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Industrial laundry, safety systems on washing machines, ironing machines and logistics

Prevention and protection are the watchwords that we are starting from. In this Reportage we take an in-depth look on the safety at work, focusing in particular on the machine’s safety in the industrial laundry sector. A few months ago, INAIL (Italian National Institute for Insurance against Accidents at Work) emphasized the safety in industrial laundries by identifying specific risks to which workers may be exposed. The aim was to identify the main prevention and/or collective and individual protection measures to be adopted in this production sector. All the phases of the work cycle must be closely examined as there are various risks involved: biological, chemical, carcinogenic, from manual handling of loads, from exposure to electromagnetic fields and, finally, the risks involved by the work equipment maintenance operations. Which are the dynamics of laundry accidents in the recent years? The number of accidents reported to INAIL in 2020 showed a decrease of about 30% compared to the previous year, and these occurred mainly during work. In general, the occurrence of accidents affects men and women almost equally and the most affected age group is between 35 and 49 years old. The hand is the most affected part of the body, but it is also the most exposed one: in 2020, it involved 28% of the injured, an increase compared to the previous four years. The spine is particularly stressed during the working hours, ranking as the second most commonly affected body part, accounting for 11% of incidents, and decreasing over the years. These data allow us to understand the phenomenon and implement corrective measures. As machinery manufacturers, what safety systems do you apply to your machines? What measures, what precautions? In relation to your expertise, what type of consultancy support can you provide regarding the laundry safety?

“We design and implement solutions that can further automate processes and consequently simplify working conditions in the industrial laundries,” says Cosimo Corleone, the Marketing and Export Manager Coordinator of Montanari Engineering Construction Srl. “The implementation of safety systems inside the laundries can significantly contribute to reducing risks and burdens on operators, improving the quality of work and working comfort. For this reason, Montanari has implemented various technologies regarding the safety and ergonomics for its machines, including:
– safety sensors with automatic stop that activate safety measures if the operator makes incorrect movements when using the machines, such as anti-hand-crushing systems;
– implementation of safety barriers to protect operators during the loading of lifts on overhead systems. In addition, the lifts have been equipped with anti-fall safety ropes in the event of accidental breakage of moving components;
– the solutions offered by Montanari are also equipped with highly visible emergency stop devices located in the close proximity of the machines.

Of course, these systems are useful if operators have been appropriately trained on how to behave in emergency situations. As far as the ergonomics is concerned, Montanari’s loading belts have obtained the Ergocert certification for the ergonomics of their machines. This is achieved primarily by having adjustable height and accessibility. Specifically, the height of the machines and workstations can be adjusted to reduce the need for excessive lifting or uncomfortable positions according to the occupational health guidelines. Additionally, we have focused on lightening the workload through systems that significantly reduce the operator’s burden when handling the linen, thereby minimizing the need for manual lifting and the risk of injuries. Intuitive and user-friendly interfaces help minimize human error. Last but not least, Montanari is also managing the computerized aspect, that allows the constant monitoring of its systems by promptly intervening in case of blockages or anomalies and at the customer’s request to carry out predictive monitoring of the installations in order to avoid potential incidents and ensure that all machines are in optimal operating conditions by taking preventive action on possible faults. The integration of advanced safety systems and ergonomic solutions in the automation processes not only that helps reduce occupational risks but also improves operational efficiency and the overall wellbeing of operators in industrial laundries”.

“The topic of safety applied to the industrial laundry machines constitutes an extremely important point. Laundry machines operators are becoming more of a rotational workforce with a high turnover ratio. They also often require specialized training. Experience and expertise are now turning out to be objectively scarce resources in companies”, says Alessandro Rolli, the Managing Director of Kannegiesser Italy, while analysing the safety aspects at industrial laundries. “Machines must be safer and more user-friendly: this will simplify the man/machine interaction. Each machine is equipped with a series of protection systems that prevent the unskilled personnel from interventions on mechanical or moving parts, etc. Adequate training is fundamental in the development of the work culture in any company, as workers must be aware of the risk assessment. Kannegiesser regularly holds training courses for the maintenance technicians because the expertise on the machines, including the evolution of machines, is absolutely crucial.
here are also risks related to the environment and not strictly to the machine itself. Let us consider a continuous batch washer and a possible obstruction caused by linen; in the past, the operator would have physically entered the machine facing all the associated risks… today this kind of problem can be solved from the outside without any contact with the process chemicals nor having to operate in a confined workspace.

Our machines allow for external manoeuvres, but they can also rotate in the opposite direction contrary to the normal operation position, minimizing the risk. We also need to emphasize safety from the ergonomic perspective, in terms of load handling and physical work stress. The repetitiveness of movements can, over the medium and long term, lead to issues that can take form of occupational disease. Postural and mental fatigue can generate a decrease in the operators’ performance from an operational point of view, but more importantly, it could lower the level of attention, which will increase the risk of injuries. Safety in general, and not just relating to the machines, should not be seen as a static element only. It should constantly be subjected to evaluations with all its evolving aspects. Safety should not be interpreted only as a protective element for employers against any potential legal disputes but rather as an essential part in the development of the industrial laundry production system. We must not forget about the protection of the operators against the emissions present in laundries, such as radio emissions and thermal emissions; a poorly insulated ironer can cause an increase in the temperature of the working environment. The same reasoning applies to the insulation of the continuous batch washers. After all, an investment in technology is also an investment in safety,” concludes Rolli.

Algitech is a company operating both in Italy and abroad, in the field of automated systems, and it is specialized in particular in producing feeding, ironing and folding machines for flat linen, as well as automatic sorting systems for the complete handling of the finished product. We are speaking about this market segment related to the industrial laundries and safety with Alfonso Caselli, the person in charge for the research and development at Algitech Srl. “The safety of machinery is one of the crucial aspects of the Industrial laundry that once again makes it a protagonist, confirming it as a “complex activity”. The Machinery Directive is the reference standard for machinery, which then connects to all harmonized standards. For some years now, Algitech has been working to raise awareness among its clients regarding the need to adopt all the necessary systems for the safety of their laundry, and particularly of the ironing line.

Training and informing personnel are among the most crucial aspects that can prevent accidents at work, such as assigning specific tasks, considering that the operator on the machinery cannot also be the “maintenance technician” unless they have undergone specific courses and received specific training for the task.
When designing the machines, it becomes crucial to pay attention to the ergonomics of the machines, an aspect that helps reducing the incidence of occupational diseases, but also an improvement in production efficiency. Another essential element in the industrial laundry is that of interfaces. There are different machines in the laundry, often produced by different manufacturers, and each machine has a different safety category. And it is precisely through interfacing that it is necessary to secure the entire line: protecting the operator’s area becomes essential. For example, between the dryer ironer and the folding machine, when opening the “safety gate” between one machine and another, the line must be automatically blocked, clearing the field from any risk. Beyond compliance with safety regulations, concludes Alfonso Caselli, we focus on raising awareness, on a safety culture, because on the short term, it may be perceived as a cost, but on the long term, it is a saving”.

“Our safety begins with the training and professional development of our collaborators to make our products as safe as possible”, says Giorgio Castino, the Sales Manager of Novopac, a company producing packaging machines. “We are almost obsessive when it comes to safety criteria aiming to position ourselves at the top of the companies that distinguish themselves for high construction standards, solutions with advanced technological innovations, efficiency and reliability that make the machines of Impianti Novopac unique for their quality features. Every part of the machine is equipped with dual-channel coded sensors ensuring an immediate stop if the protective doors are opened, while an user-friendly synoptic display reports and communicates any information to the operator, enabling prompt intervention based on the notification received. With the implementation of the 4.0 Industry, all of our systems are strictly complying with the standards in terms of safety, and technologies that allow interchanges with the customer’s management system.

This ensures real-time access to all information related to production and warehouse management. The prerogative of Impianti Novopac is the customization of the machinery according to the real needs of the customer, arriving to “tailor-made” solutions. Each of our machines is built according to the Customer’s specifications, and even the users’ manual is being customized. Regarding safety, we have an in-house technical office that also collaborates with an external specialized studio. We pay close attention to manual handling of loads, reducing risky and strenuous interventions of the operator. For instance, the rolls used for wrapping, that are weighing over 25 kg, are handled with safety using an electrically controlled hoist that places them on an additionally lowered structure, facilitating both loading and handling. We can confidently state that reliability, efficiency, and safety have been the cornerstones on which our strategic policy choices have been growing”.

When it comes to finishing equipment, remaining in the industrial laundry sector, we speak with Eleonora Cartabbia, the Marketing Manager of MACPI. We focus in particular on the shirt finishing machine mod. 291, but the approach is similar to other Macpi machines of the same size. The main goal of this machine is to simplify the shirt finishing operations for industrial laundries according to the customer’s needs. Which are the safety features of this machine or, better said, the protection systems that you have designed for the ironing machines from an industrial perspective? In terms of safety, we have been committed for long time in designing our machines to reduce dual risk. This includes addressing risks associated with the machine’s operation, with the aim of maximizing the reduction of hazards for the operator. Additionally, we focus on an ergonomic perspective through a series of dedicated studies that analyses the user-machine relationship.

All models are designed with telescopic form finishers and movable boards that significantly reduce the impact of strenuous movements, which over the long term can cause injuries or discomfort to operators. Many of our machines are certified by Ergocert (Certification Body that certifies the ergonomic characteristics of work environments, workstations, and products). In particular, the 291 shirt finishing machines guarantee a correct working position for the operator, allowing it to “dress” the dummy at a much lower height compared to similar products on the market. This is achieved through a 2-step elevation process activated by pressing the pedal control. As concerning the safety profile specifically related to our machines, we have implemented the following measures: safety barriers, if the operator surpasses them, the machine stops; the safety platform, if the operator approaches the machine and does not respect the correct safety distance, the platform “is reading” the operator’s weight and stops; and then the emergency buttons that we can install on each of our machinery present in the laundry, that allow for the immediate stop of the machine,” concludes Eleonora Cartabbia.

Grandimpianti not only faces the challenge of creating cuttingedge machinery and solutions but it is also actively involved in the design of washing machines, tumble dryers, and ironing machines designed to ensure the maximum safety and well-being of the operators. The cornerstone of this philosophy is the awareness that a safe working environment not only protects the staff but also promotes operational efficiency. “We have decided to put safety first in the design of our machines – explains Patrizia Terribile, the Managing Director of Grandimpianti – starting with the washing machines, which are equipped with dual safety devices and multiple sensors, connected to low-voltage (24Vac) safety board certified by Accredia 17025. This has been specifically designed to prevent functional faults, ensuring maximum reliability and safety.” Redundant systems and maximum safety also characterize our tumble dryers.

Safety pressure switches, magnetic sensors for the rotation of the drum, dual control in the porthole opening/closing device, a set of safety thermostats, and a burner flame detection system (for the gas models) work in synergy to ensure the proper functioning of the equipment in all environments and circumstances, as well as maintaining a healthy work environment, free of risks of electromagnetic pollution or unburnt gas emissions. We have focused on safety also when designing our latest generation of ironers, the new GI range. Thanks to the Automatic Thermal Protection System (ATPS), they are able to automatically move the ironing cylinder away from the garments in case of malfunctions or power failure. The GI ironers are also equipped with a Cooling System (FCS) for the Finger-guard and two temperature sensors which, in case of eventual overheating detected by the electronic board, these sensors intervene by switching off the heating system. A double heating activation system, with two contactors, ensures that the machine is always safe in case of a malfunction. Finally, we would like to mention the innovative Adjustable Infeed Plate (AIP), the wooden linen feeding board adjustable in various inclinations, which prevents overheating and any electrostatic charge.

We talk about ironing in industrial laundries with Corinna Mapelli, the co-owner of Trevil. “For ironing work shirts and jackets, Trevil offers PrestoTandem double buck pressed shirt finisher. Thanks to the automatic unloading system of the ironed garments, it can iron about 90-100 items per hour, with just one operator, depending on the moisture level and the fabric type. The unloading system can work independently or it can be specially designed to be integrated with the already existing conveyor system in the laundry. If we need to iron items like shirts with collars and cuffs, the installation can be completed with our double or quadruple TandemPress CP. In highly automated work environments such as industrial laundries, the presence of safety devices is absolutely indispensable. Regarding our PrestoTandem shirt finisher for pressed shirts and jackets and our Trevilpress CP presses for collars and cuffs, the prevailing risks are those of hands-crushing and the interference with the moving parts.

From the very beginning of each project, Trevil carefully evaluates the risks for the operators. When we design the first prototype of a new machine, we rely on specialised consultancy companies for examination, ensuring its safety. In all those cases where it is not possible to entirely avoid the contact with the moving parts through shielding and fencing, the safety systems are equipped with sensors capable of recognizing potential interferences and immediately stopping the moving device. Also, from an ergonomic point of view, our designing department focuses on ease and comfort of use and the minimization of tiring or unnecessary movements. The heat emission, typical on our products is limited as much as possible in areas located far away from the operator. A machine that does not cause fatigue to the operator, has also positive repercussions in terms of workplace well-being and higher production efficiency.”

We can approach the topic of safety in the industrial laundries from a dual perspective, says Marco Niccolini, the General Sales and Marketing Director of Renzacci SpA. As Renzacci, and we are very strict in complying with the current regulations both nationally and internationally. So, not only at the CE level but also with numerous certifications from third-party laboratories extending beyond the CE borders, like ETL for the United States, CSA for Canada, and many other recognitions worldwide. We must focus on the entire supply chain in terms of safety, both for the operator and for the environment (air and water). Then there is the research and development for new technologies and machinery integrating technological innovations that go beyond legislation requirements and demands, smartly anticipating the operator’s health and that of the environment. This specifically regards the study of the market where the machines operate. Let’s take an example: we produce dry-cleaning machines that, by using natural solvents as alternative to perchloroethylene, we eliminate the risk of exposure for the operator to harmful solvents while breathing. In industrial laundries where so many cleaning cycles are performed daily and the machines

have a capacity of at least 160 kg, the continuously opening of the loading door or some other inspection doors like the air filter door, pin collector, and distiller exposes operators to toxicity risks. In our case, by using natural solvents that do not evaporate under pressure or at the room temperature, unlike the chlorinated solvents, the exposure risk for operators is significantly reduced. Whether if we speak about bio dry-cleaning machines or washing machines, there has been made a huge progress. Regarding the washing machines, the interesting aspect is that of 4.0 Transition, that has allowed a strong step forward for innovation (already adopted in some other forms in other countries) that led to a strong development in technology and innovation, and has enabled a greater control for the operator over the machine. This is also due to more information available today compared to the past”. Renzacci has made this major step forward with the exclusive “My Brain” systems in bio-dry cleaning machines and “Intellectus” systems in washing machines.

“At PONY, the workplace safety and the safety related to the manufacturing of our machines are of primary importance,” tells us Paolo Fumagalli, the President of the company Pony SpA. When it comes to industrial laundry, all our products are complying with the EU directives and specific standards of the industry. From the design stage, all Pony machines are designed to ensure maximum safety in the working environment, taking into consideration any potential improper misuse. Furthermore, the design philosophy behind Pony devices is to protect and safeguard individuals even during the critical post-installation maintenance phase”. Antonio Donvito, the Technical Director of Pony SpA, explains the main safety systems and solutions adopted by Pony to reduce potential risks and hazards in the industrial laundry environment. “We focus first of all on the mechanical aspects, such as two-hand control with prolonged action and safety frames; emergency stop and reset; protective barriers that allow handling spaces and restricted access for more complex machines.

As far as the electrical part is concerned, all of our machines are complying with the EMC and LVD Directives in terms of electrical safety and harmful electromagnetic emissions and all “electrically sensitive” parts are suitably protected against direct or indirect accidental contact. As far as the thermal insulation is concerned, we have also implemented protection and insulation systems for the hot areas of the machines, as well as the covering of the ironing plates for minimizing the risk of burns in case of accidental contact. Let me expand our discussion on ergonomics, an essential element not only in terms of safety but also in terms of production efficiency. Pony machines are designed to limit physical fatigue, some are equipped with height-adjustable controls to ensure the correct posture of the operator, and with suitable lighting systems to reduce visual strain. We have also decided to simplify the use and maintenance of the machines, by taking advantage of the technological support, by equipping them with PONY TOUCH LOGIC, EASY ACCESS 2.0 and PONY CLOUD: these systems allow us to carry out scheduled maintenance, as well as proper alarm management to ensure both maximum control in case of emergency or anomaly and the efficiency of parts subjected to wear and regular maintenance”.

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