SYRACUSE, N.Y. — Washer-extractors come in four general types with specific sizes within each category. These are the open pocket, the top side loader, the tilting side loader and the end loader.
There are a number of features that are common to all four types. All are typically controlled by some type of microprocessor, with many now using touch screens to enhance the ease of programming. Also, all use either a suspension made up of coil springs and shocks or one that utilizes air bags, and most are inverter-driven.
Specifically, the washer-extractors examined here are not your average machines. These machines are built exceptionally rugged and serve industrial applications for which other types of washer-extractors may not be suitable. Most industrial washers, with proper preventative maintenance, will last for many years of service.
OPEN POCKET
The first type of washer-extractor I’ll review is the open pocket. Open-pocket washer-extractors are the typical choice for the commercial laundry, processing larger batches of various goods types. They are front-loading machines and are used in manual, semi- and fully automated wash alleys. Let’s take a look at each operating scenario.
Many of the early commercial wash alleys were configured to process large loads of varying goods types. Prior to the advent of more sophisticated automation techniques and controls, these wash alleys were set up with three to 10 open-pocket washer-extractors and one to five industrial dryers.
In the typical manual wash alley, the washer-extractor tilts back using a set of hydraulically actuated cylinders. The tilt angle is important, as it allows for easier loading than if the washer-extractor were loaded in the upright position. Most open pockets utilize a 20- to 28-degree angle of tilt for optimal positioning during the loading step. Goods are then loaded either directly from a laundry cart or, more commonly, with a sling system. The operator first positions the bag over the open door and then pushes the bag fully into the opening while pulling the draw string, allowing the goods to fall into the cylinder.
This manual loading process is still in use in many laundries today and is an area that has magnified the need for a safer and more ergonomic solution. There have been systems developed to address this need.
The second step in the manual wash alley is unloading the washer-extractor and getting the goods transferred to the dryers. Open-pocket washer-extractors allow for a forward tilt angle of between 15 and 20 degrees, providing optimal positioning to unload into a cart. During the manual unload process, the operator spins the basket via two hand controls, allowing the goods to exit the washer into a cart. Again, this process requires the cart to be held close to the machine and typically takes at least two carts, depending on the size of the washer.
In many cases, a sling bag lines the cart, and the bag is attached to a hoist when full. The sling bag is then raised back up into the rail system, allowing movement over to the dryer. These systems are typically labor-intensive and do not provide the best ergonomic environment for the operators.
Besides the safety concerns noted, the other obvious downside is the amount of labor needed to run the wash alley and the reduced productivity associated with a completely manual environment. With the potential for injury, ergonomic issues and an aging workforce, many commercial laundries have evolved in recent years to use semi-automated or fully automated systems.
The semi-automated system still carries with it the requirement to manually load washers, hence the term “semi-automated.” In this system, the washer-extractor unloading process, as well as the dryer loading process, has been automated. The open-pocket washer-extractor allows the machine to automatically tilt forward and unload to a loose goods shuttle, conveyor or to one of the loading solutions available on the market. Once unloaded to the automated shuttle system, the shuttle then transports the goods to a dryer and automatically loads them. This eliminates the manual unload step, saving time and the potential ergonomic issues associated with this process.
Two manufacturers also offer a “shuttleless” solution, allowing greater flexibility and increased productivity for fully automated environments.
The last operating environment is the fully automated wash alley. In this type of environment, open-pocket washer-extractors are loaded from an automated rail system using sling bags or from an automated conveyor system.
Most typically, the washer-extractor is equipped with an automated load chute that deploys in place during the loading step, allowing the overhead sling to drop directly into the washer-extractor. Once loading is complete, the chute swings up and out of the way, the door closes and the washer tilts level (slight tilt is recommended for the wash process) to begin the washing process. When washing is complete, the washer automatically unloads using the same method(s) as described in the semi-automated systems earlier.
The fully automated system offers a number of obvious advantages.
First is the labor savings achieved by removing the need for operators to manually move soiled goods around in carts or sling bags and manually load them into the washer-extractors or dryers. Fully automated systems remove the safety hazards associated with manual loading and unloading. However, both the semi-automated and fully automated systems must be protected, as there is now automated equipment moving without human intervention (“hazardous motion”).
Another advantage is productivity. There is typically no lag in the loading phase of the washer-extractors. When a washer completes the unloading step, it immediately readies itself to be loaded again.
Most fully automated systems have the next load pre-staged and as soon as the washer is ready to load, it is loaded. There is no waiting for the operator to move in the carts or pull in the sling bags. Also, the automated loading process is usually much faster than the manual loading process, assuming the rail delivery system is properly designed, and is safer for the operators.
There is one other less obvious advantage: capacity (increased productivity). When manually loading, the washer-extractor is often under-loaded as compared to its rated capacity. This can be attributed to the operator’s inability to hand-load this rated capacity into the washer in a safe manner. Using the fully automated solution guarantees that washer-extractors will be loaded to full stated capacity each and every time, improving throughput.
Check back Tuesday for the conclusion.
Have a question or comment? E-mail our editor Matt Poe at [email protected].