It has become glaringly obvious over recent years that feeders and folders have benefited immensely from the advent of robotics teamed with artificial intelligence. Inwatec was, and still is, a major pioneer in this area and other companies have also had a big influence on developments. Inwatec, self-styled ‘laundry nerds’, first came to mainstream industry attention in 2016 at Texcare International in Frankfurt.
Texcare International 2024, eight years on from the last edition of the show because of Covid, ably demonstrated how all things AI have developed exponentially. It is a fair bet that The Clean Show in Orlando in August will reprise a lot of the developments as it will be the first time North Americans who did not make the trek to Frankfurt will be able to inspect them first hand.
From sorting and feeding in the soiled area, fishing out foreign objects, to feeding the ironers and then folding and packing linen and towels for immediate dispatch, the industrial laundry is well on the way to becoming fully automated. Maybe not just now, but with the frenetic pace of change of the past few years, this is now in the foreseeable future. And it is not just flat linen that is being advantaged – uniforms and workwear are also getting the streamlined treatment. Inwatec continues to impress with its vision and, now a part of Jensen Group, the nerds are well and truly in the fold of the mainstream industrial textile care movement.
According to Jensen’s Nicolas Gostony, speaking shortly after Texcare 2024: “Exciting innovations on display were our range of flexible towel feeding systems, including manual, automated and even fully automated solutions: In the automated solution, a THOR.Towel separated and transferred towels to an operator who can speed up the feeding process by up to 83%, achieving 1100 pieces/hour (PPOH) compared to 600 PPOH in a fully manual process. The THOR. Towel feeder is particularly popular in Japan, where workforce is scarce, and this exhibition marks the solution’s first appearance at an exhibition.
The BLIZZ robot for fully automated towel feeding comes with a redesign that allows for more buffer inside the machine, ensuring a stable performance throughout the day – handling 500 small and large pieces in mixed batches.
A significant highlight at the booth were the three state-of-the art flatwork finishing lines, all connected to an impressive Jenway transport and storage system. The Jenway conveyor system equipped with track-and-trace and various sorting and eject technologies connected three ironer lines with Express Pro (see case study, pages 26-27) and KliQ feeders followed by Jensen’s new Silverline folder with reversing conveyors and space-saving inline stackers.
Demonstrations at the booth showed a peak production of 2000 sheets per hour in two lanes on the new Express Pro feeder thanks to four feeding stations for fast corner-less feeding.
According to Kannegiesser, the variety of textiles to be processed is constantly increasing. quality and flexibility requirements are increasing. At the same time, more intense competition requires the minimisation of production costs. The SynchroPro series will adapt to all these challenges, it says: “The system combines performance, process stability and quality to create a perfectly harmonious feeding process without compromise.”
This sounds perfect, so how could the successful feeders of the Synchro series be further improved, one has to ask? The answer, says Kanegiesser, is SwiftCare. The term ‘Swift’ in this case refers to the improved net performance of the SynchroPro and ‘Care’ complements the care, handling and precision of each individual laundry item.
The Synchro clamp enables reliable fast spreading, releasing and depositing of a wide variety of articles. Thick or thin, small or large, polyester or 100% cotton? It doesn’t matter. The large, wide-open clamping area defines the process entry and is fast and gentle on the linen.
Servotronic is what Kanegiesser calls the combination of servo electronics, servo drive and sensor technology to achieve higher acceleration and ensures transport precision as well as process stability. Operators won’t have to wait for the next item, resulting in shorter process time.
The swivable bar ensures faster feeding process with ideal depositing and tension for a wide range of articles. Its lift function ensures the highest edge quality on the market. With the swivable bar, the leading edge gets into the feeder with perfect quality. The item is elegantly picked up, gently laid down without overspreading and fixed with the strong vacuum without a clamping bar.
A vacuum force five times higher than previous models synchronises the transfer and clamping bar-free article guidance.
Whatever the weight of the items, the vacuum gives maximum support and the improved article transport is faster and more reliable than ever before. “The SYNCHRO PRO and its SWIFTCARE feeding principle directs the feeding process piece by piece towards a perfectly synchronised symphony. The outcome is always a true harmony between swift performance and careful linen treatment – without compromise,”says Kannegiesser.
Meanwhile, CLM Texfinity, emphasises that the proper feeding and folding of textiles is absolutely critical for business success. “This process not only impacts productivity but also determines the final quality of the textiles. To this end CLMTexfinity has developed a range of innovative solutions to simplify and enhance these operations,” says the company. CLMTexfinity offers a variety of feeders designed for different operational needs.
S.feed s is built for high-production laundries, featuring 3 or 4 stations for precise and efficient feeding.
S.feed s Plus is an enhanced version of the highly regarded S.feed s feeder, significantly boosting efficiency by adding an intermediate buffer position between the feeding and spreading clamps. This innovation reduces the number of operators required while increasing throughput.
S.feed m is a manual feeder that balances reability with ease of use. S.feed offers a flexible remote feeding system designed to optimise high-speed ironing lines. These feeders not only improve efficiency but also reduce the need for manual handling, ensuring consistent and highquality textile processing, says CLM Texfinity.
The S.iron c is CLMTexfinity’s pinnacle of ironing innovation, it says, offering performance with speeds up to 60 m/ min, and available in both gas and steam versions not only maximizes productivity but also reduces operational costs. Its design features direct drive, programmable speed differences between rolls, and a patented stainless steel chest design ensuring optimal heat distribution and quality ironing across various linen types. This machine exemplifies flexibility with multiple roll options.
These solutions allow laundries to tailor their ironing processes to exact specifications, delivering outstanding results while reducing energy and labour costs. Once the textiles are washed and ironed, proper folding ensures a neat and professional finish. The S.fold series from CLMTexfinity provides specialised solutions for different textile items.
S.fold l for large pieces, offers customisable folding patterns and stacking options to enhance workflow. while S.fold s has been developed for smaller items like napkins and pillowcases. S.fold m folds and stacks on multiple lanes directly within the machine.
Visitors to The Clean Show might be interested in catching up with Lavatec where, in addition to its line-up of tunnel washers, washer extractors and drying systems, the comany will showcase its finishing partnership with Vega Systems. The flatwork equipment has been chosen because it complements Lavatec’s own reputation for high performance, productivity, and reliability, says the company.
Vega Transpeed 3S1 is a high speed, three-station feeder system capable of processing sheets, heavy duvet covers, and high quality table linens. With a working width up to 157” wide, this machine offers up to four large-piece adjustable height clipping stations, a combination of one or two feeding lanes for large pieces and a movable feeding bed with multiple lanes for manual feeding.
Vega Fold 2S is a cross-folder built to accommodate a wider cross-fold section. With a working width up to 157-inches and a wider cross-fold section, this unit can process large pieces with only two lateral folds, while still offering a third lateral fold option. This unit is equipped with two automatic sorting stackers standard inside the frame of the machine that saves valuable floor space, with the option of adding a third automatic sorting stacker. Two separate air pressures are designed for thicker and thinner linen.
Vega Multifold Super 2.2 is a high quality full-dry folder that makes all lateral folds with mechanical knives to handle thick terry and heavy full-dry products. All crossfolds are performed by reverse belt folding technology. With a processing capability of up to 86” long, the MultiFold Super is available with three or four automatic sorting stackers, eliminating the need to pre-sort full-dry items by size. All finished stacks are either directed to an operator or ready for automatic transfer to a take-away conveyor.
The Vega Multifold 4S is a towel folder, sorter, and automatic stacker that many commercial laundries prefer. It handles a variety of towel sizes and can be configured for different folding needs.
This unit performs lateral folds with air knives and all cross-folds by belt reverse folding technology. Like the MultiFold Super, this unit and handle items up to 86” long with automatic sorting up to four sizes, and can be configured for manual or automatic transfer of stacked goods.(See Lavatec and Vega at Booth 1303 or visit www.lltusa.com )
GMP, meanwhile, a stalwart of the ironer line, flags up the GMP E2 line of flatwork ironers “which can be definitely labelled a market success,” according to Vera Simon of GMP.
“Today, E2 line positions as the leading product in the small and medium segment of chest heated ironers. The innovative approach to professional ironing defined by the launch motto ‘Designed Around You’ has proven being mostly appreciated by our worldwide customers and distributors, especially when it comes to the improved interaction between operator and machine.
“The integrated operator training and the troubleshooting sections offer a great added value to the equipment, granting a smooth user experience also for inexperienced operators and a reduction of service calls for the distributors.”
As well as fulfilling customer requirements, E2 supports the distributor, says simon, because:
- It provides great troubleshooting help for the service team
- It features log file keeping records of the last 50 events connected to errors and it registers the maximum daily temperatures
- It includes a test program section for a quick troubleshooting
- It gives a service advice notice.
“In fact,” says Simon, “E2 does not just iron, E2 trains the operator, suggesting best process practices and clearing operational doubts. E2 communicates with the user with simple and clear messages while the GEMINI twin sensor system solves the most common problem of ironers: localised overheating, by a constant monitoring of temperatures across the roller surface.”
The MYPROGRAMS section allows the operator to create and save up to 50 customised ironing programs, enabing the creation of work standards key to the efficiency of the whole laundry process.
E2 also contributes to saving energy thanks to Sleep Mode that automatically switches to a rest mode when unuse is detected.
GMP’s decision to use a steel chest with a specific protective hard-chrome plating treatment guarantees three years against corrosion and a facilitated cleaning of the ironing surface from residues (detergents, starch, limescale and so on) extends life and reliability.
Last but not least, GMP offers as a standard for all E2 line models the best roller cover technology available on the market, with a thick Meta-Aramid roller felt (400 g/m2), extremely resistant to heat, hydrolysis and even small operational mistakes, offering a lifespan of 4.000 working hoursl.
For the most exigent customers, lamellar spring padding technology ‘TENAX’ is available as an option and comes with a five-year warranty over the roller surface.
Meanwhile, Girbau’s PC Series ironers set a new standard, claims the Spanish manufacturer. “In the fast-paced world of industrial laundry, speed means nothing without consistency. Whether you’re managing linens for healthcare, hospitality, or institutional operations, your ironer isn’t just a machine—it’s the final handshake between your service and your customer. And that handshake better be crisp,” says Girbau.
With working widths of up to 3,500 mm and ironing speeds up to 50 m/min, the PC Series is built to handle high volumes without breaking a sweat. Whether a team is pressing bed sheets, tablecloths, or delicate items with zippers or buttons, the PC ironer adapts effortlessly with customised programmes and independent roller control, says Girbau, adding that what sets the PC apart is not just power— it’s precision. The exclusive S-Coil heating system ensures uniform temperature distribution across the ironing surface, eliminating cold zones and ensuring that every piece is finished with immaculate consistency.
Lapauw steams ahead with flexible chest ironer
Wim Demeyer of Lapauw is keen to share information on the success of the Lapauw hinged chest which he says is the only flexible chest that works with steam heating
“Lapauw has seen an increase in orders for steam-heated ironers for some time now. Steam boilers and systems are becoming increasingly efficient, making operations with the steam heated ironer more energy-efficient. The steam ironer itself also offers numerous advantages, one of the most important of which is easy maintenance.
“However, steam heating is not compatible with the thin, flexible chest, as high steam pressures exert high forces on the thin chest, which can lead to cracks and deformation.”
That’s where Lapauw comes in, he explains: “Lapauw is one of the very few manufacturers that still has ‘home-grown’ chest manufacturing. Moreover, Lapauw is the only manufacturer with a dedicated chest for gas heating and steam heating.”
The Lapauw steam chest consists out of 2 thick chest halves that are joined with a hinge:
– The thickness of the chest halves provide the necessary robustness to withstand the high steam pressure of 8-15 bar without bending or leaking.
- The hinge connecting the two chest halves offers the same advantage as a flexible ironing plate: an ironing path just as long as with a thin, flexible plate.
- The chest material is made of carbon steel, which provides optimal heat transfer and thus ensures a uniform temperature across the entire ironing surface.
Like the thin, flexible chest of Lapauw gas ironer, the steam ironer is also equipped with parallel steam circuits, ensuring maximum efficiency.“Naturally, the gas ironer with a thin, flexible chest remains an important part of the Lapauw range, as does the electrically heated ironer.
The heat exchanger of the electric ironer has exactly the same shape and dimensions as the gas-heated version, so a gas-heated ironer can be easily converted into an electric ironer and vice versa, even on-site in the laundry., explains Demeyer.
Pre Texcare International 2024, Demeyer told LCNi: “First of all we see that the market for chest heated ironers is picking up rapidly. As tourism is already surpassing pre-Covid levels, laundries need higher production capacities and the small, commercial laundries ‘grow out’ of their roll-heated ironers rapidly, replacing them with a single roll chest ironer with folder. Here Lapauw offers a wide range, from 800 mm diameter up to 1600 mm roll diameter, while the flexible chest technology combines efficiency with a high quality finish.
“Needless to say that the spiraling energy costs also still are an issue.”
The IronMAX is the latest generation 2-roll and 3-roll diameter 1200 mm ironer. With features like a heated bridge that spans more than 1 metre, the individual Lapauw spring technology and true parallel circuit for the thermal oil (gas heated versions) and steam (steam heated versions), the IronMAX is one of the most efficient ironers in the industry, offering an energy consumption of lower than 0,9 kWh/kg removed water.
“Next to increased demand for production capacity, the post-COVID world sees another issue : increased cost of personnel and difficulties to find and keep people.
This prompts the laundries to put their efforts on automatisation and look for smart feeding and folding solutions.
Together with the Japanese manufacturer, TOTO, Lapauw offers a wide range of feeding and folding solutions, among them the VS-line folding equipment.
The VS folders are large piece folders which have 3 to 5 individual stackers that are positioned inside of the footprint. This not only allows you to save valuable space (no stackers on the side) but also to already sort the folded linen to size, which reduces the workload of the personnel in the finishing and expedition departments.Additionally, we also offer centralised conveyors.”
