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/ Magazine / SOFTWARE AND RFID TECHNOLOGY IN INDUSTRIAL LAUNDRIES, APPLICATIONS AND ADDED VALUE
by
MARZIO NAVA
The industrial laundry sector is undergoing a profound transformation driven by the integration of management software and RFID technology. Each textile item, from hospital linen to workwear, can be identified via an RFID tag embedded in the fabric and monitored throughout the entire production cycle: collection, washing, sorting, packaging, and delivery. This technology enables real-time traceability, reduces handling errors, and improves inventory control. The main solution providers offer integrated platforms with readers, RFID tunnels, and management software. The key differences lie in modularity, integration capabilities with company ERPs, and reporting. From the users' perspective, the benefits are tangible: automatic item counting, reduction of losses, greater invoicing accuracy, and availability of analytical data on consumption. The true added value arises from combining RFID and advanced management software. It's not just about identifying an item, but about transforming the collected data into operational information to improve productivity, service quality, and profitability. For manufacturers, this means offering increasingly integrated solutions that support the laundry: simplification and punctuality. For users, it means moving from reactive management to predictive, data-driven management
Among the technologies attracting the greatest attention is certainly RFID, often presented as the ultimate solution for controlling production flows. But is it really so? We discussed it with Eng. Patrizio Pizzardi, head of the homonymous company specializing in automation and management systems for folding and packaging departments. RFID can be a very interesting additional element for product management, but building an entire industrial accounting system based solely on RFID still seems premature to us. The issue is reliability. Even a minimal percentage of missed readings can generate significant operational problems. In our opinion, an integrated approach is more effective. RFID should not replace the traditional tracking system but complement it, creating a sort of double check that increases the security and information quality. The ideal solution is to allow two independent and integrated systems coexist: in this way, the customer has a cross-check and obtains the highest level of reliability in data management. The entire production process must be monitored, classified, and controlled through hardware/software systems capable of following the product throughout every stage of the workflow. This is where our MATI management system comes into play. It is communicating with the ironing lines and the TEREN transport automation system, allowing real-time monitoring of production progress.
Often in laundries, there are different players, and therefore it's necessary to integrate machinery from different companies...
Over the years, we have developed interfaces with the main manufacturers in the sector. We are accustomed to integrating different systems, both in the introduction phases and in the folding stages. Interoperability is indeed a fundamental requirement to ensure operational continuity in complex plants.
You mentioned that master data is fundamental...
“The integrity of the basic data is often underestimated, while it is one of the determining factors for the correct functioning of of automated tracking systems. Customer master data must be precise and constantly updated because, through it, all the technical parameters required by the system are activated.”.
Looking to the future, how do you envision the evolution of the sector?
“After the classification and automatic preparation of deliveries, the next step could be the robotization of final handling operations. However, the real technological challenge of the coming years concerns not so much the software or RFID as a much more concrete element: packaging. Modern automatic lines today reach speeds comparable to those of large-scale logistics operations, exceeding thirty packages per minute. These performances, however, are possible especially when products are properly packaged. If the package is wrapped, we can fully exploit the potential of automation. When, on the other hand, the product is not packaged, speeds decrease drastically because handling becomes more complex, concludes Pizzardi.
Let's now speak with Dino Guidetti, Sales Manager and Trainer at KONA. According to Guidetti, the greatest value offered by RFID technology lies in the precise management of the entire lifecycle of each individual tag. The technology allows you to always know where an item is, how many times it has been washed, how long it has remained with the client and who used it, how long it has been idle in the laundry, which items live longer, and which live less. The information that can be obtained is precise 'per item,' enabling a real analysis of linen usage to optimize inventory, stock levels, and re-purchases.
From tag to customer: how does the system work?
“The process starts with the mass registration of RFID tags, which are paired with individual garments. The items, once grouped into packages, are assigned to clients. When they return to the laundry, the linen is 'read' transparently by 'gates,' without altering the normal activity of the staff with additional operations. The return documents generated automatically update inventory and schedule deliveries. When a tag is not read upon entry, the packaging system's algorithms proceed to 'recover' both the tag and the relevant client, restoring the management process and eliminating errors. Finally, RFID technology can be directly integrated into facilities through a series of services provided directly by the laundry.”.
What technological solution do you offer?
“IThe technological core of KONA s solution is MISTRAL, an extremely customizable and configurable multi-company software platform. MISTRAL manages everything natively: RFID operations, clients, contracts, accounting, workwear, flat linen, mobile apps, and customer portals. To complement the software, our company directly provides tags and devices (tunnels, cabins, antennas, portable readers) that communicate directly with the company database, ensuring precise real-time information for both the laundry and the end client.”.
Which market sectors are driving demand?
“The use of RFID technology for linen management originated fundamentally in the healthcare and nursing home sector, but in recent years we have witnessed exponential growth in demand in both the hospitality and restaurant sectors. More recently, regulations concerning the management and maintenance of PPE in companies have prompted various industrial entities to request fully certified traceability”.
What are the main challenges to address?
“The main challenge is economic: RFID technology requires sometimes significant investments, and not all laundries are structured and ready to face them. Added to this are technical constraints, such as the space required for reading equipment, and the quality of RFID tags, often underestimated but crucial for overcoming the challenge. Saving a few cents on tags can compromise an investment of tens of thousands of euros.”.
What does the future look like?
The future of the sector is moving towards greater automation, with intelligent sorting systems capable of reducing or eliminating human intervention. KONA is already testing integrations with automated sorting plants, where RFID antennas connected to the system allow for immediate recognition of items in transit. A single reading gate is enough to know what enters the laundry, Guidetti concludes. The machines automatically sort the items, and the system automatically updates traceability and returns in real time, concludes Guidetti. SCAL
“In recent years, RFID technology has revolutionized the way industrial laundries manage linen and professional garments, says Mattia Battoraro of SCAL. The ability to uniquely identify each item through an RFID tag embedded in the fabric has made complete traceability possible throughout the entire production cycle, from the collection of soiled items to the delivery of clean ones. Today, however, the sector is entering a new evolutionary phase”
From item identification to process knowledge?
Every day, an industrial laundry generates a huge amount of information. Each RFID reading performed during the collection, sorting, washing, packaging, and distribution phases produces data that accurately describes the behaviour of the items and the progress of the entire production process.
Does traceability allow for a constant snapshot of company activity?
“Real-time stock control. One of the main advantages derived from the integration of RFID and management software concerns inventory management. Through continuous item reading and automatic monitoring of movements, EXACO allows for knowing the actual availability of linen at any moment, its distribution among different clients, and its position within the production cycle. Real-time visibility allows for quick identification of any anomalies, reduction of lost items, and optimization of article turnover.”.
What potential does data utilization hold?
“The most innovative aspect of the SCAL-ID and EXACO ecosystem concerns the ability to transform the large volume of collected data into predictive information. Through the historical analysis of movements, consumption, and usage cycles, the software is capable of identifying recurring trends and generating useful indicators for operational planning. The integration of advanced analysis tools and algorithms based on artificial intelligence also allows for the development of increasingly reliable forecasting scenarios, supporting management in daily and strategic decisions.”.
From reactive to predictive management?
“Traditionally, many decisions are made when a problem has already emerged: an order requires more linen than expected, a stock runs out suddenly, or a certain item is insufficient to meet customer requests. The system allows for more precise estimation of future consumption, early identification of critical points, and planning of supplies based on the actual needs of individual orders.”.
An integrated ecosystem for the modern laundry?
“The strength of the SCAL solution lies not exclusively in RFID technology or software functionalities, but in the perfect integration between the two elements. SCAL-ID provides accurate and reliable data from the field; EXACO transforms it into operational information, performance indicators, and decision support tools. The result is a more efficient, more controlled, and above all, more informed laundry. Traceability is no longer just a control tool: it becomes the foundation for intelligent, predictive, and data-driven management of the entire business.”.
Industrial laundries manage thousands of textile items every day that need to be collected, washed, delivered, and returned while ensuring the highest service levels. The main challenge is having reliable information about the textile assets and the flows that characterize them, explains Francesco Raffagnato, Project Manager at ZUCCHETTI CENTRO SISTEMI “ZCS solutions transform textile items into a source of structured and verifiable data, offering a complete view of operational processes. This helps laundries reduce losses, operational errors, and manual activities, improving inventory management and production planning. A fundamental value is transparency between the laundry and the end customer. The data comes from automatic and objective readings, not from estimates or manual counts, creating a relationship based on shared and verifiable information”.
How does the RFID traceability process work within an industrial laundry?
“Each item is identified by an RFID tag that assigns it a unique digital identity. Reading points installed at strategic process checkpoints automatically record transits, creating a sequence of events that reconstructs the complete history of each individual item. Traceability serves not only to know the location of an item but also to govern production and logistics processes through rules that automatically direct materials and workflows. Over time, each item develops a veritable digital identity card containing information on washing cycles, destinations, users, movements, wear, and any potential losses throughout its service life.”.
What are the main innovations you are currently developing?
“The future of the sector will be driven by the ability to transform operational data into knowledge and decision support. For this reason, we are integrating RFID traceability, automation, and artificial intelligence. AI will not only allow for predicting production needs, optimizing inventory, and improving process efficiency, but above all, it will simplify interaction between people and systems. We are developing tools capable of understanding the operational context and providing immediate responses, suggestions, and real-time decision support to operators. The goal is to evolve from systems that collect data to systems that actively collaborate with people. In the coming years, we will see increasingly interconnected laundries, where RFID, automation, and AI will work together to increase efficiency, service quality, and decision-making capabilities.”.
“The future of industrial laundry lies in data. This is the message of Matteo Gerosa, Head of JENSEN ITALIA, who highlights how RFID technology is becoming an increasingly strategic element in the digital transformation of the sector. RFID is not simply a tool for identifying and tracking garments. It is a fundamental driver for transforming the information collected throughout the production process into greater efficiency, service quality, and profitability. It is a means, not the end goal. The objective is to generate reliable data and turn it into operational information that supports business decisions. Today, digitalization involves every stage of the industrial laundry process. In the past, sensors and counting systems were mainly used for machine monitoring. Today, the same data can be connected to customers, articles, and quantities, creating complete traceability across the entire production cycle. RFID adds a further level of precision by assigning each garment its own digital identity . The most common applications involve the automated reading of incoming soiled linen and the verification of finished products before delivery back to customers”.
How far can innovation go from this perspective?
“The most advanced systems use RFID data to automate article sorting during processing, distinguishing garments that may appear similar but have different characteristics. One particularly interesting area is automated sorting: thanks to robotics, vision systems, and RFID readers, linen can be identified and sorted with an increasingly reduced need for manual intervention. Automated sorting represents one of the most important developments for the sector, not only in terms of productivity but also for ergonomics and workplace safety. Sorting is one of the most strenuous activities in a laundry. Automating it means improving ergonomics, safety, and working conditions, as well as increasing efficiency.”.
Are there any limitations to this technology?
“However, the widespread adoption of RFID still presents challenges. Introducing this technology requires significant investment and often needs to be implemented gradually, especially in companies that are already operational. For this reason, many laundries begin by focusing on the most critical stages, particularly those close to order preparation, billing, and customer relationship management. Northern and Central Europe remain the international benchmarks, as higher labour costs have accelerated the adoption of automated solutions. In Italy, the path toward greater automation is growing, often also supported by incentives and investment schemes, concludes Gerosa.
We now turn to Cosimo Altavilla, Head of Sales at SOCOM INFORMATIONSSYSTEME GMBH, to discuss some of the key developments shaping the future of laundry software and RFID technology.
How does your software, integrated with RFID technology, improve garment traceability and reduce errors or losses during the laundry process?
“This is what I hear every week: we are growing, but the profit margin isn't following. It's a visibility problem. Many laundries have tags and readers installed, but the data isn't reaching where decisions are made. The real impact comes when RFID events flow end-to-end through production, logistics, invoicing, and claims in real-time, without manual intervention. What operational and economic opportunities does RFID offer compared to traditional systems (barcodes, manual records, etc.) in terms of efficiency, productivity, and cost control? The context for European laundries is clear: rising labour costs, scarce qualified personnel, increasing regulatory requirements. The question is no longer whether to digitise, but what to automate first. An integrated RFID system acts on four levers: inventory transparency, loss reduction, stable service levels, and productivity. Without visibility, you end up repurchasing garments already in circulation RFID eliminates this waste. An often-underestimated element: the software encodes processes into the system, reducing dependence on key individuals.”.
What is the main added value of your solution for the end customer: real-time monitoring, process automation, data analysis, loss reduction, or other measurable benefits?
“The real value isn't in a single function, but in what happens when all elements work together as a system. RFID data must trigger the right actions automatically. We measure success in three areas: inventory accuracy, service quality, and productivity. Added to this is the traceability of each garment number of washes, wear, and residual value so replacement is planned based on data. The broader value is resilience: with shrinking margins, whoever operates on reliable data, not on the knowledge of a few individuals, will win.”.
“The adoption of RFID technology in industrial laundries has made a significant leap forward in recent years. Back in 2018, during Expodetergo International, the focus was primarily on the automated distribution of linen through smart lockers. Today, RFID has become a strategic tool for process management, workflow monitoring, and quality control, says Alfonso Caselli, the Manager of ALGITECH.
Is data reliability the real challenge?
“RFID reading is extremely fast and powerful. The main challenge is preventing data contamination. If the environment is not properly designed and shielded, there is a risk of reading garments that should not be counted, compromising the reliability of the information.”.
What is the issue of sleeping chips ?
“In the industry, sleeping chips are RFID tags that, although physically present in a garment, suddenly stop transmitting data. To address this issue, we have developed applications that leverage the finishing machines located at the end of the production line. As sheets, towels, and other items pass through, the system automatically verifies the presence of the RFID tag. If the tag is not detected, the item is flagged and separated, just as it would be if it were damaged or stained.”.
What are the most significant benefits?
“One of the most evident advantages of RFID is the ability to perform real-time inventories. Today, systems are capable of reading approximately 1.300 items contained in a trolley in just over one second. This speed makes it possible to instantly determine both the quantity and type of articles entering or leaving the laundry. As a result, laundries can analyse item turnover, optimise purchasing decisions, and monitor the actual utilization of their textile assets.”.
Are training and system design decisive factors?
“Our field experience has shown that the success of an RFID project depends not only on the quality of the components but also on the design of the reading environment. The shape of cabinets, the materials used, the shielding of structures, and the positioning of antennas all directly influence system reliability. Even a small opening in a structure can allow the signal to read items located outside the intended area, affecting inventory accuracy.”.
Are we now looking at a mature technology?
“The ability to track every single item, monitor its lifecycle, simplify logistics operations, and provide reliable data represents a competitive advantage that can hardly be ignored today. Implementation is complex and requires specific expertise, concludes Caselli, but once the initial phase has been overcome, the benefits in terms of control, efficiency, and service quality are truly remarkable.
DETERGO MAGAZINE # JULY AUGUST 2026
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