Managers Machines & Management - Clean India Journal

Facts and Figures

If the total requirement is 2,000kg of, say, towels in eight hours of a hotel, per hour production is 250kg.
Thus, a minimum of three machines for washing/extracting and three nos. for drying are to be installed.
Thus, each washer, if total time of processing one batch is one hour, should have theoretical capacity of 83kg.
The washer/extractors selected will be of next higher capacity each, viz. 90kg or 100kg. An extra machine of 50kg will ease burden.
If driers take 40 minutes. for drying, including loading and unloading, and it is decided to have driers of 50kg capacity each, theoretically in two hours, three batches per drier, or 150kg per two hours, or 75kg per hour will be produced. Thus, 250/75 = 3.3 or four driers will be required.
If the production is to be completed in 16 hours, three machines of 50kg washer/extractors and two driers of 50kg or four driers of 25kg will suffice.
The night shift will be free for emergencies – breakdown, power failure, compressor/boiler failure, or extra requirement, etc.
Similar calculations will need to be done for bed-sheets, duvet-covers, pillow cases, napkins, table covers, banquet runners, sundries, etc. All these items will need augmentation of water-extractors and a machine known as flatwork-ironer.
For the above example of 2,000kg towels per day, there will be 2,500kg of the flat-pressing items. Hence, now, washing requirement will be 4,500kg per eight hours and production will be 600kg per hour. Three washing machines of 200kg each and one machine of 100kg(as additional) will be needed for one shift of eight hours, or, four machines of 100kg each will be needed for two shifts of eight hours each. For guest laundry and part uniforms, 40kg machine 1 no., 25kg machine one and two domestic machines of 5kg each will be needed.

Flatwork Ironer:

A, two roll 3.3m X 0.8m iron at 8-9 bar steam pressure, chest heated and rolls moving up and down, with chest stationery, will give 4.5kg/ min. or 270kg/hour. Hence, total working will be 10-11 hours.
A, three roll iron will give 7kg/min or 420kg/hour. Hence, eight hours will be sufficient.
A, one roll ironer in addition may be necessary for quality of napkins/ pillow-covers.

Uniforms:

There will be 10% (max.) of total, and for 4,500kg of other linen, these will be 450-500kg or 1,200-1,400 garments. Let us assume, there are max. shirts / trousers and some jackets, saris, suits, blouses, etc.

A typical load may be:

100 – cook jackets
30 – chef jackets
130 – chef trousers
80 – aprons
130 – scarves
100 – kitchen dusters
40 – sarees
40 – jackets for suits
40 – suit trousers
40 – blouses
100 – executive garments
200 – shirts
200 – trousers
70 – sundries
1300 – total nos.

Thus, the following machines will be required:

one dry-cleaning machine of perc of 16kg, three tank capacity
A set of steam-presses – three utility + two mushroom with two vacuum units
one steam-air-form finisher
two steam vacuum tables
one set of hot press of two mushroom and 1 utility
one cuff-collar press
one extra tumble drier for drying or conditioning of 25kg
two hot iron tables for touchup(5’x2.5’x2’10”)

It will also need:

A compressor of 75cfm at 80110psig and stand-by
A boiler of two tonnes capacity and 1 stand-by
A chiller plant for dry-cleaning machine
A spotting board for stains
A scrubbing table
Two nos. 25kg washer-extractor (for guest garments)
One complete folder for flatwork ironer
Area = approx. 4,500sqft to 5,500sqft excluding boiler/ compressor/ water softener/RO/ water storage.
Trolleys required – 200 litres capacity – 12 nos.
Laundry delivery trolleys – 4 nos.
Hanger rods – 250rft.
Small area for maintenance recordkeeping / spares etc.
Packing area & pigeon holes/racks/ desks
Marking area

Machinery

For Commercial Laundry/ Industrial Laundry:

Commercial processing retail garments – for 500 nos./day

Washing Machines = 25kg x 2
Dry-cleaning Perc = 12kg x 1, 3 tanks chiller plant
Steam Press = 2 Utility + 1 Mushroom with vacuum unit with steam iron attachment
Form Finisher = 1 no.
Cuff & Collar (hot) = 1 no.
Utility Hot Press = 1 no.
Mushroom (hot) = 2 nos.
Steam Vacuum Tables = 2 nos.
Bagging machine
Scrubbing Table = 1 no.
Boiler = 2 nos. upto 300kg/hour
Compressor = 2 nos. of 20cfm

Accessories

Rod rft = 80-100ft + 50ft
Trolleys to hang garments etc = 8000
Tables for sorting = 4 nos.(SS top)
Voltage stabiliser = 1 no.
Capacitance for pf = 1 per machine
Space = 4000sqft (optimum)
Vehicle parking bay and loading/ unloading facility
Storage of fuel (space) = one week to one month
Storage space for chemicals & packing material
ETP required
Toilet facilities @ 1 no. for every 15 staff
Packing & forwarding area with pigeon holes & desks

Management

To know more about family, if possible
Selection procedure to follow
Induction in all areas
Training in 2 areas to start with
To have communication on daily basis
To have job chats
To have first-aid kit and box
Fire fighting training
Counselling for staff and to be as transparent as possible
To convince and communicate policies of management
To maintain discipline
To see that job description is followed totally and reward system instituted
To encourage staff to have crosstraining in either their dept. or any other dept.
To encourage staff to serve social cause
To check health parameters on a regular basis
To encourage for innovation
To have stock taking of linen and inventory of chemicals and packing done every month/week respectively
To have overview of maintenance of machinery
All other points as mentioned in the beginning of article, except machinery & area.