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WHAT ARE THE POTENTIALITIES OF ARTIFICIAL INTELLIGENCE IN INDUSTRIAL LAUNDRIES?

We are not talking about a futuristic, avantgarde topic that is light-years away from us. We are talking about everyday reality. Artificial intelligence in industrial washing enables process optimization by increasing efficiency, reducing energy and water consumption, improving wash quality, and preventing malfunctions. AI can collect and analyse data from industrial washing machine sensors (such as temperature, duration, detergent level, spin speed, etc.) to automatically adjust parameters according to the type of fabric that needs to be treated. It can revolutionize logistics in industrial laundries by enhancing operational efficiency, optimizing workflows, and reducing operating costs. Is there a vision system capable of detecting stains on fabrics? We already know that many companies integrate predictive maintenance into their machines and that garments can be treated with personalized settings based on customer requirements or fabric type. How are our companies and their research and development departments operating? What innovations and improvements can AI bring to industrial laundry?

“Artificial intelligence essentially deals with data analysis, providing the most analytically and statistically relevant answer”, says Alessandro Rolli, the Managing Director KANNEGIESSER ITALIA. “Our companies collect process data handled in order to ensure the traceability. AI analyses operational data and predicts the optimisation of washing and drying cycles, and the efficient use of energy and water based on the repetitiveness of washing processes”. How can AI help in a washing process? “When certain conditions arise, when it comes to some articles and/or types of weight/bath and article/bath ratios, it can play a role in the optimisation of a production cycle based on prior experiences. Today, Kannegiesser uses AI to record events that could generate alarms due to a whole range of conditions and, in such cases with the help of AI, we basically remodel these variables so that they no longer generate alarms. We have also been considering AI in the preventive maintenance field.

MAINTENANCE MANAGEMENT

By using machine learning algorithms, it is possible to predict when machines might present problems or perhaps identify some issues that could statistically arise after a certain number of cycles. With the help of AI, we could be able to prevent it. Looking ahead, AI might play a significant role in automation, for example, when it comes to the loading and unloading robots. We could successfully use artificial intelligence to enhance processes, with data history as a base and a big quantity of available information. Let's also think about the use of vision systems in work processes, where you no longer need to measure a piece of linen but simply frame it as either a discard or a tablecloth, for example, without the necessity of defining it through manual criteria at the end of the cycle but by using a vision system that recognises the signs of its wear. If we step beyond our activity field, let’s imagine the impact AI could have on logistics, transport organization, and delivery optimization”.

Which is the latest AI (Artificial Intelligence) applications in the design of the machines produced by ALGITECH?
We ask Alfonso Caselli, Head of Research and Development of the company based in Martinsicuro near Teramo. “At the moment, as Texcare trade fair recently showed us, there is a "stagnation" regarding the innovations of the ironing lines. I was expecting significant innovations for the folding machines, feeding machines, towel folding machines, and napkin folders, but I didn’t find any. But what we notice, is the need to optimize labour and energy costs, and at Algitech, we are developing the entire optimization of the end-line process. Talking about AI does not mean talking about automation. In our sector AI will bring significant benefits in cost analysis and process optimization. The use of AI will lead to many benefits, and specifically, in the laundry sector, where there are three factors that need to be optimized: the use of linen, energy, and personnel. Applying AI in self-learning processes means achieving something extraordinary. Let’s try to imagine the visualization of dirt thanks to algorithms that allow for the study of the stains nature: while today we recognize stains on a white sheet (moreover in the healthcare sector), with AI we will be able to recognise dirt or tears even on a multi-coloured tablecloth.

WASH CYCLES OPTIMISATION

Then, there will be the management of statistics: nowadays, it’s no longer enough to know the number of items the machine processes, but it’s essential to know how many sheets and mattress covers were treated within the eight-hour shift, for how long, and with how much staff. The key is the self-learning of the machine and its internal processes. AI can play a crucial role in managing washing and monitoring discharges, as well as in logistics management for transport and deliveries. AI is the tool that, through self-learning, provides us with data and results that lead to a detailed analysis that single data processing cannot achieve. “Predictability” is crucial in industrial laundry, as there are many almost unknown variables to be managed and AI could play and important role in this context. The use of artificial intelligence in laundry also includes the transition phase toward the 5.0 Industry regulations, that is monitoring the energy savings while still keeping the worker at the centre, who remains a fundamental element in the production process. The cross-referencing of data will be essential, as will the creation of a substantial and vital database that enables the simplification of work and cost optimization. For example, calculating the costs for processing and distributing one kilogram of linen inside your own laundry facility. AI will provide us with the data that will allow us to solve this and many other questions”, concludes Caselli.

We meet Maurizio Casol, Director of the Automation Division at ZUCCHETTI CENTRO SISTEMI (ZCS), and immediately ask him a few questions, one closely related to the other.

Can AI revolutionize logistics in industrial laundries, improving operational efficiency and optimizing workflows? What innovations, what improvements can AI bring to industrial laundries?

“As ZCS group, we can see the application of artificial intelligence in various sectors we operate, bringing improvements in production efficiency, execution speed, and even cost savings. In particular, the benefits and advantages in managing logistics for industrial laundries are significant, both in optimizing workflows within the laundry and in distribution to the end customer. In the management of industrial laundry production flows, AI analyses the shipment progress of each individual item for each customer and processes the sequence of production flows needed to optimize subsequent shipments. Like this, the laundry has a real predictive production program, which not only that optimizes the use of all production factors (staff, time, utilities, etc.) but also reduces and balances the need for linen, as shipments are progressively closer to the real needs of each customer. In distribution to the customer, the management software dynamically analyzes the trends in the pick-ups of each individual item over time, and AI processes an optimized loading list for each distributor based on the specific needs of the group of users who usually rely on it.

STAIN RECOGNITION ON GARMENTS

The entire system evolves automatically with continuous updates of withdrawals, not just tracking but even “intelligently” anticipating changes regarding the user needs. Another significant application of AI in a field closely related to industrial laundry, specifically those operating in the healthcare sector, is the vision and recognition of surgical instruments within sterilization units. During the critical phase of reassembling surgical sets and kits prior to sterilization, the use of advanced AI algorithms enables the identification and differentiation of specific instruments before placing them in the corresponding kit. AI makes this application truly generative, as it allows for automatic, continuous, and incremental learning of new and different instruments and devices - an absolutely essential feature in a field where the variety and evolution of medical devices are constantly progressing”.

“Artificial intelligence (AI) is also revolutionizing the industrial laundry sector, and Impianti Novopac, always at the forefront in the research and development of new technologies with the aim to enhance and optimize the work quality of its customers is taking a leading role in the development of these new and promising technologies”, says Giorgio Castino, the Sales Manager of IMPIANTI NOVOPAC.

“The adoption of AI in packaging machines for industrial laundries not only improves efficiency but also reduces operating costs, significantly impacting overall productivity. One of the main challenges in industrial laundries is to ensure that each garment is packaged without defects. AI applied to packing machines can be combined with machine vision systems to monitor every stage of the packaging process. High-resolution cameras and sensors analyse the garment's appearance and the quality of the package in real time, detecting any potential errors, irregular folds, or issues with the plastic film. If an anomaly is being detected, such as incorrect bagging or a defect of the film, the system can automatically intervene to correct the error or alert the operator, ensuring that every package is properly sealed and free of imperfections. This automated quality control process reduces complaints and increases customer satisfaction. Artificial intelligence applied to the shrink film packing machines for industrial laundries represents an important step towards advanced automation and the optimization of packaging processes.

PACKAGING PROCESS

Learning capabilities, real-time quality control, and predictive maintenance contribute not only to improving productivity and efficiency but also to enhancing the sustainability of operations. By adopting these intelligent technologies, Impianti Novopac ensures that its customers are able respond more quickly, accurately, and cost-effectively to market demands, guaranteeing a high-quality service”, concludes Castino.

As far as MONTANARI ENGINEERING CONSTRUCTION is concerned, we spoke with Cosimo Corleone, the Marketing and Export Manager Coordinator of the company based in Modena. “Artificial intelligence (AI) is currently in an early experimental phase in our sector. Before launching new products that use this new tool, we need to carry out numerous operational tests. It is certainly a great opportunity, but it must be used with the appropriate caution, in the future, AI could be useful in various fields.
Thanks to the analysis of data collected from machine sensors, AI can predict when a machine will need maintenance. This predictive maintenance approach minimizes unplanned downtime and extends the lifespan of machinery. Through machine learning, we can detect anomalies and signs of wear before a machine failure occurs, preventing the shutdown of the entire automation system. Artificial intelligence can also be used to automate the management process of industrial laundries, including linen handling, inventory management, and production planning. In the future, AI will likely be employed to manage workflows and reduce downtime. Additionally, it is possible to monitor energy use in real time, reducing consumption through energy data analysis. For example, synchronizing machines to operate during periods of lower energy consumption helps optimize the overall efficiency of the facility”.

What can you tell us about linen sorting?

“AI-powered machine vision systems could be used to sort linen and automatically separate items, discarding those that are damaged, have persistent stains, or imperfections

REASSEMBLY OF SURGICAL SETS AND KITS

This automated quality control could increase accuracy and enhance the quality of service provided to end customers”.

How can be reduced the risk of errors for laundry operators?

“AI-based interfaces can help operators in industrial laundries monitor and control machines through voice commands or increasingly intuitive interfaces, simplifying interaction with systems and reducing the possibility of errors. This kind of growth must also be accompanied by an upgrade regarding the skills of the operators within the organization. Furthermore, AI can assist in managing more sustainable and eco-friendly practices, both in waste management and energy use, as well as in promoting more sustainable behaviours.

In conclusion, artificial intelligence is a great challenge for the future. It will be one of the most significant areas of development in the coming years, but we must strive to guide AI toward a path that can move in parallel with the development of the technical skills of operators and a change in mindset from an organizational and structural point of view in industrial laundries”.

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