Smart tracking reduces loss of articles

Mads Andresen, Kent Pettersson (CEO of KåPI Tvätt), and Morgan Olsson (KåPI Tvätt Production Manager)

At the family-owned Swedish laundry KåPI Tvätt in Bengtsfors, management has been actively investing in the fight against lost inventory. The chosen solution is to chip mark all current garments, and as part of that process, KåPI Tvätt has just invested in an Inwatec setup, which includes an X-ray scanner, a UHF Chip reader, and a sorting line.

“We continue to lose 20-30 percent of our inventory every year, and considering that we spend between 7 and 10 million Swedish kroner (680,000-970,000 €) to on the purchase of new fabrics, it goes without saying that it is a fairly large amount, we can save when we get the systems up and running. We expect the ROI to happen in a few years,” says director Kent Pettersson.

The system will initially be set up in such a way that all pieces without an existing chip are rejected and only returned to the circulation when they are equipped with chips and registered in the system. This way it is expected that the process can be completed in a relatively short time span, and from the first day there will be significantly better control of all inventory in use.

Fewer employees in production – better quality
At KåPI Tvätt, there are currently between six and ten people working to sort the dirty laundry, which includes towels, sheets, tablecloths and working uniforms from hotels, restaurants and conference centers.

Part of the explanation for the many employees is that KåPI Tvätt manages many smaller pieces of garments and that handling requires many hands. The expectation is that this part of the workforce in the laundry will be minimized significantly.

“We will only need 3-4 people with the new equipment. Fundamentally, it is expensive to have so many employees in production, and we are very aware of the efficiency as much as possible. For a while, we have been convinced that more automation and more robots are the way forward, and this is a logical next step for us,” says Production Manager Morgan Olsson, who, together with Kent Pettersson, went to Inwatec’s headquarters in Odense to have a closer look at the selected machines.

New technology is popular among the employees
Some of the tasks in the sorting disappear with the new investment, but according to Morgan Olsson, the employees look forward to the changes:

“They get a simpler working day, and they eliminate some of the dirty features. It’s not popular to be the one to check and empty the pockets. Especially in workwear, there are lots of screws, pens and similar items which have to be sorted out. It takes too much time, but that task will be improved with the new X-ray system,” he says, while Kent Pettersson agrees:

“We see ourselves as an innovative company, and we are leaders in the private sector in Sweden. It also means that we are following the progress, and our employees expect that,” says the director.

Artificial Intelligence and robots make laundries smarter and safer

The sophisticated picker of Inwatec’s Robot Separator calculates the best picking-point of the garments.

Many routines and procedures in the industrial laundries are both heavy, filthy and potentially dangerous, and on top of that, employees risk making mistakes when executing repetitive tasks.

That is why the now mature solutions combining robots, artificial intelligence and automation come into the picture.

Among the tasks which are most obvious to get rid of is the sorting and handling of soiled side garments. With modern technology it is entirely possible to obtain a setup where an absolute minimum of human interaction is needed:

The soiled garments can be dumped on conveyors where robots pick the items one by one to feed an X-ray scanner that detects unwanted items hidden in the pockets. At the same time, an RFID chip reader is registering the individual garment to decide how it should be sorted for proper handling further on in the system.

All those tasks can be achieved with employees only needed to empty the pockets on the garments that are rejected by the x-ray – and to ensure that the system is running as it is supposed to.

The X-ray system’s Artificial Intelligence automatically detects foreign items (e.g. pens)  and rejects the respective laundry article.

Endless opportunities

The challenge recently has been to make those robots smart enough to replace all these the human functions, but with artificial intelligence, it is now possible to let the computer analyze massive amounts of data and then find patterns that open new possibilities for the laundry business.

An example could be systems based on vision sorting alone. This is very useful in laundry businesses where the garments aren’t tagged because the items represent such a low value that the tagging doesn’t make sense as a business case.

Read more: The future is getting closer to Whangarei in New Zealand

The potential business cases in the laundry world that can be done with the help from automation, robots and AI today are practically endless.

As a rule of thumb, you can say, that if a typical person can perform a mental task with less than one second of thought, we can probably automate it using AI either now or shortly.

There is no doubt that the human employees at the industrial laundries will perform jobs that are not as hard or fatiguing as today, and more focused on servicing the end users or creating value to the company in another way.

The future is getting closer to Whangarei

The future of the industrial laundry depends on robots and automation, and eventually, all the players on the market will need to go in that direction. So is the prediction from Steve Baker, General Manager of Apparelmaster Whangarei from the New Zealand city of the same name.

“We have to think of a business model that supports the investments, but I’m sure that the next important steps in our business are to reduce physical labor and automate internal logistics in the industrial laundries, pushing bins and trolleys around all day and carrying stacks of laundry from one place to another isn’t a great use of staff skills,” Steve Baker says.

Recently he traveled Germany, Belgium, Norway and Denmark together with a group of like-minded colleagues and representatives from JENSEN and Inwatec to watch how the newest equipment is being implemented in other laundries right now, and Steve Baker is confident that there is a place for improvement in his business as well.

“For us traveling from New Zealand to Europe to look at the large-scale operations is just like looking into the future and helps us to define and clarify our business decisions with confidence. It would be easy to become insular and miss out on maximizing our business opportunities if we stayed at home in the South Pacific and didn’t look to learn something from the finest laundries in the world,” Steve Baker tells.

New machinery gives new possibilities

“I have been following the development of the new technology with x-ray-scanners, robots, and automatic sorting at Inwatec for a couple of years now. In the perfect world, we would invest in a fully automated production line straight away, but we still need to make some calculations before doing so and measure the cost benefits equation for our size and scale of operation,” the general manager admits.

Apparelmaster Whangarei is located in the northernmost part of New Zealand, serving the area from the top of the island “Cape Reinga” to the northern edge of Auckland city and the customers are offered different solutions for workwear and hospitality linen rental services.

The 80 employees care for everything in the rental service that includes sorting, washing, cleaning and repairing as well as a door-to-door collection and delivery of the laundry to the customers. Steve Baker believes that he can use the available hands in better ways with the use of new technologies:

“Our company isn’t that big, as we produce 65 tons a week. But today we are working 10 hours a day, seven days a week, so an upgrade in our production facility will make it easier for us to take in new projects without doing costly nightshifts,” he says.

Physical tasks will be phased out

Apart from the possible upgrade in efficiency, Steve Baker is also very interested in how to make the working conditions at Apparelmaster Whangarei more attractive for the employees.

“The regulations in Europe are stricter than in New Zealand, but I think that we all have to find solutions on how to get rid of all the heavy manual tasks in the future. Fortunately, I think that the technology is coming to a point where it is possible.”

“We have a lot of physical work in our laundry, and it is hard and fatiguing. It’s not dangerous, but it wears people out, and automation and robots will be needed to make the laundry a better place to work,” he says.

Vraa Dampvaskeri focuses on innovation and automation

Robot technology, lots of automation and innovative use of all state-of-the-art technology in the market. Those are the ingredients in the recipe, which has secured the family-owned Vraa Dampvaskeri a position as one of the leading industrial laundries in Denmark. The headquarters locates in the northernmost part of Denmark in the town Vrå, but with branches in Aarhus, Fredericia, and Køge, Vraa Dampvaskeri services customers throughout the country as well as northern Germany and the southern part of Sweden.

According to CEO Jørgen Rasmussen, much of the explanation for the success of the company is that since the establishment in 1956, there has always been a strong will to invest in new technologies to make production as efficient as possible.

“Innovation and automation are in our blood at Vraa Dampvaskeri. For example, we have had our clothing tagged with chips since 1991, and in 1997 we took our automated sorting system into use. We have always been looking for improvements to our production line in general and especially in the field of automation,” says Jørgen Rasmussen, who recently invested in an Inwatec system, which will further improve the handling of the dirty laundry.

“The new automation options with a robot and an X-ray scanner have made us able to reduce the number of employees in the soiled site sorting, and it has enabled us to release some hands that we can use for something else. Regardless of how much we have automated over time, we have just become more people – now it’s just some other tasks they perform, “says Jørgen Rasmussen, who runs the family business with his two sons Thomas and Martin Rasmussen as well as daughter Stina Rasmussen who is CSR-manager.

Empty pockets a requirement in the food industry

With the new Inwatec-setup that connects to the existing sorting system, a robot separates the garments piece by piece before an X-ray machine checks for foreign elements hidden in the garments. If anything is found, the garment is automatically rejected for further inspection. This solution contributes to the fact that Vraa Dampvaskeri can also maintain its position as Denmark’s largest supplier of clothing to the food industry.

“We have a lot of customers in the food industry, where there is a strong focus on avoiding foreign objects in the clothes, and in this context, it was obvious for us to invest in an X-ray system that will enable us to meet that demand,” says Jørgen Rasmussen, who also has other gains by avoiding foreign elements in the laundry.

“When using the X-ray solution, we can reduce the administrative costs that come when undiscovered pens and the like ruins clothes. At the same time, it is important for our working environment to minimize the contact with the laundry, “explains the director about the solution.

 

Future solutions require data

Jørgen Rasmussen and his sons in Vraa Dampvaskeri are far from finished with the development. One of the next steps will be to utilize the possibilities for tracking the individual piece of laundry.

“Recently, we have started working on UHF-chipping the garments, which we do to get as much data as we can in the clothes cycle, and because it helps us to keep track of our inventory. This way we only need to invest in what we need,” says Jørgen Rasmussen, who see that the tracking gives further economic opportunities.

“Concerning the economy, collection and use of data is also an important part of the future laundry. When we make agreements with the customers that they should roll down the sleeves and empty their pockets, it is not always they remember it. When we track the individual piece of clothing, we can detect who’s forgetting this and, for example, send them a message that they’ll have to do better if they don’t want to pay for this service,” Jørgen Rasmussen adds.

The family behind Vraa Dampvaskeri: Martin, Stina, Thomas and Jørgen Rasmussen

Interested in the X-ray machine? Find more information about the ‘ODIN’ here

Fully automatic sorting of Soiled Workwear

Inwatec's sorting lines are build to fulfill each customers' needs. Thanks to modular design, the single machines can be added to a whole system according to specific wishes. In this case, the requested line consists of a Robot Separator, an X-ray machine and a vision based sorting system. 

The robot is fed by a conveyor and performs a separation of the garments. These separated garments are directly transferred to the X-ray machine, which detects foreign items like pens and scissors in the garment and automatically rejects these clothing items.

Accepted garments are forwarded to a vision based sorting, which, in this special case, sorts into either bright or dark.


Watch the full setup here:

The system's main components:

The Robot Separator has a high efficiency in separating textiles. It works fully automatic and therefore reduces the risk of cuts and needle injuries for your staff. We use modern 3D cameras and advanced software to find the best gripping points on the garments. 

All details about the Robot Separator. 

Inwatec's X-ray machine automatically detects foreign items such as pens, needles, lipsticks and more. It can handle up to 2,200 items per hour and rejects garments which contain foreign items. These rejected garments are forwarded to a special bin, where the detected foreign items can be removed from the garment's pockets.

Find more information on the X-ray Machine here.


You would like to automate soiled side sorting processes in your laundry as well? Contact us!

X-ray: soon easier to buy on the French market

We are happy to announce, that the Inwatec X-ray system is now a huge step closer to the French customers, and we are now taking orders for expected delivery in Q2 2018.

“Syringes, scalpels, scissors, pens, markers, name tags and other items that could either harm the operator or damage the garments, courses the same problem in France as in the rest of the world. We are delighted that we soon can help solving these issues in France with our X-Ray-machine,” Inwatec Project Engineer Raphaël Baetens tells.

Raphaël Baetens with his certification for X-ray installation and usage in France

The French regulations on the X-ray equipment demand that the operator passes a thorough test on safety procedures and radiation, and to remove that hurdle for our customers; Raphaël Baetens has completed the training, and he has now received the certificate that proves he is allowed to work with and install x-ray equipment in France.

The next step is to finalise the papers to have the exemption of authorisation and declaration that mean that French owners of the machine will NOT need to have their employees to take the courses.

“We met a lot of interest from the French hospital laundry industry who saw the machine in action at the recent JetExpo 2017 in Paris, and we look forward to starting work on these projects with our French business partners,” Raphaël Baetens continues.

“The X-ray system is CE-marked and approved for the European market. It has proven its worth for years in both European and Asian laundries, so we are pleased, that we have come so far in the process of getting the machines approved for the French market too.”

 

Facts about the Inwatec X-ray machine:

  • PCR (Person Competent in Radioactivity) Certified by APAVE
  • CE-marked
  • Certified by TÜV (for the German market)
  • Certified by Force Technology (for the Danish market)

Technical specifications:

  • Running at 30 KeV
  • 0 µSv emission around the machine

Find more information about the X-ray machine on the product page here.

No more washing machines damaged by nails at Liebhardt

Nails, screws, and tools have caused considerable damage to the washing machines in the German laundry Textilservice Liebhardt GmbH & Co. KG, Biberach in the past years. The investment in an Inwatec X-ray system dramatically changed that, and recently, Liebhardt’s machine was upgraded with new AI software to further reduce the error rate.

For managing director Eva Löffelhardt, there is no doubt that future laundry needs an increased degree of automation to keep pace with the market and to ensure the best working conditions for the employees.

“We have 85 employees in the company, and our primary focus is on workwear, blue and white workwear, but we also serve hotels and health clinics. New technology like Inwatec’s X-ray machine, helps our company to be competitive on the market,” explains Eva Löffelhardt. “By investing further in new technology, we expect the work to be easier for our employees, while continuing to deliver high quality to our customers.”

Since 2015, Eva Löffelhardt has been running the family business, founded in 1936, and is sure that the laundries of the future will change a lot: “The laundry industry desperately needs innovation. We can achieve that with modern and innovative robot solutions.The industry has been very reluctant so far.”

Eva Löffelhardt especially welcomes the fact that the loose screws, nails and tools hidden in the pockets no longer stop their washing machines. In addition, the garments can not be made unusable due to forgotten ball-point pens anymore. Equally valuable is the fact that the working conditions of the employees of the family business have improved:

“I also think a lot about the health of the employees. There are many repetitive movements in a laundry, and I have been incredibly happy to lessen these tasks. Employees are also unconditionally excited about the new technology, and they are proud to be in a company investing in modern technology. I do not doubt that the future offers solutions and opportunities that I have never thought about.”


Interested in the X-Ray Machine Liebhardt uses? Find details here.

Textilservice Liebhardt welcomes the future (video)

Nails, screws, and tools have caused considerable damage to the washing machines in the German laundry Textilservice Liebhardt GmbH & Co. KG, Biberach in the past years. The investment in an Inwatec X-ray system dramatically changed that, and recently, Liebhardt’s machine was upgraded with new AI software to further reduce the error rate.


Interested in the X-Ray Machine Liebhardt uses? Find details here.

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.


Click to find out more about the X-Ray Machine and our Automatic Sorting Machine.

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