Looking at all the angles

Prospective purchasers of an ironer for an on-premise laundry need to check carefully on the details, both of the machine itself and their own operation to make sure that the final choice will be right for their particular application.

Accurate judgements on the space that is available for the ironer, and for personnel using and maintaining it, are needed. Additionally, the maximum demands for large- and small-piece throughput, the machine's engineering quality, and the after-sales service must all be considered.

These points apply equally to the small hotel OPL - where the aim may be to smooth the flatwork rather than impart a crisp finish - and to the large hotel laundry where an ironer running at moderate speed consistently gives results close to those of a commercial multi-roll machine.

Small and medium-sized OPLs tend to opt for a return-feed ironer which is labour saving and compact. The temptation to hem in the ironer, must be avoided as it restricts operator movement required for flatwork pre-feeding, feeding, and post-ironing handling. It is also usually necessary to leave a small but adequate space behind the ironer for maintenance.

Ironer capacity

In calculating the ironer capacity, data on peaks and troughs of work needs to be assembled. The establishment's past experience of workflows should be drawn on, taking account also of variations in business and the possibility of expansion.

The importance of future needs has to be underlined. If, for example, a hotel plans to upgrade flatwork stocks from polycotton to 100% cotton, this will affect the type of ironer needed.

Large-piece dimensions and weight have to be taken into consideration, along with the handling and finishing requirements for heavier classifications.

When specifying the working width of ironer, the required throughputs for different classifications will be a priority. If the laundry handles a significant, small-piece volume, the number of lanes required could mean that the working width needed is greater than would be thought from merely noting the dimensions of the largest pieces handled.

The OPL needs to be confident that it can consistently achieve the work throughputs required when the establishment is at its busiest. For hotels, this means determining not just the demands of full occupancy but also those arising from a succession of days when check-out and check-in levels are high.

Superficially, ironers may appear similar, but it is important to look beneath the outer panels to check that the engineering quality will meet the demands placed on it without undue risk of breakdown. An OPL will usually have only one ironer so if it is out of action, shortages of linen can quickly arise, especially if the business is busy and flatwork stocks are not plentiful.

It is unlikely that any machine will run endlessly without any problems, so it is necessary to check that the supplier can provide speedy on-site service, backed by a comprehensive stock of spares.

Laundry engineering consultant Dennis Curry advises making a detailed site survey with details of the utility services available, at the earliest stage of planning. Electrically heated/driven ironers are popular in small OPLs, and for some operations a gas-heated, electrically driven machine is the answer. For medium-sized and larger OPLs with an appropriate boiler on site, using steam for heating the ironer makes economic sense.

Seek expert advice if any gas-heated equipment is to be used in an area where drycleaning takes place.

With return-feed ironers, finished pieces need to be folded promptly, leaving them in the collection tray will lead to creasing.

Achieving optimum quality comes from adhering to correct wash principles, presenting flatwork with the right moisture content to the ironer, and ensuring good ironer performance.

The ironer's running speed will be determined by the type of work being handled. Calculations need to be made in order to build a picture of the overall requirements. Demands for quality and speed need to be judged together.

Mr Curry emphasises the importance of scouring and waxing procedures to maintain a high quality and smooth running. Furthermore, clothing on the roll must always be in good order. He also points out that poor rinsing practices in the wash process will affect ironing results and may damage flatwork.

Single operator

Industry experts say hotel OPL ironing is often expected to be accomplished with one operator. Return-feed models make this possible. Feed-assistance, fold and stack features are a boon.

Glen Harvey, technical and marketing manager, Electrolux Laundry Systems, says it is necessary to recognise that the smallest ironers will adequately handle flatwork but will not be able to impart the type of crisp finish that larger machines achieve.

The finish quality with the small ironers is limited as the work being fed to the machine needs to have low moisture content and because the contact area is small.

To improve the quality, braking the roll can increase contact time, but this stop-go method requires the operator to have a degree of skill, and is not often used.

The smallest ironers are suitable for use in nursing homes and small hotels but three-star hotels and larger nursing homes, tend to favour drying-ironers. The heated roll of these ironers can be of stainless steel or cast iron. A stainless steel roll reaches working temperature rapidly, does not have to be waxed and does not rust, but it also cools quickly.

Efficient operation

Teaming high-speed washer-extractors with a drying ironer makes for an efficient OPL operation. Mr Harvey says that flatwork, with a moisture retention up to 55%, can be taken straight from the washer-extractors and put through the ironer running at a temperature of 170ºC. This method of working is fast and the results should be excellent.

A typical hotel OPL might have four high-speed washer-extractors, an ironer, and two dryers which are used mainly for towels. Directing work from the washer-extractors directly to the ironer and avoiding the tumbler drying stage saves time and reduces the energy cost. Return feed with length-folding provides additional labour saving.

With return-feed ironers, it is important not to leave the ironed flatwork item in the collection tray for too long. The flow of the item from the ironer is such that it should rest in the trough in a loose concertina fold, but creasing will set in over time and the situation will be made worse if another item is ejected from the ironer on top of the first, so compacting it.

When labour-saving is a priority, automatic flatwork feeding is essential and this is available on larger OPL specialised machines, some of which are able to return large flatwork items folded, stacked and counted.

Mr Harvey also stresses that the performance of any ironer is only as good as the quality of work presented to it. Galling - the baking of detergent onto the item with resultant brown patches - may occur if rinsing is insufficient. This can be a

particular problem with heavier weight classifications.

On the subject of specifying the working width of medium-sized and larger ironers, Mr Harvey agrees that a complete analysis of the work mix needs to be conducted. Large volumes of small pieces need swift handling and the number of lanes required will definitely be a factor in determining the working width.

Carefully trained

He stresses that operators must be carefully trained in the best way to use an ironer, and maintenance staff should be instructed in machine care. Electrolux Laundry Systems sees maintenance as a sort of partnership between itself and the maintenance staff employed by the organisation running the OPL.

Some larger ironers in OPLs may cost as much as £70,000 and so, apart from operational considerations, it makes a great deal of sense to protect the investment. Carrying out routine maintenance, minimises the ironer's downtime and extends the machine's life.