Getting more production from the space you already have 

SERIES: Big Tech for Small Spaces

By Becca Anderson

You may have read stories like the one we ran last week in which an operator does a phenomenal amount of work with less than 2400 square feet of space. On the other hand, you may have visited larger plants that should be doing lots of work, but don’t seem to be as efficient. Why does that happen?

Before adding equipment or considering an expansion, operators should first look at how their existing space is being used. According to Ricky Munch, Pellerin Milnor Corp. Sales Operations and National Programs Manager, many productivity gains come not from adding square footage, but from making better use of the space already available.

Designing for Efficiency

What are the biggest mistakes laundries make when designing or expanding a plant with limited space?

(Ricky Munch): “Facilities often underestimate how much space people need to work efficiently.  We try to show layouts with isometric human figures in the drawing to better demonstrate the amount of space that will be needed to have a functional washroom. Forgetting to account for laundry carts in the layout can also lead to undersized laundries, as well.”

When evaluating a plant with space constraints, where do you most often find hidden opportunities for increased capacity?

“In many cases, opting for machinery with larger capacities can boost production. We recently helped a laundry upgrade from its old equipment mix of two 60-lb. washers and three 75-lb. dryers to three 80-lb. washers and three 120-lb. dryers. This essentially doubled their production capacity. “

How has equipment design changed in recent years to help laundries get more production out of the same footprint?

“More laundries are looking to “use the cube” and are incorporating overhead rail systems in their designs. By taking work off the floor and putting it up into the air, it helps smaller laundries get better functionality from their total cubic footage, rather than just the ground level square footage.”

Workflow Before Equipment

While technology can improve productivity, Munch cautions that equipment alone cannot solve operational problems. The way work enters, moves through and leaves a plant often has a greater impact on efficiency than simply adding machinery. 

Is there a point where adding more equipment stops being the answer, and workflow becomes the bigger issue?

“When equipment capacity exceeds planned production in the laundry, there is no reason for adding additional equipment. For instance, some laundries have soiled linen brought in at a specified point in time, whereas others have laundry carts rolling in the door throughout the day and evening. The laundry must be designed to accommodate how work is presented to it.”

What technologies are helping smaller laundries operate with fewer employees while maintaining throughput?

“Flatwork advances are helping reduce FTEs. For instance, even a small laundry can benefit from a simple towel folder. This can often reduce labor requirements by two FTEs or more.”

Editor’s Note: FTEs (Full- Time Equivalent) is a metric used to convert the hours worked by part-time and full-time employees into a standardized number of full-time workers.

How important is data collection and machine connectivity when trying to maximize productivity per square foot?

“It depends on the size of the laundry. The larger the laundry, the more important data collection becomes. Smaller OPL laundries often operate very efficiently with limited data collection while larger laundries require metrics to help find and correct production limitations.”

Planning for the Next Decade

Can retrofitting an older plant sometimes be a better investment than building a larger facility?

Munch says the answer depends less on the age of the building and more on the operator’s long-term objectives. 

“What’s the 10-year plan? If we know where a laundry wants to be in 10 years, we can make recommendations to either reduce labor costs, grow production or both.”

What role do modular or phased-growth strategies play in helping laundries expand without overbuilding?

“We routinely offer phased-growth plans to our customers, with some of them reaching milestones more quickly than anticipated. However, some laundries do not require the additional capex investments when their earlier plans do not develop fully. This can be a huge savings for a small business.”

Looking ahead five to ten years, what technologies do you think will have the greatest impact on helping laundries do more with less space? 

“Laundries pull in a variety of technologies and advances will be needed from all of them. This includes faster-acting chemistries, high-speed washer-extractors, limited-footprint dryers, and finishing systems that assist workers with stain detection and folding accuracy.”

One thing is clear after our talk with Munch: before you start dreaming of new equipment or a new plant building, take a look at what you already have and get everything you can out of it through more efficient use of space—in all three dimensions. Your next remodel might well be within your grasp right under your own roof.

---