THE “C” FACTOR, COSTS, ENERGY SAVINGS AND REDUCED CONSUMPTION IN LAUNDRIES

In an increasingly competitive market, the challenge for professional laundries extends across multiple fronts: energy management, operational organization, and quality. As Corinna Mapelli emphasizes, “technology must be a concrete tool for improving efficiency, not merely an item of capital expenditure.”

Water recovery, lower energy consumption, reduced solvent use, and increased ironing productivity, these four pillars form the foundation of the efficiency strategy presented by Marco Niccolini Global Sales and Marketing Director of RENZACCI SpA, a company specialized in producing washing and dry-cleaning machinery. The goal is clear: helping small laundries to control costs while maintaining both quality and sustainability.

“When it comes to water-washing”, explains Niccolini, “the company has invested in the Special One system, a ‘washing battery’ that combines an Eco Care - certified washing machine with automatic water recovery from the final rinses. The system allows up to 40% of the water used to be recycled, without requiring additional space in the laundry. Space is a strategic resource, and cost rationalization begins here as well. Water savings are complemented by energy reductions of around 15% and lower detergent consumption, thanks to the more efficient application of washing solutions. The system is completed by a closed-circuit dryer with a heat pump, which delivers three additional levels of savings:

• Simplified plant design: eliminates the need for exhaust and ventilation hoods;

• Reduced energy consumption: requires less than 10 kW of installed power;

• Optimized operating costs: the heat pump reaches the required temperatures without relying on high-consumption heating elements.

An additional advantage is water preheating: the system supplies hot water ready for the next washing cycle, creating a virtuous loop between washer and dryer that boosts overall self-sustainability.

Shifting focus to dry-cleaning, the new Nebula series brings bio-dry cleaning to the forefront, combining efficiency with sustainability. Key benefits can be identified, all of which contribute to tangible cost reductions:

• installed power is reduced by approximately 50% compared with traditional machines;

• energy consumption per cycle decreases by up to 60%;

• costs for energy, water, and waste disposal are significantly reduced.

Equally important is the use of a “natural solvent”, which does not evaporate at room temperature. In addition to providing greater prot• costs for energy, water, and waste disposal are significantly reduced.ection for the operator’s health, this feature significantly reduces solvent consumption compared with previous-generation solutions.

Efficiency extends beyond washing: garments treated with bio-dry cleaning emerge more relaxed and softer, leading to estimated reductions in ironing time of 25% to 30%, depending on the type of garment. A figure that translates directly into productivity gains and further reductions in operating costs”, concludes Niccolini.

PONY SpA

“In the laundry sector, from local small laundry shops to mid-sized commercial facilities, ironing represents one of the most delicate and strategic phases of the entire production cycle”, says Andrea Astolfi, Sales Director of PONY SpA. “It is not merely the final stage of the process, but the true point of balance between initial investment, work organization, and profitability. “The first critical factor concerns system configuration. Equipment selection must begin with a thorough analysis of the incoming workflow. The volume and type of garments: shirts, trousers, jackets, dresses, technical fabrics - directly influence both machine productivity and economic return. Each solution entails a defined cost and a measurable production capacity. While hardware investments can be planned and amortized over time, they must be precisely sized to align with operational requirements. The issue of operating costs for the finishing service is more complex, as the human factor, labor, plays a decisive role. While automation has significantly reduced direct labor in washing and drying, ironing still requires a considerable amount of time per garment, making it a critical cost variable. Even a difference of just a few minutes per item can translate into a substantial cost deviation by the end of the day. Moreover, the higher the level of finishing: attention to detail, precision of creases, and perceived quality - the greater the labor component becomes. For this reason, ironing represents one of the most significant items on the income statement and must be accurately incorporated into the final price charged to the customer.

In recent years, the sector’s focus has decisively shifted toward energy efficiency. Rising energy costs, combined with sustainability-driven policies, have accelerated the engineering of machinery, optimizing steam flows, reducing heat loss, and incorporating automatic savings systems during idle periods. The goal is clear: maintain high-quality standards while reducing consumption per cycle. Within this context, the choice between centralized boilers and integrated solutions within individual machines becomes particularly relevant. Centralized boilers deliver strong performance but require complex infrastructure, structured maintenance, and continuous energy use. Integrated solutions, by contrast, offer greater flexibility: they activate only when needed, incur lower installation and operating costs, and are often better suited to small- and medium-sized businesses. There is no universally right choice: everything depends on the volumes handled and the organization of work. Even the recovery of hot air and thermal optimization are becoming decisive levers. Reducing energy losses not only helps contain costs but also strengthens a positioning oriented toward sustainability, today tesboth a competitive and ethical advantage. Against this backdrop, the market itself is transforming. The number of low-cost synthetic garments with shorter life cycles is growing, which in turn alters the demand for high-quality finishing services. Laundries must therefore rethink their operational model, finding a balance between quality, efficiency, and competitiveness.

Ultimately, ironing remains the key variable by which the strength of a laundry is measured: it is here that technology, organization, and the ability to generate value converge, determining the real economic sustainability of the business. At Pony, we work alongside our distributors and clients daily to first analyze and then implement finishing solutions tailored to every ironing and environmental requirement”, concludes Astolfi.

MONTEGA®

For MONTEGA®, a company producing professional detergents, we speak with Francesca Iannone, Head of the Laundry Division. “At Montega®, our strategy for cost reduction focuses on two main levers: increasingly concentrated products and the use of raw materials that remain effective even at low temperatures. These are approaches we have applied with our clients for years. Research in this area has always been a priority, not only as an internal goal, but in response to consistent market demand. A few years ago, for instance, we launched Rapid Dry, an additive used in the final rinse that reduces drying times and temperatures, thereby cutting energy consumption in the tumble dryer. The product proved highly successful, with strong sales volumes. Its development began months before the sharp rise in natural gas costs; we completed our internal testing and brought it to market just as energy prices were surging. Optimizing washing processes through more concentrated formulations, lower temperatures, and reduced water consumption, by maintaining a lower bath ratio, also entails more precise and, at times, higher dosing levels during the wash cycle. Montega® supports its clients by making its expertise available through its laboratory facilities, sales network, and technical team”.

Specifically, which raw materials and active molecules do you supply that deliver added value in textile treatment, even at low temperatures?

“The raw materials that enable effective textile treatment at low temperatures include specific surfactants, whether plant-based or synthetic. In our laboratory testing, we systematically evaluate high-performance raw materials across varying concentration and temperature levels, selecting those that consistently deliver the best results”.

Let’s take a closer look at Rapid Dry: what are its key technical features?

“Rapid Dry cuts drying times for terry cloth, commonly towels, by 15–20%. Designed as an additive for the final washing cycle, it additionally imparts softness and fragrance to fabrics. Tested in multiple laundries, the product is both manufactured and distributed by Montega®, consistently receiving positive feedback from clients”.

Are there greater microbiological concerns when washing at low temperatures?

“That is true; however, all laundries use bleaching agents such as chlorine, oxygen, or peracetic acid, that eliminate bacteria even at low temperatures. As a result, bacteriological risks are essentially absent in professional laundry processes. Additionally, many detergents include additives that further mitigate these risks. These compounds act not only as preservatives but also as solvents, enhancing both cleaning performance and protective action”.

Water, energy, and chemical savings: what does the research focus on, and how is it oriented?

“Research has focused on this for many years, with ongoing efforts to improve and increase savings. Yet, the wash quality remains the fundamental priority. It is essential to emphasize that stain removal must always be our primary objective in detergent development. Other factors, while important, are secondary”, she concludes.

In the industrial and professional laundry sector, the “C” for costs is no longer merely a line item to be trimmed at year’s end, but a genuine indicator of competitiveness. Energy, water, chemical products and process management: each variable directly influences the cost per kilogram processed, and, ultimately, profit margins. In a landscape marked by volatile energy tariffs and persistent price pressure, reducing consumption without sacrificing performance has become the sector’s central strategic challenge. We explore these issues with ÈCOSÌ, a company specializing in chemical solutions and control systems for professional laundry operations. Our conversation is with Antonio Ciccarella, Head of the Laundry Division of the company.

Lower temperatures are often seen as a pathway to energy savings, but do they risk affecting overall results?

“It is a persistent and difficult myth to dispel: low temperatures do not equate to reduced effectiveness. Today, thanks to advanced formulations and precise calibration of chemical and mechanical parameters, high standards of washing and disinfection can be ensured even at lower temperatures. Our solutions are validated in accordance with UNI EN standards, guaranteeing microbiological efficacy at reduced temperatures and full compliance with the protocols required in highly sensitive sectors such as healthcare and hospitality. Innovation lies not only in the product itself, but in the ability to manage the entire process. Time, mechanical action, concentration and water quality must work in synergy to achieve optimal results”.

What tangible benefits does this bring to a professional laundry facility?

“Running a washing cycle at 30°C can significantly reduce energy consumption and, as a result, reduce indirect CO2 emissions The impact on the cost per kilogram processed is both immediate and measurable. However, assuming that lowering the temperature alone solves the problem would be simplistic. True quality improvements arise when the entire process is designed holistically, eliminating waste and structural inefficiencies. This approach not only controls costs but also extends textile lifespan, reduces machine downtime, and enhances result predictability”.

What steps do you take to optimize and maintain machinery in your operations?

“Il punto di partenza è sempre un audit tecnico approfondito. Analizziamo la qualità dell’acqua, la tipologia di sporco, la struttura dell’impianto e i flussi produttivi. Sulla base di questi dati, definiamo un piano di ottimizzazione che include prodotti specifici, sistemi di dosaggio automatico e programmi di lavaggio calibrati sulle reali esigenze del cliente. Abbiamo inoltre sviluppato un software proprietario di monitoraggio e calcolo previsionale dei costi. Questo strumento consente di simulare scenari, confrontare parametri, stimare i risparmi e mantenere sotto controllo nel tempo le variabili economiche. Non si tratta solo di consuntivare, ma di prevedere e correggere”.

So, does the “C” factor also represent control?

“Exactly. Control stems from awareness of process parameters, consumption, and performance. Without data, there is no management, and without management, there is no competitiveness. Our philosophy is clear: we don’t just sell chemicals; we offer a method. Energy efficiency, reduced consumption, and performance validation are all part of an integrated strategy that makes the laundry operation both economically stronger and environmentally sustainable”.