing they are

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normally positioned on top of the bed sheet and are designed to prevent the need for continual stripping of beds and washing of sheets. They are durable and can be laundered +200 times without losing their effectiveness and absorbency. However, these MUST NEVER be washed in a cycle that contains fabric conditioner as absorbency is reduced, rendering them useless. 2) Micro-fibre cloths/mops etc. The popularity of micro-fibre cleaning products such as towels, mops, and dusters has grown significantly in recent years as they are effective at removing all manner of soils, quickly and efficiently from a variety of surfaces. These items are highly absorbent, absorbing up to seven times their weight in liquid and can last hundreds of washings when cared for properly. Again, fabric conditioner will clog the fibres, reduce absorbency and render them ineffective. Laundry Starch: This is a finishing product and the desired level of crispness is wholly dependent on the correct level of starch being used. It should also be noted that excessive tumble drying of starched items will destroy most of the starch before ironing, so care must be taken not to over dry or dry at too high a temperature. Starching table linen gives the fabric a stiff feel which enhances appearance, texture and durability. All fabrics, natural or man-made, have a tendency to crease, pucker up or flop even after high-pressure ironing, so starching can overcome these problems. Starching allows a table cloth to lie perfectly flat on a table with sharp edges, napkins can be sculpted into creative shapes, chefs and nurses’ hats can be made to sit proudly. It gives linen more body and a high quality feel/appearance and is available in liquid and natural powder form. Synthetic Liquid Starch: Man-made fibres such as polyester and poly-cottons do not respond to natural starches such as maize or rice starches, so modern liquid formulations have been introduced as an alternative for synthetic fibres. These are normally a blend of man-made glues and starches with stabilising agents to produce an emulsion starch liquid which can be used on both cotton and synthetic fabrics. Chapter 3 looks at the subject of disinfection within the laundry and examines thermal, chemical and ozone technologies.

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3. Ozone, Thermal and Chemical Disinfection

Foul/infected linen should not be handled any more than is absolutely necessary. If you have clothing or linens that have been exposed to bacteria or body fluids, disinfecting the laundry is important to prevent spreading disease. Here we look at disinfection by ozone, heat and chemicals.

Ozone Disinfection One of the most recent innovations in laundry disinfection is the use of Ozone. As a gas, it is present in low concentrations in the Earth’s atmosphere, with the highest levels of Ozone in the stratosphere – known as The Ozone Layer – where it filters out much of the harmful UV rays from the Sun and protects life on earth as a result. It is formed from oxygen when hit by electrical discharges – often seen as lightning during a thunderstorm.

Ozone is a highly powerful oxidising biocide and is commonly used for killing bacteria and destroying odours in a variety of industrial applications.

It is often used as a disinfectant in municipal drinking water systems, food processing and bottling plants and more recently in the cleaning and disinfection of fabrics.

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What is an Ozone Laundry System? It is a disinfection system whereby ozone gas is generated and fed into the washer extractor machine. Existing washing machines can easily be adapted to work in conjunction with an ozone generator, so there is no need to replace existing capital equipment. There are studies to show that ozone kills bacteria, including “superbugs” such as MRSA, VRE and Clostridium difficile.

Ozone actually works best in cooler water, which means that high temperature washing (for thermal disinfection) is no longer required. The resultant benefits can be summarised as follows:

Less hot water required.

Less energy required – both for washing and drying.

Reduced wash and drying times – thus increasing productivity.

Kills pathogenic bacteria.

Attacks mal-odours in the laundry.

Reduces chemical damage to linen thus increasing the linen lifespan.

Easy to install in conjunction with existing washing machines and low maintenance.

Environmentally beneficial over conventional systems.

The combination of a significant reduction in water, gas and electricity consumption, plus shorter wash cycles, faster drying times and longer linen life, can yield significant cost savings. It is estimated, if operated properly, that an ozone laundry system can provide up to 14% savings on electricity costs, >5% on dryer gas costs and 25%-35% on water costs.

Many of the ozone providers also claim that there are significant savings to be achieved in detergent consumption but RP Adam refutes this through working experience. Although ozone has significant merits, it is NOT the Holy Grail and has limitations in terms of cleaning performance. In terms of disinfection, however, the evidence of effectiveness is clear and proven.

It is critical that the chemical supplier has a good working knowledge of ozone laundry systems and works closely with the machine manufacturer to ensure that wash programmes and chemical dose rates are set correctly to maximise the benefits of the system.

If standard wash programmes are used in conjunction with an ozone laundry system, the system will not perform to its optimum level. RP Adam has worked closely over the years with all the main washing machine suppliers in the UK to develop wash programmes for ozone systems that offer maximum benefits at minimum costs.

For a detailed explanation of how an ozone laundry disinfection system works, click on the link below and see the video from JLA, one of the leading suppliers of Ozone systems in the UK – JLA Otex System. For a layman’s’ explanation, see also Dr Hilary Jones on Ozone.

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Thermal Disinfection In Part 2 of this series we referred to the importance of the sluice cycle. All foul and infected linen should be laundered using the sluice/hot wash cycle of the washing machine and should never be done by hand, as this could lead to contamination of hands, surfaces and uniforms.

Sluice washing consists of one or two high level cold water pre-rinses with agitation. It is done to dislodge solids from the linen and to suspend the solids in the water so that they can be flushed away prior to the linen entering the thermal phase of the wash cycle. The sluice stage is critically important – if contaminated laundry is washed without this pre-stage, the likelihood is that the linen will not be disinfected adequately in the thermal wash.

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For thermal disinfection a hot cycle must be used with temperatures reaching either 65°C for at least ten minutes or 71°C for at least three minutes (plus machine mixing time in both cases). Remember some modern fabrics can only be laundered at lower washing temperatures and should therefore be washed and disinfected separately.

Chemical Disinfection Under the guidelines for the disinfection of laundry in hospitals and care home environments (CFPP_01-04_BS_EN), infected items that cannot be laundered on a hot wash can be disinfected by adding sodium hypochlorite (bleach) at 150 parts per million to the final rinse.

Again, it is important to check individual washing instructions before adding bleach to clothes. Always take care that the machine is not overloaded or it will not wash effectively. Soiled or foul items, which are not washable, should be dry cleaned.

Process validation is now an essential requirement for the healthcare sector – BS EN 14065 Decontamination in laundering and CFPP 01– 04 Decontamination of Healthcare Textiles.

The Safe Management of Contaminated Laundry The provision of clean linen is a fundamental requirement in healthcare and the incorrect handling, laundering and storage of linen can pose an infection hazard.

Particular care should be taken not to cross contaminate clean linen with soiled linen.

There should be a defined segregated area where no soiled linen should be allowed.

Clean linen should be kept on a separate covered trolley or area outside the laundry room until ready for use and should be placed in the patient’s room only when all soiled linen and items have been removed.

Personal protective equipment (gloves and aprons) should be worn.

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Hands must be washed after handling soiled linen.

Trolleys used for the transportation of soiled linen must be completely different to those used for clean linen. All trolleys/baskets (both clean and soiled) must be disinfected on a regular basis.

The good management and movement of soiled and clean linen, and careful management of the laundry environment in which the linen is stored, will reduce the risk of any cross contamination. The drying process is also an important element in reducing contamination levels as thorough drying can reduce any contamination that may not have been removed during the wash process to levels that pose no risk to staff or patients.

Although staff may not regularly handle soiled laundry, they should be taught how to handle it safely. It is important to remember that it is not always possible to know if linen is infected or contaminated. It is vital, therefore, that all soiled laundry is treated with care and respect, and that standard precautions (including the wearing of personal protection equipment) are adopted at all times.

Requirements for a Laundry There are a number of basic requirements to ensure a hygienic and efficient laundry, namely:

A proper designated laundry area. Ideally, this area should have separate ventilation and a dirty to clean through-system so that dirty laundry can arrive through one door and be quickly washed before drying and removal, through a separate exit, to a clean storage area. Where this is not possible, arrangements must be made to ensure a dirty to clean workflow, so that clean and dirty laundry is always kept separate.

Washing machines in residential care homes should have “specified programme ability” to meet disinfection standards. Ideally this will include a pre-wash service cycle.

In care homes, an industrial dryer should be used to dry all clothing and linen. This should be well maintained and serviced on a regular basis.

In care homes, a regular service and maintenance inspection schedule should be available for examination by CQC inspectors.

A wash hand basin preferably with lever taps, liquid soap and disposable towels

Training of Laundry Staff Legislation requires laundry staff to be trained in the following areas:

Infection Control

Manual Handling (inanimate objects)

COSHH

In addition laundry staff should receive instruction concerning:

Cleaning Schedules

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Standard Infection Control Procedures

Hand Hygiene

Sluicing

Colour coding for laundry

Type and category of laundry

How Should Laundry Be Handled?

Laundry must be handled, transported and processed in such a manner that prevents direct exposure to staff, contamination of their clothing and the environment and the infection of service users.

Before handling dirty laundry, staff should wear protective clothing (gloves and apron).

Linen should be removed from residents’ beds with care, avoiding the creation of dust, and put in the appropriate bag outside the room.

Personal clothing should also be removed with care and placed in the appropriate linen bag and not on the floor.

Linen should be separated into the correct containers, handled as little as possible, and bagged at the point of use.

Linen bags containing infected laundry should be sealed and tied before removal from the care area.

Staff should never empty bags of linen onto the floor to sort it into categories as this presents an unnecessary risk of infection.

Linen should be segregated into 3 categories (see section below on segregation). Many care homes use water-soluble/alginate bag liners within cotton sacks in a washable, plastic, wheeled trolley to aid this separation.

All soiled laundry should be placed directly into the washing machine. If this is not possible then soiled laundry should be placed into a plastic bag until it can be put into the washing machine.

Hands must be washed after handling dirty laundry and following removal of personal protective equipment.

Each establishment / service should carry out their own risk assessment if in doubt as to how laundry should be handled, ensuring that dirty and clean linen are stored separately.

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How Should Laundry Be Segregated and Washed?

Where water-soluble bags are used, these should never be opened once sealed, prior to transfer into the washing machine.

Laundry facilities should be sited so that used / soiled items and infected linen are not carried through areas where food is stored, prepared, cooked or eaten and not intrude on service users.

Ensure that dirty and clean linens are stored separately.

Residential care homes are required to have sluicing facilities. However, avoid manual sluicing wherever possible.

Soiled communal laundry e.g. pillowcases, sheets, towels should be washed separately from other clothing on the hottest temperature the clothing will allow (65˚C or above).

Foul/soiled or infected laundry to be washed at an appropriate temperature (minimum of 65°C for not less than 10 minutes or 71°C for at least 3 minutes).

Chapter 4 looks at the importance of automated chemical dosing systems, devising the correct wash formulas and programme settings for different loads and fabric types, and the importance of professional engineering services and preventative maintenance programmes.

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4. Chemical Dosing & Wash Programmes

By electronically controlling the dosing of liquid laundry detergents, we can ensure that the correct amount of laundry chemicals are used in every wash cycle, which in turn will yield the best possible wash results as cost effectively as possible.

Because the systems are pre-set and automated, there is little chance of human error and less chance of chemicals being wasted unnecessarily. Achieving the optimum chemical dose rates can sometimes involve a bit of trial and error on a new installation, but the default calibrations are always calculated mathematically based on loads and wash types.

This sophisticated equipment is hugely flexible and can be programmed to dispense all laundry chemicals at whatever dose levels are required for each wash programme. Most modern washer extractors can have up to 20 different wash programmes so this level of flexibility is essential. For example, detergent levels can be set at different levels depending on wash loads, softeners can be added at different levels or not added at all, or specialist chemicals such as emulsifiers or starches can be programmed as required. Likewise, there might be a requirement for hypochlorite bleach to be dosed into some cycles for low temperature disinfection. The number of dosing permutations caters for all launderers requirements.

Most modern electronic dosing units also have the capability of providing various management reports that can be used to monitor chemical consumption and/or monitor the programmes selected by the operative over a period of time.

Chemical Control in a Liquid System A basic OPL laundry dosing unit usually has 2, 3 or 4 chemical pumps (but can have more if required). The laundry dosing unit is programmed to deliver different pre-set amounts of laundry detergent, destainer, fabric conditioner, and/or additional specialist chemicals which, when combined, will make up a chemical wash formula for the appropriate type of wash load.

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On most occasions the chemical supplier will supply the dosing unit with a cable-connected controller called a “Formula Select”, shown below with the LED display, which enables the chemical supplier to accurately programme the amounts of chemical that each pump should deliver. When set, it is capable of storing up to 20 different wash formulas.

The volume of chemical concentrate that a pump can deliver is dependent on the size or capacity of the pump, the diameter size of the tubing and the length of time that the pump runs. Generally, a pump should be capable of delivering the required dose within 45 to 60 seconds so it is important that the correct sizes of pumps are chosen in relation to the demand/size of the washer extractor machines.

To calibrate the pumps, each pump is run prior to full installation for a 1 minute test cycle at a per cent of its maximum speed capacity. The chemical run-off is physically collected and measured in a liquid measuring cylinder so that we can accurately calculate the ‘flow rate’ based on the percentage speed the pump is turning. This information is then programmed into the dosing equipment to ensure accurate dosing with each wash cycle.

The programming of dosing equipment must be carried out by experienced chemical laundry technicians otherwise the system will be compromised and the laundry will not achieve optimum results. Chemical dosing within a laundry environment is far more difficult and sensitive than in mechanical glass and dishwashing, and only reputable chemical suppliers will have the knowledge and know-how to do this properly. Once everything is calibrated and set-up, the laundry chemicals will be strictly controlled to dispense precise doses into each wash programme.

The Use of Flush Manifolds (Inlet & Outlet) In many OPLs, space in the laundry room is at a premium and chemical containers are often sited next to, between or even behind the washing machines in tight and inaccessible spaces. Where there are multiple machines but insufficient space for many chemical drums, then one set of chemicals can be used to service all machines with the installation of an inlet manifold unit between the chemicals and the pumps.

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Chemical is drawn from a single drum via a single tube but it is then distributed via the manifold outlet to the dosing units on each machine e.g. one drum of laundry detergent chemical may supply four laundry machines.

An outlet manifold can then be fitted after the laundry pump unit to pre-mix the chemicals with water and then transport the chemical solution to the machines through one single pipe rather than through individual pipes for each chemical. These are normally fitted on larger machines (over 23kg) where it is important to get the chemicals into the machine whilst the water solenoid valve is still running.

It is normally the case that these manifolds are fitted when there are a number of different chemicals being dosed for particular wash cycles. The ancillary pieces of equipment improve the overall appearance and neatness of the installation.

Setting the Right Wash Programmes by Wash Type During the initial survey of the laundry, the chemical supplier aims to gain as much information as possible about the types of washing being done. Successful laundry processing cannot be achieved by simply fitting a chemical dosing unit, pumping in chemical and walking away. You can install the best equipment, use the best chemicals and still obtain poor results – even when dispensing chemical reliably and effectively, this still represents only part of the laundry process.

The different wash loads cannot be laundered to a satisfactory standard using only two or three standard wash programmes, such as ‘Heavy Soiled’ or ‘Medium Soiled’ as this too vague. Wash programmes should be as detailed as possible and each category of load washed on a bespoke basis – remember there are up to 20 different options available so makes sense to make use of them. Example of different categories of wash are as follows:

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The more wash programmes that are used, the greater the chances of getting good results. Very often, when items come out of the washing machine and are still not clean, have shrunk, have been bleached, etc., the first reaction is to blame the chemicals and contact the chemical supplier. From experience, we know that the most common reason for poor wash performance is that laundry staff have simply chosen the wrong wash programme.

The chemical supplier controls what chemicals are dosed into the selected wash programmes and it is the responsibility of the laundry to select the correct wash temperature/programme on the laundry machine. Washing should be sorted into different wash categories based on type of soiling, fabrics and care label guidance, and the appropriate wash programme then selected for each wash category. In Part 7 of this series, we will look at different fabrics and care labels and their importance.

Another common error among some laundry operators is that they assume that different chemicals can be inter-changed on a like for like basis and that they all work at the same temperatures or in the same way. Different chemical suppliers may adopt different chemistry within their products which may require different temperatures from the chemicals that are in use. Operators should be aware that, if changing chemical suppliers or simply changing the chemicals in use, adjustments to wash temperatures may have to be made. An example of this might be if you chose to switch from a chlorine bleach to an oxidising bleach – one is only effective at very low temperature and dosed at the end of a cycle whereas the other is only effective at higher temperatures and dosed much earlier in the wash cycle.

The Importance of Professional & Reliable Engineering Support Good ongoing engineering support is critical to achieving consistent, quality results in any laundry operation. There is little point in having a modern laundry dosing unit fitted if it is not installed, maintained, and programmed correctly. Reliable engineers offering preventative maintenance support can ensure that problems are avoided rather than reacted to. If a laundry starts to suffer staining problems through poor maintenance and support, then these stains may become locked into the fabrics and cause dissatisfaction for months afterwards, even after the cause of the problem is eventually resolved. Laundry problems need to be addressed immediately – or before they happen – to minimise long term and recurring rewash problems.

Chemical dosing units in a busy professional laundry work hard – very hard – and sometimes even 24/7. As such, there will be wear and tear on equipment. Likewise, with constant dosing, the chemicals eventually put severe strain on the pump tubing which, if left unattended would eventually lead to tube failure or inconsistent dosing. Regular service calls and preventative maintenance checks can highlight impending problems, be fixed on the spot and avoid problems further down the line.

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Some chemical suppliers may “talk the talk” about regular service calls, but these claims need to be substantiated and we at RPA “walk the walk”, by continuously checking the integrity of tubing and pump heads as part of our regular service call, and changing them as and when they begin to show signs of wear and tear. By adopting a proactive approach to engineering support, we reduce the incidence of breakdown callouts and laundry downtime.

The customer too has a role to play in helping him/herself to speed up and maintain a quality engineering service. In simple terms, where there is a problem, it should be reported as quickly as possible to the manufacturer (not distributor) so that it can be quickly resolved. Delays can lead to more serious and costly problems so both the chemical supplier and customer should share the responsibility of maintaining standards to the very highest level.

Residual Soiling When setting up wash processes, the chemical levels, wash times, dip levels and temperatures will have been programmed for a specific type and level of soiling on specific types of textiles. However it is not uncommon for some items to be processed in the wrong wash programme leading to poor wash results and residual soiling – this is most common where heavily soiled items are washed in a programme designed for lightly soiled items. Care should be taken to select the wash programme applicable to the items being washed – a little care at the beginning can save lots of time and effort later on.

You will find Professional Laundry e-book 2 (Parts 5-8) covering ‘Processes and Practices’ on the Arpal Group Blog at www.thearpalgroupblog.com from the end of June 2015.