Part I: Laundry Start-Up Procedures – Tips and Guidance
First in a Two-Part Series
As companies finalize plans to reopen plants in the coming weeks, a group of industry suppliers have offered tips on start-up procedures aimed at bringing plants back online quickly and safely with quality processing. Supplier companies (and one individual industry veteran) that contributed to the first installment of this two-part article include:
Chicago Dryer Co.
Chicago® has long been involved in the start-up and installation of numerous laundry operations worldwide for hospitality, healthcare, government, etc. Initial system/equipment start-ups/installation go hand-in-hand. The supplier and customer need to ensure that utility connection points as well as having sufficient utilities and space clearances are available. If this is not accomplished, expect major delays with installation and start-up. It’s always best to make utility installation the responsibility of the supplier. This requires much coordination between the customer and equipment supplier. Start-up procedures should be part of the system/equipment procurement process, which takes place long before the actual start up, so plan ahead. Issues such as having products available to process and ensuring that new equipment is stored properly prior to installation is key, also quality-assurance indicators applicable to safety and productivity of the purchased system are very important. All this ensures that the customer is satisfied and that proper training of employees is part of the process. Everything begins during start-up; not later.
Chicago suggests that prior to shutting down ironing systems that each heating surface for heated rolls or chest be protected from moisture. The impact of COVID-19 in the hospitality industry is likely to have reduced occupancies, so this would be a good opportunity to go over all laundry equipment for the purpose of addressing maintenance needs.
Equipment warranties covering start-up and beyond are important, ensuring the manufacturer and customer are fully involved long after installation and start-up. www.chidry.com
Charles Hawkins, an industry veteran and previous Professional Management Institute (PMI) faculty member
Some things are based on what you did to shut down or mothball the plant.
Did you drain the boiler? I would have drained it to prevent any rust buildup while the plant was shut down. If you didn’t drain the boiler, I would do many blowdowns after bringing the boiler to pressure. Continue blowdowns until there is no rust or sediment in the blowdown. Purge all steam and condensate lines. You should assume rust and sediment has built up. This will get into the washers when they steam to temperature.
Purge the air system after coming up to pressure. Any sediment could cause fouling of actuators, causing long-term maintenance headaches.
Purge the water lines to remove any rust and sediment. You do not want this getting into your washers.
Bring the chemical company in to review the chemicals. Test them for continued strength. Some chemicals may need to be disposed of and replaced if they have sat for too long. Test all chemical delivery systems to ensure there are no blockages in the lines.
I would test everything. Put every washer into manual mode and test every output function and inputs to ensure they are working properly. At a minimum, run an empty test formula.
Review the ironer chests. Depending on their condition, it will determine the level of cleaning necessary to restore the ironer back to full service. It is reasonable to expect that chests sitting for a period of time will develop corrosion. This also could lead to a changing of the ironer pads. If you anticipate needing ironer pads, now is the time to get them on order. If you wait until everyone else is trying to bring their plants back online, there could be a shortage of ironer supplies. 0520chawkins@gmail.com
Ellis Corp.
Ellis Corp. recently announced a special offer inspired by COVID-19 – the company is making its entire library of online maintenance videos, offered through its Uptime Control program – available to operators at no charge as they begin the process of ramping up equipment for a resumption of operations in the wake of COVID-19. “These videos can be used for training or maintenance, while we all prepare for business to come back,” said President Bob Fesmire Jr. “Please tell us what else you may be looking for in terms of video training. Thank you and stay safe!”
In a separate message, the company reiterated that it remains open for business and welcomes inquiries on parts, 24- hour technical support, and requests for assistance from service technicians through its Itasca, IL, headquarters. “The past few weeks have been unlike anything we have ever seen, and we are all adjusting to a new reality that seems anything but normal,” Fesmire said. “Please feel free to contact us directly with any questions.” www.elliscorp.com
G.A. Braun Inc.
One of the main culprits that inhibit and delay the start-up of equipment that has been shut down or idled for a period of time is moisture. It is equally important to properly shut down equipment to ward off the potential issues that moisture can create as it is to be concerned about its impact when restarting equipment. Laundry operators should consider the following questions when reviewing start-up procedures:
- Were air lines and air-controlled components cleared of moisture to avoid internal corrosion that may affect the functionality of air cylinders and switches during the start-up operation?
- Were reuse water tanks – either free-standing or on tunnel washers – and presses, drained of water, cleaned and dried out to prevent biofilm contamination?
- Have ironer chests been blown out? Condensation is usually acidic in nature, which will advance corrosion and oxidation. Have the ironers received an extra coat of wax to ensure that the chests do not oxidize?
- Was the plant HVAC system kept on and temperature maintained at some nominal level? If not, humidity could have risen in the facility, causing oxidization on noncoated carbon-steel components.
- There are resolutions to addressing moisture-related issues. However, unfortunately the replacement of parts that have internal corrosion could be problematic and costly.
As a laundry facility begins the process of restarting operations, one of the first things to do is to assess the equipment. This is done not only to determine if there will be moisture-related issues upon start-up, but it is imperative that all seals be properly lubricated to avoid tears. www.gabraun.com
Girbau Industrial
- It’s really important to have planned maintenance during this downtime. This was the time to have the machines serviced to have them “ready to go” when you are back up and running at 100%, avoiding any stops in production.
- This downtime would’ve allowed you to fully and properly clean the areas surrounding the equipment.
- Re-plan and/or re-check the workflow of the laundry … try to correct any inconsistencies or procedures to maximize the processing and time.
- Make a checklist of everything that has been done during this time.
- Be proactive and get samples of linen from new customers, check your washing process (involve your chemical supplier on it), drying procedures and commission finishing machines, such as ironers/feeders/folders.
- Ensure that your staff is properly trained! Spend some time with you current staff and go through any challenges they may have. Retrain them if need be. www.girbauindustrial.com