How to empty +10,000 pockets a day

In Shanghai, China, the laundry company Fornet in 2015 established one of Asia’s most modern laundries where more than 10,000 pieces of garments are handled each day for both laundry and cleaning.

 

Such a significant volume needed extra attention from the beginning, and for that reason general manager Zhu Lijun was aware, that automation could play a part of the solution.

 

“We had identified the problem of emptying the pockets of 10,000 pieces of garments a day, and we realised that it was a hurdle that we needed to solve. I had read about Inwatec’s x-ray machine on the internet, and after a short dialogue, I went to Denmark to see the x-ray scanner in action on a Denmark laundry facility,” Zhu Lijun tells about the process.

 

Automation gives stability and efficiency

The setup in Shanghai that includes both x-ray scan of the garment and RFID-based sorting has now been running for more than a year, and Ms Zhu Lijun is certain, that she and her colleagues made the right choices from the beginning.

 

“Everything works excellent. It is a new laundry, and we have no historical data to compare with, but we’re sure that the automation is more efficient than a manual solution,” Ms Zhu Lijun reveals.

 

“Apart from helping us emptying the pockets, the setup also sorts the garments into nine different categories to pick the right washing or cleaning processes.  In that part of the equation, there is no doubt that the machine makes fewer errors than a human would do, and the speed is also higher and with fewer stops than a person could handle.”

 

Long distance service via the Internet

Ms Zhu Lijun had no worries choosing a Danish setup for the laundry in Shanghai, and time has proved, that she did not have to worry about having a service department 8,300 kilometres away.

 

“We have had very few issues so far, and when the line stops for some reason, we have solved it online without problems. It hasn’t been that complicated,” Ms Zhu Lijun tells.

Inwatec X-Ray Machines

Detect foreign items in your laundry

Our solution for efficient and high-quality detection of foreign elements for laundry allows you to handle up to 2,800 items per hour.

Due to the combination of X-Ray and highly advanced software, the machine detects and rejects laundry articles containing foreign elements such as pens, needles, knives, keys, coins, paper clips, hair needles or even softer objects as lip balms or lipsticks.
 
Moreover, the X-Ray scanner can connect with other modules such as a robotic picker and an advanced sorting system, where the laundry is automatically sorted out according to your wishes.
 
With the help of RFID chips, it allows you to define your sorting plan according to the material, size or color. By adjusting a Bag Packing Machine, it is possible to automatize the whole process.
 
Note: The X-ray Machine is not currently available in the US, but do not hesitate to contact us, if you are interested.
 
The Automatic Sorting Machine is the perfect solution for your automatic sorting of different soiled laundry items, e.g. linen, mops, rags, etc. The machine sorts based on weight control and can sort 2-3.000 pieces per hour. With the help of RFID-chips different kinds of laundry items can be recognized, correspondingly placed in the right container and finally transported automatically to the washing by the conveyor belt.

The Bag Packing Machine counts the items automatically and wraps the desired amount in a plastic bag. It is the perfect solution for automatic full-scale handling of small laundry articles such as mops or rags by handling 2.200 items/hour. The automated picker grasps them automatically laundry items with the correct RFID-chips or right weight to transfer them to the bag packing station. After the packing of the desired amount, the printer puts a label automatically with customer information on it. The vertical conveyor transports the wrapped and printed plastic bags to a higher level and drops the bags into a stand-by trolley to be ready for delivery.

 
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X-Ray Machines

British food industry demands empty pockets

Garments ruined because of forgotten pens and markers have been a big issue in the laundry industry for decades. More recently the demand of empty pockets has come from the food industry where the tiniest pieces can become significant problems.

“The recent years we have had more and more potential customers asking us specifically if we can offer them X-ray scanning of the laundry. It’s dominantly from the food industry, where even a small paper clip can be a huge expense if it drops from a rolled-up sleeve or a pocket into the production area,” tells Carl Heeley, General Manager at Johnsons Apparelmasters Hinckley office.

”These companies will do anything to minimise that risk, and when they ask for the possibility of scanning the garments for foreign elements. Of course, we would like to offer that shortly,” Carl Heeley added when visiting Inwatec in Odense to watch how an X-ray system could help solving the issues.

Fewer expenses to ruined garments

Apart from getting rid of unwanted elements in the washed clothes, Apparelmasters also wish to minimise the costs that occur because of garment destroyed when pens or markers are forgotten in pockets and not found until after washing the clothing.

“We have huge issues and expenses because of ruined garment. Every week we must replace 200 pieces of clothing. While the garments themselves obviously has a price, we also have expenses and a lot of frustration in the administration when we must search for replacements,” Carl Heeley admits before underlining that direct costs have less focus than giving the costumers the optimal product:

“Even though we expect huge savings if we introduce X-ray systems in our laundry, the main focus is actually on delivering better service to our customers, and this could be a game changer in a rather traditional business. If we can reduce the number of ruined garments, we will also be able to deliver the cleaned clothes as promised, and that would be a unique selling point for Johnsons Apparelmasters. We are not the only laundry that faces problems with ruined garments,” Carl Heeley says.

Safety is top priority at Berendsen

In the Danish laundry and textile services group, Berendsen, Clean Room business with washing, rental and maintenance of clean room clothing and accessories among other things, pharmaceutical, biotechnology, medical device and food industry across Europe has grown steadily in recent years.

Berendsen employs 800 people in clean room business in 11 laundries throughout Europe, and the volume means that the Director of Operations, Clean Room, Berendsen, Camilla Kondrup look closely at the next steps.

“Our primary motivations to invest in new equipment is that we are always working to enhance safety and quality in all our processes in Clean Room laundries, both in the handling of dirty clothes and equipment, washing and cleaning and packing and distribution,” says Camilla Kondrup.

Automatization for safety at working place

“We have business from the pharmaceutical industry, where they work with what we call the hazardous liquids”. Although our employees obviously wear special equipment when they sort and handle the clothes, there is a particular risk profile by working with these subjects. Among others, our clients count pharmaceutical companies working with development of various types of virus,” remarks Camilla Kondrup, who for that reason is considering whether X-ray technology and automated sorting can reduce the risk factor in clothes management.

“Our employees handles a lot of garments from the pharmaceutical industry, so we have full focus on maintaining maximum security. In time, we could consider robots to do the first handling of the laundry on arrival and to separate the garments, and we could perhaps also take full advantage automating other processes or the entire laundry operation. In the best world, we had no contact with certain types of clothing and equipment,” Camilla Kondrup continues.

In addition to the safety aspects of the work, Berendsen, like any other laundry, are working on how to further improve the quality of washing and handling of clothing and items in the future.

“When people are involved, there is always greater a possibility of errors than if sorting is fully automated and based on RFID-chips. If I must list the priorities of our investments, it is first and foremost about risk management. Next, it is about proper sorting. And finally, we are obviously keen on streamlining our processes with automation,” Camilla Kondrup concludes.

Airport X-Ray is not optimal for sorting of garments

 The type of X-ray machines found in airports worldwide operates brilliantly at new02spotting unwanted objects hidden in pockets and bags. But without associated software to interpret the scans, the performance is wholly dependent on the human watching the screen.

That is confirmed by the Swedish company TvNo Textil Service, who have invested in an X-ray machine of the airport type to find pens and other objects such as needles and knives in the laundry, to avoid the classic ink damage to clothing and needlestick injuries among employees.

“Since we bought our X-ray machine, we have reduced the number of ink injuries by 50 percent, but it is evident that we would like to decrease it even more. We also note constant challenges with all plastic pens as they are not visible on the screen,” said production engineer Anders Ohlsson, when he, along with two colleagues from the laundry were visiting Hvidkærvej in Odense.

 

Display requires constant attention

TvNo Textil Service has no fewer than 12 men employed in the sorting line, and during each working day, 24,000 pieces of garment pass through the X-ray machine. And while Anders Ohlsson has no doubts about the efficiency of the human resources at TvNo, he acknowledges that operating the X-ray machine is an arduous effort:

“We constantly have a person seated in front of the display. There is nothing that gets rejected automatically, and it is of course quite demanding in the long run,” Anders Ohlsson says, while watching a new test of typical problems like pens, credit cards and markers from the TvNo laundry run through Inwatec’s X-ray machine to see if the object is detected and rejected by the computer algorithms.

“It is not only pens that give damage to clothing. Lip balms are also a challenge in the winter season. We can not spot them with our existing X-ray system, and that leaves grease stains on clothes when a lip balm passes the washing machines and tumble dryers. We have the means to remove the stains, but we do not always discover the issues before the clothes are returned to the customer, and then it’s too late,” Anders Ohlsson explains.

 

Costly mistakes can be minimized

new04Buying new machinery also requires investments in engineering, logistics and training, but the board of the TvNo laundry are acutely aware that the return on investment could happen reasonable fast, and that recognition has brought the three-man delegation to Odense.

“We figured out that we still spend approximately 25,000 euros a year just to purchase the replacement for clothes that are destroyed by blots. On top of that expense we have the administrative cost associated with it, “says Anders Ohlsson.

How to connect the SiteManager – Tutorial

How to connect the SiteManager

  1. Locate the Secomea SiteManager inside the power cab
  2. Make sure the device is powered on (green LED)
  3. Make sure DEV1 is connected to the touch panel (PLC)
  4. Connect a Ethernet cable with Internet connection to UPLINK1
  5. When ‘STATUS’ is Solid Green the device is online
  6. Contact us for further Information

X-Ray Machine cuts labour costs in half in hospital laundries

claes Efficient X-Ray sorting machine leads to 50 percent staff reduction in hospital laundries; DFD Aalborg has experienced. For five years, none of the employees at the soiled side sorting has received a stab injury. Dirty laundry, sorted by the innovative X-Ray technology and RFID-Chips is not a future scenario – it already exists.

At “De Forenede Dampvaskerier” (DFD) in Aalborg, Denmark, there are no doubts for the division manager Morten Christensen, that the X-Ray technology is a must if a company still wants to play a significant role in the Danish laundry industry.

The manual sorting system at the laundry in Aalborg was replaced by a sorting system from Inwatec, which allows, with its X-Ray technology and advanced computer algorithms, to select and reject garments, when carrying foreign items before beeing sent to the washing machines.

“Following the costs, the X-Ray machine is a splendid investment. We have cut off our labour expenses in this business part. Since it was a development project, it needed some time until everything was installed and put in the right order. But it has resulted in savings of three headcounts each year. In other words, we halved our cost by using X-ray sorting of the garments”, said Morten Christensen.

X-ray technology secures the workplace

On top of the savings, no stab wounds have happened since the X-Ray machine arrived. In addition to the efficiency savings, Morten Christensen recognised as well, that the work environment at the particular department approved significantly. Securing the workplace were also a primary purpose of developing the machine.

“It is a success story, which builds on two pillars. On the one side, the injury caused by needles when sorting out pockets is painful and is provoking a direct stress for the employee. On top of that, it takes at least one year until the employee knows if any diseases are caught with the cut. In turn, this leaves the person constantly uncertain about possible consequences, and that results in psychical stress for the staff member,“ tells Morten Christensen, who have experienced 4-5 stab injuries at DFD Aalborg – fortunately, all these incidents happened in the past.

“We are rummaging in garments when they are rejected, but at least we know now on which piece we need to give more awareness. Since we started to use the X-Ray machine, no similar accidents and injuries have happened”, he declared.

Smoothly working prototype since five years

img_0615-1-01-01DFD in Aalborg was the first company which invested in an X-Ray sorting system from Inwatec and Morten Christensen does not hide his enthusiasm for having a prototype in his laundry. He mentions that it has given him a market advantage.

“The competitiveness of our business is a condition for further innovation and development. We are not allowed to stay and keep existing systems, if they probably may restrict us. Therefore, it is clearly a necessity for us to work together with Inwatec to develop this business,” told division manager in Aalborg, who also owns one of the first Mat-Rolling Machines from Inwatec.

The Mat-Rolling Machine was purchased in 2010 and a year later the X-Ray Machine was acquired as well. In accordance to Morten Christensen, the willingness for new investments and developments is existing, but the present Inwatec machines are well maintained, and updated with the newest software. In result, there are no other more efficient and productive machines on the market at this time which means there is no need for acquiring replacements.

“Our machines are a few years old, but they are still working perfectly. We need neither an X-Ray Machine nor a Mat-Rolling Machine right now, but we have some other machines on which we have to think about the replacement.”

Pockets hide all kinds of expensive problems

xray messeAt laundries all over Europe, one of the most expensive returning problems are items left in pockets of the garments. At Texcare International in Frankfurt in June, the X-ray machine from Inwatec drew a lot of attention as a possible solution.

“Pens are always a huge issue, but we keep finding all kinds of different things in the pockets. Scissors, screwdrivers, markers, wallets, phones, glasses and bottles. You name it – we have it,” tells Mathieu Decraene, who is Production Manager at Klaratex in Belgium.

“We have tried a lot of different campaigns where we want our customers to think about it, but in the long run, it doesn’t change a lot, and we still find a bucket full of different objects every day,” he adds.

Mindblowing solution to the problem

In Ilkeston, the UK, Giltbrook Cleaners have the same issues, and here Production Process Manager Ian Filsell concludes that the left objects often harm the business:

“It damages our business strategy when we have an entire batch destroyed because of one single pen we did not find. The replacement cost in textiles quickly reaches 100 Euro, so even if we stick to our one shift-teams, it looks like an investment in the X-ray technology would quickly pay back,” Ian Filsell reasons.

His Belgium colleague draws the same conclusion, and he admits that Klaratex wasn’t looking in that direction coming to the fair in Frankfurt:

“We were not aware that X-ray sorting could be a smart solution to our issue. I think that the Inwatec machine is a different and mindblowing take on how the sorting can be done. I hope that I will soon be able to test the sorting functions with our garments and textiles,” Mathieu Decraene says.