Shining a light into the tunnel

23 March 2022



Tunnel washers are the leading lights for commercial and industrial laundries and with good reason. Nevertheless, massive advances in technology over the past few years have fine-honed their considerable existing advantages, writes Kathy Bowry


Tunnel washers, or continuous batch washers (CBW), are still the latest big development in commercial laundry despite them having been among us for more than 40-plus years. Milnor developed its first CBW in 1979. The company continued to innovate the technology registering a slew of trade marks including PulseFlow Technology, Rinsave, Miltouch…the list goes on. Milnor probably has more registered trade marks and patents (not just on their CBWs) than any other laundry equipment manufacturer, but that doesn’t mean its competitors have been slow at coming forward with innovations.

Jensen

Latest news from Jensen tells us that its washers can be customised with all sorts of dedicated options. “Heavy-duty laundries process high linen volumes for which a solution a Jensen tunnel washer which is equipped with the options customers really need for an excellent wash quality. At the same time, laundries save energy, resources and therefore money. Accorsing to Jensen’s Gerda Jank: “In the laundry business, and especially for Jensen, productivity, efficiency and growth are vital key words. This is what interests laundry managers most; Jensen’s most versatile tunnel washers revolutionized the market as they reuse energy and water internally in a most efficient and sustainable way.”

Dedicated options, says the company, for all kind of quality requirements include the newly patented UVClean system which prevents bacterial growth in double drum sections automatically and focuses on hygiene without any chemical supply. The development represents Jensen’s commitment to achieving sanitary results, avoiding the use of additional chemicals and providing low-maintenance systems. In addition, UVClean can also be retrofitted.

QuickSoak (a registered patent) provides an extra shower for the linen in the prewash for maximum soaking and superior wash results and allows processing of the greatest variety of linen types while keeping consumption at extremely low levels and achieving best wash performance and highest productivity. As QuickSoak does not consume any utilities, no resources are wasted.

EcoTune controls the exact rotation of the drum and ensures a smooth operation. It optimises synchronisation of the drive motor and the frequency converter, thus ensuring much quieter operation. In addition, the more precise adjustment of water levels allows for lower water and energy consumption.

EcoSafeguard is the automatic monitoring and logging of pH and conductivity value as well as water hardness and ensures a higher quality assurance in the laundry, with more satisfied customers and higher productivity thanks to lower rewash.

Meanwhile, EcoTanks contribute to sustainability and are additional large volume storage tanks for an even better separation and up to 100% higher recovery of process water, especially for frequent colour changes.

Jank says that Jensen tunnel washers reach very low consumption values of only 1.6 l/kg or 0.19 gal./lbs. This result is outstanding, she says, and helps laundries to grow their business, be more productive and efficient.

Kannegiesser

Kanegiesser has calculated that six factors influence sustainability in washing. “In a laundry, several tonnes of linen are processed every day. Textile service providers want to provide their customers with impeccable linen. First and foremost, the linen must not have a single stain and must be hygienically clean. However, it is also important that the laundry is processed in a sustainable way,” it says.

To this end, Kannegiesser believes the following six features make its Power Trans Vario washing process as sustainable as possible. First of these factors, combined, says Kannegiesser, are: Mechanical action, Time, Temperature and Chemicals. This is also described as the ‘Sinner Circle’. If one factor is increased, other factors can be reduced. In the case of ActiveDrop, the highly efficient mechanical wash action ensures that the textiles are permanently compressed and rinsed instead of just being rubbed on the textile surface. This means chemicals can be reduced.

The second factor is best use of the energy supplied to the machine. For thermal or chemo-thermal disinfection, says Kannegiesser, the temperature must be controlled and maintained for a certain time.PowerTrans Vario has insulated drum walls with granulate filling both at the beginning and at the end of the main wash. They reduce heat transfer from the main wash zone to the colder pre-wash and rinse zone. In combination with the high-quality foam insulation (60 mm for clear wash chambers and 40 mm for heating chambers) this ensures a completely encapsulated main wash area. Heat radiation to the neighbouring drum areas and to the environment is thus reduced and the required temperatures can be maintained without reheating.

The third factor is water and chemicals - not too much and not too little. According to Kannegiesser, every batch of linen should be processed with exactly the required amount of water and chemicals - no more, no less. With the straight drum wall design of the PowerTrans Vario, Kannegiesser guarantees complete batch separation. This means that every batch is treated individually according to its true batch size and its wash programme. In particular, the ratio metric dosing and the liquor ratio are precisely adjusted. Since liquor mixing between neighbouring batches is avoided, there is no unnecessary dilution.

Fourth are special steam injectors of the VENTURI type to ensure maximum utilisation of the injected heat. This design works without the addition of compressed air during steam injection. The energy required to generate the compressed air can thus be saved.

At five in Kannegiesser’s league table for efficiency comes its energy –saving drive system. The motor of the PowerTrans Vario is controlled by a frequency converter. This frequency converter reduces the starting currents and the torque peaks. Kannegiesser also uses drive rollers made of POM (PolyOxyMethylene) an ideal plastic which, in addition has a particularly low coefficient of friction so less total energy is required for the drive.

Finally, the magic six. Large, insulated cockpit tanks for maximum water recovery. The purpose of the integrated recovery tanks is to recover water from the washing process. But this is not just about the water as a raw material. The process water is loaded with energy and chemicals. If the recovery tanks are too small, the machine consumes more cold fresh water, which increases the water and heating requirements. Kannegiesser machines have large and fully thermally insulated recovery tanks as standard. Less fresh water needs to be drawn and less heating is required.

Girbau

Mercé Bover at Girbau has this to say about the Vic, Spain-based manufacturer's tunnels. "The Girbau Industrial Business Unit is made up of a multi-skilled team of professionals with experience as engineers, maintenance technicians, project managers, experts in energy efficiency and processes and others. It is focused on industrial laundries handling over 5 tonnes a day, to offer them comprehensive advice, prioritising the comprehensive advice, prioritising the most innovative, efficient and effective resources. 

"This, together with our star products such as the Girbau TBS50 batch washer, continue to offer guarantees of success for our customers. In today's changing world, its features offer the perfect solution for most high and medium-output laundries. 

"Variations in the amount and type of linen to be processed, different washing processes, working hours, rotating staff and so on alter working conditions in the laundry as a whole, greatly complicating its management," says Boyer. 

"This is why the solutions offered by the TBS50 batch washer make it possible to meet requirements for high throughput (up to 1,500 kg/h) and efficiency (in terms of water, energy and chemicals), while at the same time being extremely easy to operate and change working conditions. 

The TBS50 batch washer is characterised by its great versatility, allowing any washing system to be added and offering easy programming and use. Its mechanical simplicity means it needs little maintenance throughout its life.

"In the design phase the customer will be supported to make sure they find the right solution for their laundry, in terms of layout, average and peak throughput and more. Moreover, working together with the chemical supplier, the washing process will be customised to meet the customer's requirements. On the basis of the three proven models we supply, MULTI, HYGIEN and FLEXI, which offer a range of options and accessories, whatever is necessary."


EMERALD TEXTILES SELECTS LAVATEC EQUIPMENT TO ACHIEVE HIGHER CAPACITIES AND EFFICIENCIES

The state of California is famous for many things, and especially for its tourism, motion picture and television industries. It’s also known as the leader for energy conservation in the United States, which is certain to continue as an important consideration for many industries this decade and in the future, says Lavatec.

Emerald Textiles, recognised as the largest commercial healthcare laundry and linen service business in the western part of the country with headquarters in San Diego, raised their conservation standards years ago. Formed as an environmentally responsible healthcare laundry provider, each equipment purchase decision is based on the strict California regulations and what’s best for their customers.

Due to the growing demand and need for energy efficiency improvements at the Commerce commercial linen and laundry facility in Los Angeles, one of the capital investments Emerald made as part of a multimillion dollar commitment was the purchase of a new continuous batch washer system (CBW). Company leaders decided their best solution was to turn again to Lavatec Laundry Technology, Inc.

Emerald had first installed a Lavatec CBW system in 2019 that exceeded all expectations. Consequently, they also have invested in a new rail and conveyor system that is scheduled for installation this summer. It will be the next phase to help the facility nearly double its volume in 2022.

“These Lavatec CBW systems are right there with the most energy efficient tunnel systems on the market,” explains Sean Mageean, the Commerce facility’s general manager. “Energy savings is very important to us. We do our part to preserve natural resources by regularly investing in energy and water saving equipment so our healthcare customers can feel good about choosing Emerald Textiles.”

Major acquisition expected to propel growth

Timing of the new equipment and increased volume projections coincide with a 4 December announcement that Emerald Textiles had acquired the west coast assets of the Angelica Corporation, a national healthcare linen service provider. The acquisition included nine facilities, allowing Emerald to expand its western footprint into Phoenix and Las Vegas and strengthen its northern and southern California markets.

“We are focused on building out our strong network of customers and expanding our footprint of facilities, while investing $35 million in capital across our locations to create world-class linen and commercial laundry facilities in the west,” says Andy Kratky, Emerald Textile’s CEO. “At the Commerce facility, we have welcomed several newly won healthcare customers that is the primary growth for 2022, along with 100% renewals of linen services to all our acute hospitals and medical centers.”

Located in a business park, the 70,000 square-foot building opened in 1950. But the energy crisis in the early 1970s would lead to new regulations for businesses in the state.

The California Energy Commission was created and in 1978, it adopted stringent energy efficiency standards requiring businesses to decrease the energy intensity and carbon emissions of their equipment and buildings. Emerald has championed those efforts and it led to their San Diego facility winning a Savings by Design Award in 2011, which is sponsored by the California Public Utilities Commission and San Diego Gas & Electric. In 2020, the Commerce facility was recognized by the Los Angeles County Sanitation District for converting waste into resources by reducing the amount of wastewater.

New equipment to meet greater demands

Emerald’s new Lavatec CBW system in Commerce went online the first week of October 2021. It included a custom built, 12-compartment bottom transfer tunnel washer, a new 50-bar, LP583S washer extractor speed press, six pre-owned TT-745 gas dryers, a 4-pocket loading conveyor and shuttle conveyor, and a dryer shuttle control cabinet. It’s the second time in the last three years they have chosen Lavatec.

“In 2019, we purchased a Lavatec CBW system to replace one from Jensen that had reached the end of its useful life,” said Mageean, who has worked in the linen and garment service industry for 26 years. He’s been with Emerald for the last three.

“The system installed then included a new loading conveyor, a 12 module, 200-pound pocket CBW, 50-bar press extractor, shuttle system and five dryers. This new system replaced another Jensen and compliments the other. Price, dependability and support were all factored into the decision to go with the Lavatec systems in our facility.”

Mageean indicated his facility is ready to take on a greater workload after the new acquisitions announcement was made in December 2021.

LOW CONSUMPTION: Depending on the wash process, Jensen tunnel washers reach very low consumption values of only 1.6 l/kg or 0.19 gal./lbs
EXTRA SHOWER:QuickSoak provides an extra shower for the linen for superior wash results
CHEMICAL FREE:The new patented UVClean system focuses on hygiene without any chemical supply
GREATER CAPACITY: The new Lavatec 12-compartment bottom transfer tunnel washer installed in December is helping Emerald to reach greater daily wash capacities
TEAM EFFORT: Key management at Emerald Textiles in Commerce include, from left to right: Jim Hernandez, director of engineering; general manager Sean Mageean; operations manager Alicia Silva; and chief engineer Luis Lopez.
HIGH VOLUME: Girbau’s TBS50 meets the requirements for high throughput
TEMPERATURE CONTROLLED:: PowerTrans Vario has insulated drum walls with granulate filling both at the beginning and at the end of the main wash


Privacy Policy
We have updated our privacy policy. In the latest update it explains what cookies are and how we use them on our site. To learn more about cookies and their benefits, please view our privacy policy. Please be aware that parts of this site will not function correctly if you disable cookies. By continuing to use this site, you consent to our use of cookies in accordance with our privacy policy unless you have disabled them.