Parker Boiler’s New Vertical Water Wall

Everyone has their own set of thrills.  For instance, some guys get excited about cars; my wife tends to be enthusiastic when it comes to jewelry; my blogger is motivated by chocolate; and I have a thing for boilers.  So, imagine my reaction when I learned that Parker Boiler has a new process boiler under development.  While this sort of thing isn’t new to Parker – their engineers are constantly developing, reworking, and improving equipment and processes, and even though their Water Wall tubing design and the Low NOx Metal Fiber burner system is top notch, they’ve found yet another way to improve upon it.
 
Here are just a few advantages when choosing this model:

• Safety – Parker’s tube bundle is extremely flexible and provides a long-life with a 25-year warranty against thermal shock.
• Large Heating Surface – This provides increased efficiency, long boiler life, and reduces chances of scaling.
• Sealed Combustion – Reduces the heat loss and increases efficiency to 84%.
• Variable Speed Blower – which provides a wide turn-down ratio for production matching steam supply, saving on utility costs.
• Internal Accessibility -- Cabinet inspection panels are easily removed for service access to the burner, tubes, and steam storage drum.
• Heavy Insulated Cabinet – The cabinet is constructed to effectively reduce heat loss.

Plus, we get all the great Parker traits we have all grown to expect like 100PSI in 10 minutes and extra dry steam from the large horizontal steam drum.  Of course, this model will be manufactured in conformance with UL Standard 795 & ASME-CSD-1.  But to top it all off, this Parker Boiler from 9.6 H.P to 24 H.P will easily pass through a 35” door .......BAM!!!

TriState is a proud distributor for Parker Boiler equipment, and if you have questions about our Parker Boiler equipment, please contact us.

Laundry Equipment Removal and Installation Project in California

In October, we shared an update on a laundry equipment removal project we’d been working on with RW Martin & Sons, Inc. out of Kent, Ohio.  That project, which was in Brockton, Massachusetts, led to another large hospital project, which was in Los Angeles, California.  Our company may be called Tri-State, meaning we are in Virginia, North Carolina, and South Carolina, but believe me, we are all over the place these days.

This was a big job, done in several phases.  During the first phase of laundry equipment removal, Tri-State staff tore everything out of the facility – Milnor tunnel washers, dryers with shuttle systems, and so on.  This was a large facility with a lot of big commercial laundry equipment.  In about 6 weeks, we got it down to bare bones.  After the tradesmen got the new electrical, plumbing, and such completed, Tri-State went back to receive the equipment on the docks, stage the equipment, and then complete the installation.  In about 3 weeks, we installed a large Milnor tunnel washer, dryers, a conveyor system – everything you would need to make a facility like this run smoothly and efficiently.

I must stop here because I’m making it sound way easier than it was.  This facility was going from a steam powered production plant to a plant running without steam, now using two Parker Boiler T6800s to heat their wash, no steam up needed.  This required assistance from our friends, Gulf Steam Company out of Florida, to get the plant running.

In all, we spent about 9 weeks making these changes, and I have to say that I couldn’t be more pleased with the results.  Check out the photos to see for yourself.  I couldn’t be prouder to be a part of an organization that gets to upgrade the equipment for some of the finest healthcare facilities in our country.

Ultimate Dry Cleaner Receives Award

In last month’s blog post, we shared with you a project we’d been working on with a long-time customer whose operation had been destroyed by fire.  After we posted the blog, we learned that that cleaners – Brothers Cleaners in Raleigh, North Carolina – received the grand prize from American Drycleaner magazine in the 57th Annual Plant Design Awards.

What made this plant so special?  The plant is designed so that the soiled work comes in the side door at the 5 - 90LB RealStar Heated Hydrocarbon machines, is sorted, and then cleaned.  Once cleaned, it goes to the adjacent finishing area and flow down isles to the Metalprogetti Assembly Conveyor where they are assembled by customer and continue through the auto bagging station and automatically sorted again to the corresponding customers route storage conveyor.  Besides the efficient workflow, this plant's boiler requirement of 75 horsepower led us to suggest that they install two boilers, a Parker Boiler 105-70 H.P and a Parker Boiler 104-50 H.P. The 70 H.P provides the needed steam to operate the plant on most any given day. Adding the 50 H.P and setting the on-off limits will have it fire only when the 70 falls a little behind.  In addition to Parker Boiler and RealStar, the plant boasts equipment from Sankosha, Leonard Automatics, and Covers, Etc.  Finally, their front counters are made of recycled glass bottles and resin product.

“We are honored to have been chosen by Brothers Cleaners to help with this project,” said Kevin Lawson, Vice President of Tri-State Laundry Equipment.  “They showed their complete confidence in our judgement and capabilities.  This was an all-encompassing project for our company, requiring most of our staff and capabilities for virtually two years. First by building a complete temporary facility in a leased building, while designing and planning for the rebuilding of their facility.  This project was a tremendous undertaking for Tri-State, and in my opinion, the most rewarding too.  All our folks were very proud to have been there for the Hilker Family and Brothers Cleaners when their whole world had come down around them. I will always be proud that they turned to us and put their total faith in our ability.”

Steam Systems Design for the Ultimate Dry Cleaners

I recently designed a large, state-of-the-art dry cleaning and laundry facility for a long-time customer whose plant had been destroyed by fire.  The new plant would consist of five 90-pound Realstar heated hydrocarbon dry cleaning machines, six Sankosha dry cleaning finishing bays and four Unipress Double Buck shirt finishing bays with six Unipress hot head finishing units for jeans, touch up, and linen.

To ensure the plant ran properly, I had to calculate the steam requirements accurately, so I began by referring to all the manufacturers specs for each piece of equipment.  Then, I could take the boiler horsepower required and determine the pounds of steam per hour required and size the steam supply and return headers.

This plant's boiler requirement of 75 horsepower led me to suggest to the owners that they install two boilers, a Parker Boiler 105-70 H.P and a Parker Boiler 104-50 H.P. I know you’re adding this up, and it's greater than the 75-horse requirement I stated earlier.  That's because the 70 H.P will provide the needed steam to operate the plant on most any given day. Adding the 50 H.P and setting the on-off limits will have it fire only when the 70 falls a little behind. 

Here’s the logic behind my recommendation:

• We can almost get enough BTU’s out of a stack economizer on the 70 H.P. to heat all their shirt laundry water with a storage tank and circulating pump.
• Hot water generated from a stack economizer is truly free energy because you have paid for it, and it’s on its way out of the stack.  Why not harness all that energy?
• The 70 will be the master and carry most of the load.  We want it on and firing on high as much as possible to carry the load and make hot water.  Additionally, flue gas heat exchangers don’t make a lot of ROI unless your boiler is 50 H. P. or higher.  You simply can’t get enough BTU’s to do the job.
• One issue with this type of water heating system is that it’s making hot water the entire time the boiler is firing, and if you don’t have the demand, your storage tank weeps or pops off due to overheating.  Then you have wasted water down the drain, giving up your free BTU’s.  The 50 H.P comes in when, in the afternoon, they no longer have the demand to make hot water while perhaps finishing up some shirts or running dry cleaning for the next day.  They can turn off the 70 and finish up with the 50.
• They will also just use the 50 on Saturdays to run dry cleaning machines only and maybe press some dry cleaning for a head start on the week.
• The steam header is also designed with valves for the header to separate the high-pressure and low-pressure sides allowing them to open or close for fewer loads and not building steam pressure throughout the plant and wasting energy. Of course, this would be done using the 50 H.P because boiler requirements are low and there is no need for hot water.
• One final detail that I consider to be very important but almost always overlooked or misunderstood is when designing steam headers, you should slope the supply and return so the system drains the condensate, and it is pushed by pressure on the return side.  A slope helps it drain completely after shutdown, avoiding corrosion and hammering on startup.  Parker Boiler engineers recommend 1” every 20’.

If you need to look at your plant’s steam system requirements and are unsure where to start, give Tri-State a call at 1.866.885.5218. We are happy to help.

Electrolux Barrier Washing Machines

I found several on-line articles that talked about how most washing machines are crawling with bacteria; throw your clothes in for a wash, and they could come out being dirtier than before.  There are several industries out there – hospitals, medical labs and facilities, nursing homes, and food manufacturing – where that’s simply unacceptable.  These businesses require washing machines that are designed for disinfecting; where items go in unclean and come out free of germs, bacteria, micro-organisms, and dust particles.  That’s where the Electrolux Barrier Washer comes in.

Here are just a few things we like about this washer:

1. Guaranteed Hygiene – Electrolux is a global expert in linen hygiene, and their Barrier washers offer an ideal solution by allowing unclean clothes to be loaded through one side of the machine and then clean items to be unloaded on the other side of the machine, reducing any chance of cross contamination.
2. Economical – Electrolux designed a unique drum and uses their own specialized dosing system that utilizes less water and detergent to help lower costs.
3. Reliable – Electrolux builds their machines to last, and the Barrier washer is no different with its unbalance detection system, translating to less vibration and wear and tear on the machine.

Here’s a photo from a VA Hospital we recently worked on where control is extremely important, so we have a glass separation wall between the incoming wash side and the outgoing drying and finishing side.  Of course, this operation is on a much larger scale than most, but an Electrolux Barrier Washer can adapt in any facility.

If your business needs a washing machine that offers a guaranteed line of defense from spreading germs, bacteria, and micro-organisms, then Tri-State believes you should look at the Electrolux Barrier Washer.   To learn more, feel free to contact us online or call us at 1-866-885-5218.

American Dryer Corp.’s New I-Series Dryers

Y’all have heard that quote about boys versus men and the cost of their toys.  Most men get excited over new televisions, stereo systems, motorcycles, boats, and while I love all those things, I also get really excited about new laundry equipment.  It’s true, and American Dryer Corp.’s (ADC) new I-Series Dryers are sweet.

What’s new about the I-Series Dryers?

1. They are calling them the I-Series, ‘I’ standing for intelligent airflow design; ADC continues to fine tune and make improvements with each model they introduce, and with this series, they’re boasting shorter drying times and safer, more reliable operations.  
2. ADC has also developed and patented an Automatic Airflow Compensator, which can be added to the I-Series. This automatically adjusts and compensates for the high static pressure caused by airflow restriction.  This compensator senses, calculates, and maintains proper airflow through the drying process, resulting in faster dryer times, lower energy costs, and more efficient use of personnel time.
3. ADC’s Sensor Activated Fire Extinguishing System (S.A.F.E.) completely removes any concerns about dryer fires because it instantly senses fire, quickly delivers water to that area, and then shuts itself down whether it occurs when in use or sitting idle.

American Dryer Corp. has always been known for high performance and outstanding reliability. This new series delivers all of that with a sleek-looking design, stainless steel basket and front, and self-cleaning lint screen. It comes in both gas and electric for any facility connection.  If you are in the market for a new commercial dryer, give Tri-State a call at 866-885-5218.  We are happy to answer any questions you might have and to get you started in the right direction.

Laundry Equipment Removal Project

Tri-State is working with RW Martin & Sons, Inc. out of Kent, Ohio on a project at a hospital in Brockton, Massachusetts.  You might be wondering how a partnership between a company in North Carolina and a company in Ohio came to be.  Well, Kevin Lawson and Shawn Martin met while serving together on the board for the Textile Care Allied Trades Association (TCATA), the two developed a friendship based on a mutual love of all things laundry and dry cleaning equipment related, and the rest is history.

Tri-State spent approximately 4 weeks removing 3 – 800 pound, 2 – 400 pound, and 5 - 150 pound washing machines along with feeders, ironers, folders, an immense soil sorting system, laundry trolley system, all tanks, pump stations, and air compressors. Our knowledgeable combined staff ensured that as much as could be salvaged or re-used would be. Much of the equipment will be scrapped and recycled, while the remaining will go into storage until the renovations are complete.

Soil Sorting System before removal

Soil Sorting System in the process of being removed

Soil Sorting System removed in 4 ½ days

400 pound washing machine being prepped for removal

Removing the mounting bolts of the washing machine

Washing machine being removed for scrap

The renovation will take approximately 1 – 1 ½ years to complete and after that the stored equipment along with new, up-to-date equipment with the latest technology will be installed.  We are so excited to be a part of this project and look forward to sharing more photos as it continues.

Not only does Tri-State Laundry Equipment repair, sell, and service new and used dry cleaning and laundry equipment, as you can see, we can also clear out old and dated equipment, leaving the space a fresh, clean, blank slate ready for the latest and greatest.  If you need help updating your facility, give us a call at 866-885-5218.

Boiler Skids

While boiler skids are common for industrial projects, they are uncommon for dry cleaning and laundry facilities because most equipment sellers either don’t have the knowledge of skidding or don’t have the equipment or facility to fabricate.

Tri-State’s first boiler skid project was for Mega Yacht Cleaners in Ft. Lauderdale, Florida.  The customer approached us having just recently built a new facility, wanting a Parker Boiler, and understanding the value of getting the boiler into his facility ready to connect to utilities.  He also understood the importance of having a properly piped, up-to-code, complete package designed specifically for his business.

When the unit arrived, the customer called me to say he “couldn’t believe what he was seeing being unloaded at his location.”  He thanked me profusely and went on to say that “it was beautiful.”  I had a fellow distributor drop by his location shortly after the installation, and he said the first thing the owner did, acting like a proud father, was take him to the boiler room and show him the skidded Parker Boiler System.

When most dry cleaners consider pricing for the boiler and other needed components, they typically don’t have any idea how much time and expense goes into rigging and piping the equipment.  Plus, there is the risk that it could be done incorrectly or worse, on the cheap.  Tri-State charges around $7,000 for skidding up a 15-25 H.P. boiler, return, blow down, chemical feed, and softener system.  This is an incredibly fair price given the extensive knowledge of skid design and equipment placement, welding, steel cutting, tools, and time required to do the job.

Once the customer receives the skid, all that is required is the gas vent stack out, steam supply header connection to the boiler, return header connection to the return system, blow down vented through the roof, drain to their floor drain, electrical hit to the boiler (the return system is already wired into the boiler by Tri-State), and a city water hit to the return system. Then they are ready to go; this is a big-time saver for an install job.

If you are interested in learning more about boiler skid options for your dry cleaning or laundry operation, please give us a call at 1-866-885-5218.

Washing Machine Preventative Maintenance

The majority of our OPL washer and dryer service comes about because facility owners and managers fail to perform routine preventative maintenance measures on their equipment.  Setting up and maintaining a proper preventative maintenance program may seem like a headache, but a bigger headache will come about when you have to deal with downtime and pay for emergency repair service.  Avoid the headache by picking a date, and sticking with that date each month, and following this outline:

• Check washing machine belts for wear and proper tension.
• Check to make certain the drain valve is closing properly with no water running out while the basket is full of water. If it is, it will extend the cycle time to make the level control and cause excessive water use.  To correct the issue, take the drain apart to make sure nothing is inside keeping it from closing.  Also, make sure the drain motor is functioning properly and the linkage is lubed.  If all else fails, replace the valve.
• Clean the inverter fan filter if it is clogged with lint.  If it is, it could cause the inverter to overheat.
• Check all water valves, as well as the soap hopper, for proper function.  If they aren’t working properly, most valves can be disassembled and sand or debris cleaned out or rebuild kits obtained for repair.
• Check the shocks if the machines are soft mounted; some shocks will require a proper oil level.  For those that don’t require a specific oil level, make sure the drum assembly form doesn’t show excessive vibration which leads to excessive wear.  Worn shocks and springs will cause the washer to continually redistribute the load during extraction and will fail and stop or at least extend the program time.
• Check hard mount washers for mounting bolt tightness during extraction, observe the frame at the floor for any movement.  Once the bolts loosen the washer will shake badly, damaging the floor and washer basket bearings from excessive vibration.
• Check the bearings for lubrication; some require grease and some have an oil bath bearing housing. Check for bearing wear by opening the door and lifting on the basket. There should be little to no minimal play. If the washer is shaking badly and you have play in the basket, then replace the bearings and seals as soon as possible.  Letting this continue will badly damage the washer and cause the repairs to be much higher.
• Check all hoses for leaks. I can’t tell you how many times a motor and inverter has needed replacing due to a leaking hose dripping down on the motor or electrical components, causing costly repairs.

Simply taking a little time to check the above items on your washers could save you lots of time and money in the long run.  But of course, if you have questions about your washers or need repair service, Tri-State is always here to help. 

Using Chilled Water Spot Cooling

Dry-cleaning and laundry facilities can be hot in the winter months which means they are downright unbearable this time of the year.  Understandably, there are lots of folks that simply cannot endure that kind of heat, and that translates to lower production rates and possibly loss of good employees in a tough labor market.

Last year, we offered several solutions to help keep your dry cleaning plant cool, and today we want to focus closely on the one that we believe is the only serious cooling alternative – chilled water spot cooling.  This system uses a process water chiller, like those used for cooling water for dry-cleaning machines, along with a heat exchanger or coil and fan to blow cold air like air-conditioning.  Duct work is run overhead to each work station with trunks rated to handle the cubic feet per minute (CFM) of the air handler and then drops pointed down at each work station.

Here are some important tips when it comes to installing this type of cooling system:

• Before installing, study the space using known figures like 2 drops per ton of water chiller, a chiller sized for the drop station amount, an air handler sized for the chiller tonnage, and a header trunk sized for the CFM of the air handler before beginning installation.
• As you are doing planning, focus on routing and how to hang the main header trunk as well as where to install the air handler, supply and return chilled water piping. 
• Tri-State recommends an 8” drop, which handles around 300 CFM, terminated approximately 7’ above the floor at each station, using an elbow on the end of each drop to fine tune the direction of air flow.
• Remember, this is a process water chiller with a high amperage compressor and pumps.  Using this system will increase your utility cost. 
• While it is rather costly to install and run compared to other options, it is much more effective and less expensive to operate than trying to add air conditioning to the entire facility.  Sometimes it is cheaper to cool people than to try cool an entire space.

If your dry-cleaning facility has hit that unbearable point, feel free to give Tri-State a call at 1-866-885-5218 or send us a message.  We are happy to answer questions and offer assistance.

Tri-State Laundry Equipment Provides Rigging

A few years ago Moneysworth Linen Service, a large commercial linen and beach rental company that services North Carolina and Virginia, called us for steam pipe installation for a couple Parker Boilers and stack declaimers they’d purchased.  As the relationship developed, we learned that they were in the middle of a $5 million expansion, which basically doubled their capacity, and we were fortunate enough to get to be a part of that expansion project.  The job, which consisted of rigging all new and existing equipment into place, included installing a new 12-module Kannegiesser tunnel washer with an extraction press; 6 new dryers with shuttle system for auto loading of the dryers; and 3 new iron lines complete with feeder, ironer, and folder-stackers.  One of the ironers was a specialty ironer for high quality flatwork linen of which is only one of two in North America.

 

This unique experience taught us something – that we are really good at rigging and installing large quantities of new dry cleaning equipment.  This experience also equipped us with all the necessary tools – from lifting straps to toe jacks – to take on more of these projects, regardless of size and weight.  And since this job, that’s exactly what we’ve been doing.

Our most recent rigging project, which was for Pratt Abbott Uniform & Linen Rental in Westbrook, Maine, consisted of job site rigging equipment from containers, uncrating, assembling, rigging into precise locations; leveling and bolting for the Kannegiesser Technicians; pulling miles of wire and installing controls to make the tunnel-dryer-shuttle come to life; and making huge differences in the customer’s linen production capabilities and cost of operation.

 

 
If your business has a big job in the works, and you know you’re going to need help, give Tri-State a call at 866-885-5218; we are happy to help.

Meet Matt Harris

I remember when Kevin hired Matt (pictured in the middle), who was just 19 at the time, back in 1999, to be in charge of Preventative Maintenance.  The office staff, myself included, quickly took a liking to him, and we all not only went out of our way to mother him, but we also peppered him with our sage wisdom.  Over the years, we watched Matt grow into a responsible man, a talented mechanic, a devoted husband, and a doting dad.  Those last two are especially important given that he married the boss’s daughter!

Matt spent about two years doing Preventative Maintenance before Kevin transitioned him to repairs and then ultimately installation.  While Matt has attended a few training sessions, most of his training has been on-the-job with some of the best in the industry.  Today, Matt likes nothing better than to walk into a job, having no clue what to do, face the challenge head on, and then ultimately figure it out.  And the bigger the job, the better.  Here are a few recent examples of big jobs with challenges that he, of course, solved:

• In 2015, a dry cleaner in Raleigh experienced a devastating fire, so Tri-State installed an entire plant’s worth of new dry cleaning equipment in a temporary location.  Just a short time later their new facility was completed, so Tri-State then moved and reinstalled the equipment at the new store.  He spent about a year practically living in Raleigh.
• Then there was the time a broken-down boiler installed in a boiler room was too large to take out through the doorway, so Tri-State had to bring in a crane to remove the old one through the exhaust hole in the roof as well as bring in the new boiler the same way.
• “And it’s always fun,” explained Matt, “When the dry cleaning machine won’t fit through the door.”  But these are the problems Matt enjoys solving.  “No two jobs are ever the same,” he went on, “and each one always teaches me something.”
• Lately, Tri-State has been doing equipment work in Maine with a few linen and uniform companies in dealing with massive washing machines that are 80 feet long.  Matt said it is hard and heavy work, and I hope to share more about that in our next post. 

Of course, even when you love what you do, there are tasks that aren’t so much fun, and for Matt it’s installing conveyors.  Why?  “It is labor intense, there are lots of parts, and everything is overhead,” he shared.  “My arms get really tired.”

With 18 years in this industry, I wondered what sorts of changes he’s experienced.  “Laundry equipment is definitely more computerized than it used to be,” Matt explained.  “A few years ago, washing machines lasted longer and could be repaired with a $30 part.  Today when there’s a problem, it’s usually computer-related and costs significantly more to repair.”

Lastly, I asked him if he had any parting words of wisdom to share.  “I guess to remind folks to always take care of their equipment and to follow the manufacturer’s suggestions on proper care and maintenance,” said Matt.  “Typically equipment that’s really well taken care of doesn’t require nearly as much attention as equipment that’s neglected.”

Condensate Return

Over the last couple months, we’ve been focusing on boilers; specifically, we’ve talked about boilers based on fuel options, and we’ve also discussed determining capacity needed.  Today I want to talk about improving your boiler’s efficiency, and one way to do that is to monitor the condensate returned to the boiler with a goal of maintaining a return temperature of around 180 degrees.

Let’s dive into specifics.  One type of energy steam contains is latent energy or latent heat.  According to mobile-dictionary.reverso.net, latent heat is the heat evolved or absorbed by unit mass or unit amount of substance when it changes phase without change of temperature.  In a dry cleaning plant, when steam is supplied to a process, the steam releases latent energy to supply the piece of equipment with the steam it needs to function and then condenses to a liquid condensate.  That condensate still has energy, and if pumped back into the boiler, makes the boiler run more efficiently.  How?  First, less new make-up water is required, which helps keep water costs down.  Second, that water is already hot, so less energy is required to heat the water.  Third, most of the corrosive dissolved Oxygen has been removed from the water, reducing system corrosion.

Do these three things to make sure your plant is set up properly:

• Always T upwards off of the supply and return header to the equipment connections
• Always put a check valve after every steam trap
• Confirm that all steam traps are in good working condition

This last point is exceptionally important as equipment will not work properly without steam supply and as a result, it’s constantly blowing steam by heating the condensate return system above the 180 degree target temperature.  Then the pump can’t pump water into the boiler at over around 200 degrees so it takes longer to fill the boiler which equals more cost to run the pump longer. Also, remember that increased return water temperature equals malfunctioning steam traps that allow steam to blow through the trap and heat the return water.  This can result in more than 14% flash steam loss.  It’s basically like you’re putting a brick on the steam pedal of a puff iron, and its blowing steam all the time the boiler is up to pressure.  Double utility cost hit when the steam is blowing by heating the return water which causes the pump to run longer using more electricity and the boiler to cycle more often because the pressure is being lost through the malfunctioning steam trap. All this can be detected by checking the return tank water temperature, if you are regularly running over 185 degrees.

What Size Boiler Do I Need?

Last month we discussed the different fuel source options for commercial boilers, showing the cost savings and other benefits of choosing natural gas or propane over other options.  Obviously based on last month’s post, Tri-State Laundry Equipment prefers natural gas boilers, and we want to continue the boiler conversation focusing on what size natural gas boiler best fits your business.  To determine this, we’re going to talk in terms of BHP (boiler horsepower), which is a boiler’s capacity to produce steam.  One BHP is the amount of energy required to produce 34.5 pounds of steam per hour at pressure and temperature of 0 psig and 212 degrees Fahrenheit.

When I try to determine boiler need, I use two sources: first, a spec sheet from Unipress that provides finishing equipment technical specifications (all pieces of dry cleaning and laundry equipment have a BHP number), and second, years of experience.  For instance, I know that a dry cleaning utility press is rated at 1 BHP as is a dry cleaning legger or any other dry cleaning press that uses steam to heat and steam emitted for finishing.  Pants toppers with a form and emit steam to condition are rated at ¾ BHP, where form finishers which are any bag form that finishes dresses and tops and blows air and steam are rated at 2 BHP.  I tend to rate puff irons at ¼ BHP regardless of whether they are single or triples because they don’t emit steam all the time, and they consume a very small amount when at rest.

We all have our own unique set of talents, and mine is knowing all these numbers off the top of my head.  But for the remainder of the population, pressing equipment manufacturers provide a BHP number for all their laundry, shirt laundry, and dry cleaning pressing equipment as well as for dry cleaning machines and washers and dryers.  Sometimes a little digging might be required, but this is an important number to know when outfitting a new plant or when purchasing a single piece of equipment simply for an upgrade.  Once you have all your BHP numbers, figure in about 5% for header heat loss but be careful not to oversize unless the customer demands it.  And when it’s time to replace your boiler, don’t simply replace it with your current size.  Instead, run through this exercise to see if a larger size is necessary.

Determining your required boiler size can feel a bit complicated and overwhelming, but an experienced boiler system sales and design person can come up with a really close calculation.  And of course, Tri-State Laundry Equipment is always here to help whether is it’s dry cleaning or laundry boilers or dry cleaning or laundry equipment.

Choosing the Right Boiler Based on Fuel Type

While there are a number of fuel options for boilers, with some of them being quite unusual or messy (think biomass or coal), we’re going to focus on three for several practical reasons.  First, the last thing you want is an employee shoveling pulverized coal into your boiler and then heading over to press white shirts.  Second, it can be difficult to round up burnable plant material and debris from wood construction.  You get the idea.  For our purposes, let’s talk about the following three:

• Gas Fired – Gas fired boilers burn Natural Gas.  Natural Gas is chiefly Methane, but when it is removed from the ground, it may also contain Butane, Ethane, Pentane, and Propane.  These other products are stripped out before the Natural Gas is sent down the pipeline.  Natural Gas is one of the most efficient fuels to use for boiler operations because it is relatively inexpensive, energy efficient, dependable, and environmentally friendly.  While Propane is used in similar ways, it is quite different from Methane.  For instance, a smaller amount of Propane is required to produce the same amount of heat.  The good news is that it is easy to compare costs because both are done based on BTU ratings.  To learn more on how to compare costs, click here.  There is a down side to installing gas – the initial investment can be rather costly depending on your current set up.  We suggest bringing in a qualified technician to provide an accurate estimate of what is involved so that you can take the initial cost into consideration. 
• Oil Fired – Oil fired boilers are particularly popular for homes and businesses that are not connected to gas mains.  There are several downsides to going with oil.  For instance, the cost of oil can vary greatly.  You need to have an oil tank onsite or nearby and have oil delivered.  Finally, oil fired boilers require more maintenance and attention because of dirt and soot buildup.
• Electric – Compared to gas or oil boilers, electric boilers are more efficient because there’s no need for an exhaust flue for waste; therefore, no heat escapes from the system.  They also tend to take up less room than other boilers and can be more cost effective to install.   Plus on top of all of that, they are quiet.  On the downside, electricity is more expensive in most parts of the United States. 

Let’s do some cost comparing.  Our benchmark is Natural Gas which will give us 1,075,000 BTU’s per 1,000 cubic feet at a cost of approximately $3.87.  Propane will give us 91,000 BTU’s per gallon at approximately $.86 per gallon, which calculates to 11.8 gallons of Propane for a cost of $10.14.  Oil is our next fuel choice at 138,500 BTU’s per gallon priced currently at $1.59 per gallon, which translates to 7.8 gallons of fuel oil at a cost of $12.40.  Our last option of electricity requires 1-KW to produce 3,413 BTU’s at an average cost of $.1031 per KW and that translates to $37.80.

Summary:

To create the same quantity of steam, it costs

Natural Gas    $3.87

Propane    $10.14

Oil        $12.40

Electricity    $37.80

When you take a look at all the factors, not only is there a big difference when it comes to costs, keep in mind that Natural Gas is clean burning, and oil requires burner adjustments and maintenance to keep it in proper tune.  While there are some positives to electricity, the high cost makes it impractical.  Even though everyone doesn’t have access to Natural Gas, it would be beneficial to find a location that has it or petition your local gas company to expand into your area. 

If you need help choosing a boiler, feel free to contact Tri-State Laundry Equipment Company.  We are always glad to help.

Solving Compressed Air Leaks

When running a dry cleaning plant, we seem to come up with all kinds of work-arounds to temporarily resolve machine issues just so we can get through production.  Compressed air issues are no exception – we simply solve this problem by increasing the regulator pressure, but doing this should not be a long-term fix.  If you are having compressed air issues, here’s what Tri-State Laundry Equipment recommends:

1. Check each machine’s air connection, which is typically into a coalescent filter and an air pressure regulator.  Ninety percent of the time, the filters we see are leaking air from the drain.  This is easily solved by either disassembling and cleaning or by a kit from the maker for a rebuild.  These kits contain the needed seals which have gone bad; the same applies to the regulator.
2. Examine each machine by closing off the air supply to the machines then opening only the air to the machine you are checking for leaks.  This will make it easier to pinpoint the location of the leak.  If the machine has vacuum or blower motor, you’ll need to either turn them off or disconnect the power to the motor so the machine can function, and you can hear and find the leaks more easily.  Specifically check fittings and cylinders as they are the most common locations for leaks.  Once they’ve been located, you’ll need fittings, air tubing, and cylinder repair kits to make the repairs.  Repeat the process on every machine until they’ve all been thoroughly examined, identified as leak-free, or all repairs have been made.

We realize this is quite a process.  I’ve been guilty of letting this kind of issue go in order to complete production, but I promise that the effort is worth it.  In the long run, having a properly operating machine with constant air pressure at the right pressure will reduce wear and tear on your air compressor, help reduce your utility costs, increase the quality of your product, and improve overall productivity.

If your business is struggling with air pressure issues, contact Tri-State Laundry Equipment at 1.866.885.5218.  We are glad to help.

Caring for Your Air Compressor

Good quality dry cleaning is part science and part art.  Over the years, dry cleaners have become more and more reliant on compressors, in part for the role they play in the proper function of a plant’s equipment but also for precise amounts of air on demand for things like specialized, detailed work.  So if your goal is to provide customers with bright, clean, crisply finished garments, but you are using dirty air, then you are fighting an uphill battle.  Luckily, it’s not difficult to use clean compressed air to run your equipment and to clean customer’s clothes. 

Below are some simple steps to keep your air compressor operating at peak efficiency:

• Intake Vents: If your intake vent is dirty or clogged, it will force your air compressor to work harder.  Regularly check and clean your vents, especially if you’re in a dusty environment. 
• Belts: Inspect them for excessive wear and damage, replacing them as needed.  Also be sure to check the tension, ensuring the belt can travel freely.
• Air filters: Exceptionally dirty or blocked air filters allow dirt from outside in, requiring your compressor to work harder to intake air.  Check your filters often and change them if they have a buildup of dust and dirt.  
• Oil: Consult the manufacturer’s guide to make sure you are using the proper oil.  Some manufacturers recommend non-detergent oil or synthetic oil.  Check the oil level on a daily basis to make sure it isn’t running low.  Finally, change out the oil every 500-1,000 hours to keep your compressor functioning properly.
• Separator:  If you allow water to accumulate, it will eventually get pulled back into the system.  Check and empty your separator regularly, and replace the element every 2,000 hours of operation.
• Heat Exchangers: Dirty heat exchangers won’t function at their max potential.  Cleaning them regularly will make it easier for them to keep temps down. 

Being proactive and properly maintaining your air compressor translates to money saved in the end because you reduce your chance of down time, will produce a quality product consistently, and your equipment will last longer.  But maintenance isn’t the only air compressor related topic we need to discuss.  It’s also important, especially important, to detect and solve air compressor leaks immediately.  Next month we’ll tackle that issue.  In the meantime, if you have an air compressor issue and need help, just contact Tri-State at 1.866.885.5218

Coin-Operated Laundry Equipment

I’ve never really liked doing laundry, but I particularly disliked doing laundry while I was in college.  It was so incredibly inconvenient to lug a week’s worth of laundry to the laundromat, along with a pile of quarters, and then spend the next several hours babysitting my laundry while trying to study too.  I think my biggest frustration, though, was how long it took for my clothes to dry.  Many times, I had to put a second round of quarters in, so between the time and the expense, I really began to dread laundry day.

It’s funny that I have such vivid memories of college laundry.  I could describe the place in great detail, though I couldn’t tell you what brand the washers and dryers were.  Of course, I had no idea I would be writing about coin-operated washers and dryers twenty-five years later.  But as you think about your coin-operated laundry facility, what do you want your customers to remember?  Do you want them to dread laundry day, or would you rather they have memories of how quickly and efficiently they were able to get that weekly chore completed so they could move on to other things?

When it comes to coin-operated laundry equipment, Tri-State Laundry Equipment looks for brands that will provide customers with easy, convenient, quick, and reliable service, and that’s why Tri-State features American Dryer Corporation and Wascomat coin-operated equipment.  Dryers come in heavy duty double-stack or single-stack options, and washers come in a single-stack front-loading style.  Both washers and dryers have a coin pay or card pay option.

While your customers will appreciate the easy pay, easy use, and quick washing and drying results, you’ll appreciate the energy efficiency, low maintenance, and access to interchangeable parts.  If you are in the market for either new or used coin-operated washers or dryers, contact Tri-State Laundry Equipment at 866.885.5218.  We’ll be glad to answer any questions and help you determine which products will work best for you and your customers.  

Preventing Commercial Dryer Fires

According to the U.S. Consumer Product Safety Commission, clothes dryers account for roughly 15,600 fires annually, and the number one contributing factor to dryer fires is failing to clean built up lint.  But homeowners aren’t the only folks forgetting to properly clean the lint from their dryers, those of us in the commercial laundry and dry cleaning business are guilty too.  Given that October 9-15 is Fire Prevention Week, we thought this might be a good time to remind you why this simple little task is so important.

Below are some photos of the inside of a dryer from a nearby hotel that hadn’t been properly maintained.

The accumulation of this much lint could have blocked the airflow and caused heat to buildup, ultimately resulting in a fire.  Not only are dryers a common cause for home fires, commercial dryers are also a leading cause of fires in the commercial laundry and dry cleaning industry.  Thankfully, the owners of the above dryer made a service call, so Tri-State pulled it apart, cleaned it thoroughly, and now it’s running properly.  To help avoid a commercial dryer fire and to keep your commercial dryer running efficiently, Tri-State recommends the following:

1. Clean the lint compartment after every load.  When cleaning the filter, check for items that might have gotten trapped, such as dryer sheets, which can hamper proper air flow.
2. Monthly, check the duct for lint and other items that might have made it past the filter.  Also, vacuum the exhaust duct monthly to ensure proper airflow.
3. Biannually or annually, have the entire dryer, including the lint filter system, thoroughly cleaned and maintained by a professional.

These three simple steps will not only help reduce the chance of fire in your facility, but they will also help clothes dry more efficiently, and they will help keep your utility costs down.  If you need help with commercial dryer maintenance, feel free to send us a message or give us a call at 1.866.885.5218.

Configuring a Dry Cleaning Plant

A customer of ours recently experienced a fire in their central plant, so Tri-State was asked to help relocate and install equipment in a temporary facility more than half the size of the original plant.  It’s interesting -- I’ve been in a lot of dry cleaning production facilities and have seen what I thought to be smart and efficient layouts as well as poorly designed layouts.  Plus, I’ve been in this industry for over 33 years and always felt I had a good grasp on how to properly layout commercial dry cleaning and laundry equipment for maximum productivity, that is until we underwent this exercise.  If I am being completely honest, we all, including me, learned a lot about how much production space is really required to achieve maximum productivity.  Here are three things I learned and would like to share with you thanks to my recent experience:

1. Have a plan with a final goal in mind.  In our case, the customer had a catastrophe and had to set up a new facility, but many times the need for reconfiguring or moving is to accommodate an increase in volume.  Making these sorts of changes can be really expensive and may not all fit into the budget at one time.  Don’t cut corners; instead consider implementing a plan in phases until you reach your ultimate goal.
2. Just because you are great at operating a dry cleaning plant doesn’t mean you will also be great at designing one.  If you’ve been in the business as long as I have, then you’ve experienced a reduction in piece count over the years.  Because volumes aren’t what they used to be, it can pay to take a closer look at each station to see if there is an opportunity to reduce steps or to see if one person can handle multiple pieces of equipment.  If you are concerned about productivity and layout, consider hiring a professional dry cleaning designer.
3. Bigger isn’t always better.  It’s so tempting, since you’re already in the middle of the project, to get the biggest, best, fastest, coolest, most state-of-the-art piece of dry cleaning or laundry equipment out there, but do this with every single piece and suddenly you’ve gone way over your budget.  Be realistic with your choices. 

If you find yourself needing to reconfigure or move your business, don’t hesitate to give Tri-State a call at 1.866.885.5218.  We’ll be glad to help you figure out what you need so that you can maximize both your productivity and resources.