Candidate Support Pack. DRY CLEANING OPERATIONS Level 2 G8CC 22

Transcription

1 Candidate Support Pack DRY CLEANING OPERATIONS Level 2 G8CC 22

2 Publishing information First edition Published date: March 2007 Publication code: DB3332 First Published 2007 Published by the Scottish Qualifications Authority The Optima Building, 58 Robertson Street, Glasgow G2 8DQ Ironmills Road, Dalkeith, Midlothian EH22 1LE The information in this publication may be reproduced in support of SQA qualifications. If it is reproduced, SQA should be clearly acknowledged as the source. If it is to be used for any other purpose, then written permission must be obtained from the Assessment Materials and Publishing Team at SQA. It must not be reproduced for trade or commercial purposes. Note: Activities should be carried out in conjunction with current Health and Safety legislation and local safety practices. Scottish Qualifications Authority 2007

3 Contents Section 1: Introduction Section 2: F0JK 04 Health, safety and security at work (HS1) Introduction Fire Accidents and emergencies Other hazards in the laundry plant Electricity and machine safety Control of Substances Hazardous to Health (COSHH) Security End of Unit activity Activity answer sheets Section 3: F0JL 04 Classify items and make up loads for cleaning (LDC3) Introduction Sorting domestic, personal and specialist laundry Sorting contract laundry Classification Activity answer sheets Section 4: F0K4 04 Remove stains by dry cleaning (LDC12) Introduction Stain removal Activity answer sheets Section 5: F0JN 04 Clean items by dry cleaning processes (LDC13) Introduction Fabric soiling and staining Dry cleaning solvents The dry cleaning machine Detergents Dry cleaning: systems, processes and key facts Application of textile finishes Activity answer sheets iii

4 Section 6: F0JS 04 Form-finish and inspect garments using steam/air (LDC11) F0JV 04 Garment and item finishing using the ironing table after dry cleaning (LDC14) F0JT 04 Garment and item finishing using a free steam press (LDC15) Introduction Health and safety and maintenance procedures Types of steam, types of press and folding Finishing heat sensitive fabrics Press clothing Activity answer sheets Section 7: AT6W 04 Carry out the washing process (LDC4) Introduction Health and safety and maintenance procedures The ingredients for a successful wash process The wash process Troubleshooting Activity answer sheets Section 8: F0K7 04 Tumble-dry items (LDC7) Introduction Tumble-dry items Activity answer sheets Section 9: F0JW 04 Inspect and prepare laundered and cleaned items for dispatch (LDC17) Introduction Retail packing and dispatch Bulk packing and dispatch Activity answer sheets iv

5 1 Dry Cleaning Operations Level 2 G8CC 22 Candidate Support Pack Section 1 Introduction

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7 Introduction About this pack Welcome to this candidate support pack. It has been designed to enable you to meet the requirements of the SVQ in Dry Cleaning Operations at Level 2. The Units you will cover are as follows: Mandatory Units F0JK 04 Health, safety and security at work (HS1) F0JL 04 Classify items and make up loads for cleaning (LDC3) F0K4 04 Remove stains by dry cleaning (LDC12) F0JN 04 Clean items by dry cleaning processes (LDC13) Option Group choose ONE of the following Units F0JV 04 Garment and item finishing using the ironing table after dry cleaning (LDC14) F0JT 04 Garment and item finishing using a free steam press (LDC15) The following Units are available as additional Units, but are not required for an SVQ AT6W 04 Carry out the washing process (LDC4) F0K7 04 Tumble-dry items (LDC7) F0JS 04 Form-finish and inspect garments using steam/air (LDC11) F0JW 04 Inspect and prepare laundered and cleaned items for dispatch (LDC17) Once you have completed these Units and worked through this support pack, you should know all there is to know about the dry cleaning process! How the pack is organised The learning and teaching materials in this pack are organised around the Units themselves. These materials will help you to develop the specific knowledge and skills that you require for each Unit. They will also help you to generate the evidence you need to pass each Unit. Each section of the pack contains the information you need to know about a particular topic, while the activities give you the opportunity to apply what you have learned. There is also a self-check questionnaire at the end of each section, which will test how much you have remembered and understood. You should discuss the results with your trainer this will highlight your strengths and weaknesses, and is a good basis for self-evaluation. 1.1

8 Assessment Your trainer will use the various activities and self-check questionnaires to assess you as you work your way through this support pack. They will also tell you what the evidence requirements are for each particular Unit. Finally, remember that you will be formally assessed by an assessor once you have completed each Unit. Workplace skills As a result of working through all the Units in Dry Cleaning Operations, you should be able to: communicate effectively with colleagues and customers comply with written instructions complete forms, reports and other documentation keep accurate records These are generic skills. In some Units, however, you will develop more specific skills. These are outlined in the Introduction to the relevant section. Resources Before you begin working on this SVQ, you should ask for a copy of the following documents from your employer or trainer: Health and Safety policy The Health and Safety at Work Act (relevant sections) Control of Substances Hazardous to Health (COSHH) Fire instructions Emergency procedures in the event of a major occurrence Environmental policy And finally We hope that you enjoy using this pack, and that it will help you to pass the SVQ in Dry Cleaning Operations. Good luck! 1.2

9 2 Dry Cleaning Operations Level 2 G8CC 22 Candidate Support Pack Section 2 F0JK 04 Health, safety and security at work (HS1)

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11 Contents Introduction About this Unit Key areas of knowledge and understanding Skills and techniques Regulations, rules and guidelines Additional requirements for man-made fibres About this learning and teaching pack Fire Introduction Guidelines Activity 1 Fire alarm and your reaction Fire drill procedures Activity 2 Activity 3 Activity 4 Contacting emergency services Activity 5 Self-check questionnaire Accidents and emergencies Introduction Main causes of accidents Injuries and first aid Activity 6 Self-check questionnaire iii

12 Other hazards in the laundry plant Introduction Steam Activity 7 Water Activity 8 Compressed air Activity 9 Litter and debris Activity 10 Hygiene avoiding cross-contamination Activity 11 Activity 12 Activity 13 Lint and dust Self-check questionnaire Electricity and machine safety Introduction Protection from electrocution Your ten point protection from electrocution Activity 14 Activity 15 Accident prevention: case studies Activity 16 Self-check questionnaire iv

13 Control of Substances Hazardous to Health (COSHH) Introduction Labelling of hazardous substances Safety procedures Activity 17 Safe Handling Data Sheet Activity 18 Correct storage and handling of chemicals Activity 19 Chemical spillage Self-check questionnaire Security Introduction Self-check questionnaire End of Unit activity Major incident! 2.39 Activity answer sheets Fire Accidents and emergencies Other hazards in the laundry plant Electricity and machine safety Control of Substances Hazardous to Health (COSHH) Security Notes 2.65 v

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15 Introduction About this unit This Unit F0JK 04 Health, safety and security at work (HS1) is designed to help you develop responsibility for your own health, safety and security in the workplace, and to monitor the workplace for hazards. Your role will involve: contributing to the safety and security in the workplace taking action in the event of an incident raising the alarm following correct procedures for shut down and evacuation using emergency equipment correctly and safely monitoring the workplace for hazards As a competent person, you must: take action in the event of fire, emergencies or accidents monitor the workplace for hazards contribute to maintaining the security of the workplace and its contents Key areas of knowledge and understanding The Unit will help you develop the following key areas of knowledge and understanding: Where alarms, emergency exits, escape routes, emergency equipment and assembly points are located. What the alarm sounds like. The different types of hazardous substances that are used in the workplace, and the methods you can use to make them safe or reduce their danger in the event of an accident. How to handle and store hazardous substances. What the most likely accidents and emergencies are in the workplace, and how to deal with them. Who the nominated First Aiders are. How to deal with the loss of property. 2.1

16 Skills and techniques After working your way through the Unit, you should be able to: identify the location and type of incident raise alarms follow emergency procedures use emergency equipment recognise potential hazards and rectify them as soon as possible store materials and equipment handle waste and debris and move them to safe locations identify malfunctions in machinery and equipment you should correct them if possible, and report them note service malfunctions and chemical leaks Regulation, rules and guidelines You should read and get to know the following regulations, rules and guidelines: The organisation s rules, codes, guidelines and standards relating to health, safety and security. Equipment operating procedures. Handling and lifting techniques. Correct use and maintenance of any protective clothing and/or equipment. Responsibilities under the Health and Safety at Work Act and Control of Substances Hazardous to Health (COSHH). Environmental requirements. Manufacturers instructions. 2.2

17 Additional requirements for man-made fibres You will need to fulfil the following additional requirements. 1 Correctly use at least three of the following types of personal protective equipment: eye protection hearing protection safety gloves safety footwear hard hats respirators 2 Comply with procedures in the event of the following types of emergency: fire contamination (eg from leaks, spillages, gas emissions) accident and injury to persons explosion About this learning and teaching pack This part of the learning and teaching pack is designed to help you develop the knowledge and understanding and generate the evidence required to pass this Unit. It is divided into the following sections: Fire Accidents and emergencies Other hazards in the laundry plant Electricity and machine safety Control of Substances Hazardous to Health Security Each section contains information and follow-up activities to help you apply what you have learned. At the end of each section there is a self-check questionnaire to help you check your knowledge and understanding so far. You should discuss your answers with your trainer. And finally, there is an end of Unit activity that puts all your knowledge to the test! Your trainer will discuss this with you before you undertake it. 2.3

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19 Fire Introduction On average, the British laundry industry loses one plant or retail shop per year to fire. At worst, they never reopen and jobs are lost forever. At best, many peoples livelihoods are seriously affected. You can play a major role in preventing fire from destroying your place of work by being vigilant and following simple housekeeping and production guidelines. Guidelines The following guidelines will help to prevent fires starting: Do not allow lint to build up on machines and overhead. This dry and combustible material burns quickly and easily and will enable a fire to spread rapidly around the building. Rubbish and litter should not be allowed to accumulate, as it will act as an effective fuel to a fire. A cool-down period should always be programmed on the end of a fully dried classification in the tumble dryers. If the load is transferred to a barrow without being cooled down, the trapped heat in the centre of the load can start a chemical reaction. Spontaneous combustion can then take place and the work will smoulder and then burst into flames. Smoking is only permitted in designated areas outside (as per Scottish Executive guidelines) where ashtrays and smoking bins are available. Stacking garments or linen on or near hot surfaces can result in scorch marks or, at worst, a fire. Poor washing of items contaminated with grease, oil or protein foods can result in the residual grease and oil igniting when subjected to the heat of the tumble dryer or tunnel finisher. Operating tumble dryers or tunnel finishers at too high a temperature can create enough heat in cotton fibres to cause a fire. Always clear trapped fabric items from finishing equipment as quickly as possible to prevent heat build-up and damage. Leaving items contaminated with kitchen oils packed in a barrow or washing machine can lead to spontaneous combustion caused by heat-generating chemical activity. 2.5

20 Activity 1 Answer sheets p Add two more guidelines to this list to prevent fires starting in your laundry. 1 2 Fire alarm and your reaction You must know what to do if a fire breaks out in your workplace. Your senses will probably be alerted to the risk of fire before it actually occurs. For example, you might: smell fabric scorching or a motor overheating touch a machine, electrical item or fabric that your common sense tells you is too hot see wisps of smoke Carry out any obvious safe remedial action immediately (eg turn off an overheating machine) and inform your supervisor of your observation. If you see a fire, your first priority must be the safety of yourself and your workmates. Shout 'FIRE! FIRE! FIRE!' and activate the Fire Alarm. After you have sounded the alarm, you should only attempt to put out small fires. There are different types of fire extinguisher for different types of fire and selecting the correct one is vital if you are going to put out the fire safely. If you use the wrong extinguisher you could make matters worse. If you are unsure about what to do, just sound the alarm and evacuate the area. 2.6

21 Fire drill procedures When the fire alarm goes off you must follow your company s fire drill, which will be part of its Health and Safety policy. You should know and be well trained in this fire drill, and you should be absolutely clear about where fire exits, alarms and extinguishers are located. Now do the following activities. Activity 2 Answer sheets p What does your fire alarm sound like? Is it a buzzer, bell, klaxon, etc? Is it continuous or intermittent? 2 What should you do if it goes off? 3 What should you do with the equipment or machine you are working with? 4 Which exit should you use? 5 What route should you take to the exit? 6 Should you carry out any tasks on the way to the exit? 7 What should you do when you get outside? Activity 3 Answer sheets p Using a plan of your laundry or dry cleaning plant, write Fire Exit in red where each designated and signed fire exit is. 2 Put a red X where each fire alarm button/box is located. 3 Put a red O where the fire extinguishers are located. Activity 4 Answer sheets p A number of company policies and procedures should be in place to reduce the risk of injury to members of staff when the fire alarm sounds. Answer the following questions to determine the level of preparation for an emergency evacuation of your laundry or dry cleaning plant. 1 When did you last take part in a fire drill/evacuation practice? 2 Are gangways to the fire exits marked on the floor? 3 Are gangways kept clear? 4 Are all fire exits kept clear on both sides? 5 Is all fire fighting equipment well maintained? 6 Are all fire exits clearly marked? 2.7

22 Contacting emergency services There are usually nominated people who are responsible for contacting the emergency services when a fire or serious accident occurs. However, if for some reason this job falls to you, it is important that you know what to do. Activity 5 Answer sheets p Design a sign for fixing next to the telephones that can be used to ring the emergency services. You should include the following information: 1 The method of getting an outside line. 2 The number to be dialled. 3 A list of the services available. 4 The address and telephone number of the plant. Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about the fire section. When you have finished, discuss the answers with your trainer Where are the fire exits in your laundry? Where are the fire call points? If you discovered a fire what would you do first? Who would you tell? What would you tell them? What should you do with any machinery? What would you do with any doors and windows and why? Where is the fire evacuation point for the laundry? Why is a roll call taken? When would you re-enter the building? What is spontaneous combustion? How and why does it start? What is good practice to avoid spontaneous combustion? What types of work should you be particularly careful with? How many types of fire extinguishers are there in your laundry? What types of fire are they used on? 2.8

23 Accidents and emergencies Introduction Health and safety warning: machinery, equipment and services can seriously damage your health! Most accidents that require first aid in the laundry will be minor, and will probably involve trapped fingers, small cuts, minor burns and so on. However, the procedure for responding to any of these accidents should be followed as if for a major accident. This will test your company s procedures and ensure that everything is in place in case of a major incident. All accidents and injuries at work must be recorded in The Accident Book so that the health and safety committee can review all incidents and make improvements to operating procedures or equipment, and so improve the safety record. Main causes of accidents Sharps these will possibly be found in pockets, bed linen and hospital theatre linen and must be disposed of safely. Machinery trap injuries can occur in machinery that is either not guarded or badly guarded. These types of accidents will occur in calendars and presses. Equipment care should be taken when operating equipment such as forklift trucks or pallet trucks to avoid injury to fellow workers. Equipment that is hot care must be taken when operating tumble dryers: if no cool-down programme is allowed, the items will come out extremely hot and can cause burns. Rotary presses have a bed temperature in the region of 180 C. These must only be used as per the manufacturer s instructions and after appropriate training has been given, as they can cause severe burns to the body. Gas in your laundry some or all of the machinery will be gas fuelled. Care must be taken to ensure that all the burners are free from obstructions and that there are no breaks in the pipes or leakages that will cause injury to you. Steam you should ensure that all steam pipes are properly lagged and that all pipe joints are not leaking, as this can cause severe burns. Electrics you must always treat electricity with respect otherwise it can kill you. 2.9

24 Sharp things Machinery that can trap Equipment for moving things Things that get hot Steam Gas Electrics 2.10

25 Injuries and first aid Any injury sustained at work should be brought to the attention of your supervisor and the person responsible for administering first aid. Advice should be given on remedial action this could range from a plaster from the first aid box to a visit to the health centre or to the casualty department of the local hospital. Activity 6 Answer sheets p Who is your trained first aider? 2 Where is your first aid box kept? Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about accidents and emergencies. When you have finished discuss the answers with your trainer Where are the first aid boxes? Who checks the boxes? Who is the nominated first aider in your laundry? What would you do if you had an accident? What are the most likely accidents in the laundry? How would you treat them? What items would you find in the first aid box? 2.11

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27 Other hazards in the laundry plant Introduction The outbreak of a fire in your laundry or dry cleaning plant is a potential hazard, but there are other hazards that surround you every day. Many are not obvious, but it is important for your health and safety that you are aware of them. Many substances can be hazardous if handled incorrectly. These hazardous substances are either used to enable you to do your job or are a result of the laundry and dry cleaning process for example, hot laundry waste water and dry cleaning waste. Please note that chemical hazards will be dealt with in a separate section. Steam The steam used to heat a lot of equipment you use is extremely hot. Usually it is contained within well-insulated pipes or within machines but some tasks, such as pressing, require the steam to be released. This is live steam. Remember the higher the pressure, the hotter the steam. Special training is given to people who have to work with live steam but everyone should be aware of the risks of a steam leak. Here are some clues to help you identify a steam leak: You may hear it it sounds like a steam train letting off steam. You may see it but only if it is wet steam dry steam is invisible. You may feel it not recommended! It will burn you. You may notice reduced steam pressure on a machine gauge. You will get damp work off finishing equipment. Activity 7 Answer sheets p Identify and name a machine in your laundry or dry cleaning plant where you could come into contact with live steam. 2 Can you think of two other effects on productivity of reduced steam pressure? 2.13

28 Water You should always check for water leaks at your work area in the laundry. You (or other employees) could slip on water from a leak and injure yourself, or be burned by water from an overhead leak. If you discover a leak it must be cleaned immediately, and the appropriate warning signs put in place to warn others of the hazard. If this spillage is not treated it can also damage the linen in the laundry for example, it can cause mildew on the finished items in the packing area. Activity 8 Answer sheets p Think of what could happen as a result of a water leak. 1 What risks do pools of water on the laundry floor pose to laundry staff? 2 What are the dangers of hot water dripping from an overhead pipe? 3 How can linen be damaged as a result of being allowed to become damp in storage? Compressed air A compressed air leak can lead to the following problems: There can be an uncontrollable flicking in the flexible airline causing injury. Equipment will not work correctly for example, air valves will not operate. Lost productivity and quality for example, the water valve does not open on a washer extractor or sheets not folded correctly. Air leaks can be noisy. Dust and lint blown into the air can be inhaled and may coat clean linen with dust, resulting in rewash. Machines may operate slowly. Increased cost of electricity used to produce compressed air that then leaks uselessly away. Quality of work produced will be affected, for example, by oil contamination. Malfunctioning equipment can be dangerous for example, washer extractor trying to extract when full of water. 2.14

29 Activity 9 Answer sheets p What would you do if you identified a water, steam or air leak on the piece of equipment you were working on? 2 If you came across a large pool of water in a gangway, what would you do to minimise the health and safety risks to your colleagues? Litter and debris There are a number of potential risks to health and safety that can be caused by litter and debris build-up. Litter and debris are a potential fire risk. Rodents (rats and mice) and insects (for example, cockroaches) are attracted to edible litter and they bring potential health risks, quality problems and can damage machinery and fabrics. Overflowing litterbins can lead to trips and falls. Good housekeeping procedures will reduce potential health and safety risks and give any site visitors a positive impression of the laundry. Activity 10 Answer sheets p How should you deal with litter in the laundry? 2 What should you do to avoid an infestation of rodents in the laundry? 2.15

30 Hygiene avoiding cross-contamination It is becoming increasingly important to maintain good standards of hygiene. Bacteria and viruses are becoming more virulent, and the risks of cross infection are increasing with outbreaks of for example scabies, MRSA and chickenpox. Soiled linen and workwear can be contaminated with body fluids that may infect the careless laundry or dry cleaning sorter with viruses like Hepatitis B and HIV. To prevent contaminated linen coming into direct contact with the laundry sorters, they should always wear gloves and any other recommended personal protective clothing such as apron and face mask to handle the work. Foul and infected linen comes into the laundry in red bags. Red bags must not be opened. They are placed unopened into the washing machine and the bag or the stitching dissolves in the wash to release the contents safely. The best systems use hot water-soluble bags so that linen soaked in blood or urine cannot break free in transit. You must maintain a high level of personal hygiene by ensuring that hand washing is carried out as you leave the soiled linen area and after you visit the toilet. This will help prevent cross-contamination. You could risk picking up an infection by not maintaining good hygiene standards, and you could also infect clean linen with bugs from your hands. Taking your workwear garments home for washing is to be discouraged, as you could be transferring bacteria from one location to another. With most domestic washing machines at home being operated at low temperatures, you might not destroy all the bacteria, and you could infect other people's linen. It is a far better policy to have your workwear garments washed in a commercial laundry where thermal disinfection guidelines are followed. The National Health Service guidelines (HSG (95) 18) for thermal disinfection of linen recommend that one of the following wash processes be used: ten minutes wash at a minimum temperature of 65 C for polyester cotton three minutes wash at a minimum temperature of 71 C for cotton Mixing time for the washer (three minutes or four minutes for a large machine) should be added to both of these times to ensure that the required contact time at temperature is achieved. An alternative to thermal disinfection is chemical disinfection, which can be achieved using a low concentration of sodium hypochlorite bleach ( parts per million concentration in the rinse water) or a special disinfectant/detergent. Maintaining a hygienically clean laundry means following a strict cleaning routine. This routine should include tables, shelves, trolleys, packing cages and van interiors. It involves a regular wipe down using water containing a safe disinfectant, and chemically disinfecting surfaces that will come into contact with clean laundry. 2.16

31 Activity 11 Answer sheets p Which of the following methods will reduce cross-contamination from soiled laundry? Tick the correct statements. Washing above 40 C. Washing above 65 C for 10 minutes. Sweeping floors regularly. Chemical disinfection of work surfaces. Encouraging frequent hand washing. Banning cigarette smoking from the laundry. Activity 12 Answer sheets p Try to find out at least three ways used in your plant to reduce cross contamination. 2 What risks are there from contact with soiled linen? 3 What could be the result of sharp blades, syringes or swarf left in a soiled boiler suit pocket sent to the laundry? 4 What could be the result of a box of matches or a cigarette lighter left in a soiled boiler suit pocket sent to the laundry? 5 If fabric items that are contaminated with bacteria or viruses are sent to the laundry, how should they be packaged to protect the sorter? Tick the precautions which give protection. Bag labelled. Bag colour-coded. A hot water-soluble bag. Container labelled with details of contamination. Only packaged in cardboard boxes. Net bags used that can go directly into the wash. 2.17

32 Activity 13 Answer sheets p What protective clothing is available for you to use? Please tick the appropriate boxes. Smock coat Boilersuit Apron Rubber gloves Goggles Face mask Jacket/trousers Safety shoes Cotton gloves Other? Lint and dust There are a number of potential risks from lint and dust in the laundry. Because cotton is a cellulosic, fibrous material it sheds small fibres due to the mechanical action of the laundering process. These fibres are called lint. Dust, debris, human skin scales, hairs and so on are brought into the laundry with the soiled linen. The variable airflows in a laundry caused by heat, the movement of goods and the opening and closing of doors cause turbulence, which moves all this dust and lint around in the air. A 50kg dryer sucks 3500 cubic feet of air per minute in through the tumbling work and out to the atmosphere. When the plant closes at night or for longer periods, airborne dust and lint settle on surfaces throughout the laundry. It is important that the cleaning procedures prevent the build up of lint and dust in the laundry because it is a health hazard and a fire hazard. Cotton lint itself is not a health hazard, but no dust or lint should be inhaled in large quantities. The quality of the air breathed in by laundry operatives should be checked by the manager from time to time and the level of potentially irritable dust kept to a minimum by good cleaning procedures. The quality of washed and finished fabrics can be spoiled because of recontamination by dust. Equipment should be cleaned frequently. This prevents the dust and lint build-up that can potentially reduce efficiency and become a cause of malfunction and danger to the operative. The build-up of dust and lint on machinery and overhead is a serious fire risk. 2.18

33 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about other hazards in the laundry plant. When you have finished discuss the answers with your trainer What does a red alginate bag contain? How is the linen from a red bag handled and why? What would you do if you found a needle or something similar? What personal protective equipment (PPE) should the sorter wear? What are the risks from coming into contact with soiled linen? What do you think might happen if blades, syringes, etc are sent to the laundry? What do you think might happen if matches or lighters are sent to the laundry? Where do dust and lint come from? What are the potential risks from dust and lint in the laundry? Name six risks. When was the lint and dust last cleared from all the machinery at your workstation? 2.19

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35 Electricity and machine safety Introduction Electricity is used in laundries and dry cleaning plants to provide power to machinery. There are numerous safety features built into all machines to prevent this powerful energy source from becoming a risk to the health and wellbeing of the machine operators. Protection from electrocution To help prevent accidents from electrocution, you should be aware of the signs of system failures. Electrical circuits often give warnings of imminent failure. You may notice a slight tingle when you touch a machine, smell an overheating motor, see smoke, touch an electrical casing that feels hot or notice frayed or damaged electrical wiring. You could help prevent a major breakdown or incident by switching the machine off and reporting your observations to your supervisor or engineer for investigation. Your employer should ensure that safety devices on all the machinery and equipment you use are working. If you identify a faulty safety system or a fault on a machine, it is your responsibility to report it to your supervisor, engineer or manager. You could be a victim if you: are careless around electricity use equipment improperly use faulty equipment You do not touch any electrical panel. Read and follow the instructions you are given. Beware of frayed cables, bare wires

36 Note: The Electricity at Work Regulations of 1989 came into force on 1 April The Regulations require that precautions be taken to reduce the risk of death and injury from electricity at work. Your ten point protection from electrocution 2.22

37 Activity 14 Answer sheets p Choose a machine that you use regularly and identify which of the following safety devices are available for your protection. Machine: Safety guards Insulated pipes Emergency stop Warning signs Flashing light Cut-off device Button/audible alarm Electrical fuses Activity 15 Answer sheets p What would you do if a safety device stopped a machine for no apparent reason? Tick the box(es) you think are appropriate. Report incident to supervisor. Set out yourself with spanner and screwdrivers. Reset the safety device and continue to work. Report incident to an engineer. Ask a workmate to help you restart the machine. 2.23

38 Accident prevention: case studies One or two deaths occur every year as a result of people ignoring or bypassing safety devices. Continuous batch washers are fully automated washing and drying installations with many safety features including magic eyes, special keys and safety cages. However, as the two magazine articles on the following pages illustrate, they can be responsible for fatal accidents if safety procedures are not followed. 2.24

39 Courtesy of Laundry and Cleaning News, published February 1997 Tumble dryer death at Warrender plant Staff at the Warrender Aircraft Services laundry in Stevenage made a horrific discovery in the early hours of the morning when they opened one of the plant s massive tumble dryers. Inside one machine was the body of Mr Ray Washbrook, 26, who had been working overtime on the previous evening. It is thought that Mr Washbrook, who recently joined the company, died during a 15-minute period when the dryer was operating at a temperature of around 110 C. It was believed that Mr Washbrook was attempting to remove a piece of linen which had not been ejected from the rear of the dryer at the end of the cycle. It is thought he entered the conveyor enclosure, climbing into the dryer through the front loading door, taking the interlocking key with him. When he removed the piece of linen however, it allowed the rear door to close and the machine began a new cycle, leaving him trapped inside. The fully automatic Lavatec system, fitted with a number of cut-out systems, had only recently been installed by Broadbent Laundry Systems as part of a computer-controlled continuous batch washing and drying line. The installation included three tumble dryers which had been installed on a mezzanine floor. Washing was fed to the dryers by a shuttle conveyor system which was safeguarded by an enclosure fitted with a captive key interlocking system. Operation of the dryers was not linked to the interlocking system. The tumble dryers measure some 1.5 meters in diameter. Mr Washbrook, who had been unemployed for a time, had only recently started work at the plant. He was last seen alive on Friday 27 November. Other employees at the factory did not become concerned because they thought he had gone home. A post-mortem carried out by a Home Office pathologist put the cause of death as multiple head injuries. Experts from the Health & Safety Executive visited the plant on the day the body was found to carry out an investigation. This was followed by mechanical and electrical inspections concluded in December and meetings with both Broadbent and Lavatec. Mr Stephen Barney, managing director of the Sketchley Group, which owns the Warrender operation was horrified by the accident. He told Laundry and Cleaning News that the company had met with the HSE to ensure this type of accident does not happen again. Mr Barney emphasised that the machinery was brand new industry standard equipment which had only been operated for about two weeks before the accident. We use this equipment across the group and have never had a fatality, certainly since I joined the company in He said the company had been through all its procedures, reinforced them and discussed with the manufacturers why this type of incident might happen. As a result, we have made some changes to the way things operate, but we are in the hands of the manufacturers to look at how this type of installation would operate in future, he said. Mr Barney offered to speak to anyone operating similar machinery and to put them in touch with Sketchley s chief engineer. Health & Safety Executive inspector Mr Robert Meardon said there are many factories using these types of tunnel dryers. In most cases there is a lower risk of injury because the machines are set on legs out of reach. In a few cases, such as this instance, the tumble dryers have been placed on a mezzanine floor which allows operators to come into contact with dangerous machinery. Steps have already been taken to advise users of recently-installed equipment about the steps which can be taken to prevent a similar accident, he said. Companies with these types of installations were urged to contact their local HSE inspector. 2.25

40 Courtesy of Laundry and Cleaning News, published September 1997 Dryer death in Detroit US: An operator was killed after being trapped inside a dryer at a detroit laundry, Richard Neil reports Mr John McKinney, a 45-year-old worker, had been employed for three months at Palace Quality Services, Detroit. He was performing a routine maintenance on a dryer on the day of the accident. Eyewitnesses informed the Homicide Division of the Detriot Police Department that Mr McKinney had been working on the discharge side of the dryer at the time of the accident. According to the medical examiner s office, Mr McKinney had suffered blunt trauma injuries to the head and face and most likely died immediately. The Homicide Division ruled the death an accident. The Michigan department of Consumer and Industry Services the state s Occupational Safety and Health Authority (OSHA) launched an investigation into the cause of the accident. Its finding will determine whether it should cite the management of the plant for violations of OSHA s safety regulations. Nothing like this has ever happened in our 115 years in business, said Mr Don McKnight, owner of what has long been a family business. He speculated that Mr McKinney did not observe OSHA s lockout-tagout regulations. Everything else is just conjecture, he stated. Records in the Michigan OSHA office indicated that the laundry had received citations for two previous accidents. In 1983, it was fined for failing to guard its conveyors. In 1988 the fine was for negligence in guarding its electrical systems, lack of guarding to chains and sprockets, a failure to guard its sling system and violations involving folders. During a routine safety inspection in August 1996, Palace Quality Services was fined 8400 for various violations of OSHA safety regulations including a rule governing access to confined spaces. It later agreed to pay 3000 in an informal settlement. 2.26

41 The maintenance of machinery and equipment may be the role of specialists within your organisation, but maintaining a safe working environment is a task which every employee is responsible for. It is your and every employee s responsibility to keep your work area clean and tidy, to ensure that aisles, gangways, walkways and exits are clear and that floor and work surfaces are free from hazards. This will also help to ensure that a good safety record is achieved. Activity 16 Answer sheets p Look around you and give details of three posters or signs that help to make your work area a safer place. Write or draw the information on the signs onto paper and attach to the portfolio. Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about the electricity and machine safety. When you have finished discuss the answers with your trainer Where are the emergency stop buttons for your laundry located? Can you describe the various audible alarms that sound in the laundry? Are there any warning signs in the laundry? Can you identify them? If you came across defective electrical equipment what would you do? There are 10 points that can protect you from electrocution can you list at least eight? 2.27

42 2.28

43 Control of Substances Hazardous to Health (COSHH) 2.29

44 Introduction Control of Substances Hazardous to Health (COSHH) Regulations resulted from a European Union directive concerned with the protection of workers from the risks related to exposure to chemical, physical and biological agents at their work. The legislation comprises nineteen regulations, although its core message is embodied in regulation 6 paragraph 1. An employer shall not carry on any work which is liable to expose any employees to any substance hazardous to health unless he has made a suitable and sufficient assessment of the risks created by that work to the health of those employees and of the steps that need to be taken to meet the Regulations. It is the responsibility of your employer to assess the potential risks of any substance you are likely to come into contact with during your work, and to put in place procedures to prevent the substances being a hazard to your health. Labelling of hazardous substances Concentrated chemicals that are used in the laundry or dry cleaning department are potentially hazardous substances that require special attention. There is a legal responsibility on suppliers of chemicals to provide safe handling information on all product labels. This information can take the form of a hazard symbol and brief description of the hazard. Hazards Safety Precautions Irritating to eyes. In case of contact with eyes, rinse immediately with plenty of water and seek medical advice. Keep out of reach of children. Irritant 2.30

45 Products that have been assessed as being hazardous to health are labelled as follows. Label Harmful Irritant Highly flammable Flammable Toxic Corrosive Oxidising Agent Example Dry Cleaning solvent fabric conditioner Polymark fluid, typewriter correction fluid (Tippex) petrol and diesel oil rust remover laundry detergents hypochlorite bleach Safety procedures You will have products with these hazard symbols in your laundry or dry cleaning department and you should be aware of what special procedures are in place to enable you to handle and use them safely. These procedures will have been determined after the relevant Safe Handling Data Sheet has been assessed. Safety procedures for handling hazardous chemicals may well include wearing gloves, facemasks and specified protective clothing. Activity 17 Answer sheets p Identify two products that you use in your laundry that have a hazardwarning symbol on the label. 2 Write down the product name and detail the recommended safe handling advice given on the label. 3 Draw the hazard warning symbol exactly as it appears on the label. Safe Handling Data Sheet If there should be an accident involving a hazardous substance, you will be able to find advice on how to treat any injury or to clean up a spillage on the Safe Handling Data Sheet. You should be aware of where the Safe Handling Data Sheet records are stored in your laundry, and how to find the information you need in an emergency. 2.31

46 Activity 18 Answer sheets p Go and find the Safe Handling Data Sheet for one of the chemicals you handle. Now answer the following questions: 1 Are there any restrictions on this chemical coming into contact with other chemicals? 2 Is there any information that should be given to the Fire Service if this chemical is in the vicinity of a fire? 3 What should you do if this product is swallowed by a workmate? Correct storage and handling of chemicals The correct storage of chemicals that are hazardous to health is an important safety precaution. The Safe Handling Data Sheet will provide advice on storage. There can be a chemical reaction between some chemicals if they are mixed, and this can result in serious consequences. If sodium hypochlorite bleach is mixed with an acid sour it will liberate chlorine gas, which is poisonous. If you accidentally mix other chemicals from the laundry or dry cleaning departments they can become very hot, or even explosive! Corrosive chemicals such as washing detergent can cause skin burns and irritation. Correct storage reduces the risk of chemicals being mixed, of spillages occurring and of accidents causing injury. If your job involves handling chemicals you should receive special training in handling techniques and instructions on how to avoid any risk of injury. If special personal protective equipment (PPE) is provided and recommended to be worn you will be putting yourself at risk if you do not use it. You will also be breaking the law. Follow the advice given during your training and provided on product labels, Safe Handling Data Sheets, posters and signs and you will be able to work safely even with very hazardous chemicals. Activity 19 Answer sheets p How should chemicals be stored safely? 2 You have to change a container of bleach, how should this be carried out? 3 What information would you find on a safety data sheet? 2.32

47 Chemical spillage Spillages or leaks can be hazardous. If you respond immediately, you will help to prevent someone injuring themselves through contact with the chemical or by slipping on a puddle. Spillage blankets look like a limp duvet and are manufactured to be highly absorbent. They are laid over spillages, allowed to absorb the spilt chemical and then processed through a washing machine or dry cleaning machine. 2.33

48 Granular sand is used to absorb chemical spillages and then transferred to a properly labelled, sealed container for safe and proper disposal. Granular sand can also be used to contain a chemical spillage and prevent the liquid entering drains, sewers, work pits, and so on. 2.34

49 Self-check questionnaire Answer sheet p Use this self-check questionnaire to make sure that you now know all that you need to know about the Control of Substances Hazardous to Health. When you have finished discuss the answers with your trainer What do the letters COSHH stand for? How many plastic chemical kegs can you stack one on top of another? Where is the COSHH information kept in your laundry? Identify two products that are used in the laundry that have a hazardwarning symbol on the label. What is the symbol and what does it mean? Using a hazard data sheet for one of these products, list key points for storage, and so on. List the potential COSHH hazards in the laundry. Now carry out a full risk assessment in the laundry using the form provided by your trainer for cleaning a tumble dryer lint screen. How do you deal with the following waste materials: polythene bags string waste fabric Your colleague receives a bleach splash to his eye. What do you do? To whom would you report hazards in the laundry? 2.35

50 2.36

51 Security Introduction Your trainer will supply you with your company s guidelines on security. Self-check questionnaire Answer sheet p Use this self-check questionnaire to make sure that you now know all that you need to know about the security section. When you have finished discuss the answers with your trainer How would you maintain the security of employees personal belongings? How do you protect employees from risk of attack? How can you prevent theft of laundry equipment for example, a computer? How would you deal with an unauthorised person entering the laundry during working hours? How can a laundry protect commercial information such as customer lists or this training manual? 2.37

52 2.38

53 End of Unit activity Major incident! A major incident occurs in your laundry or dry cleaning unit when you are on duty and you are the person in charge, as all the senior management are attending a meeting at another plant. How would you deal with this? Take the incidents listed below and say in which order you would take action for example, mark 1 in the box you think is most important, then 2 in the one you think is the next most important, and so on. You might want to tackle this activity as a project and write what you would do on a sheet of paper. This is also acceptable. Inform emergency services Inform supervisor Inform engineer Inform workmates Sound fire alarm Stop machine Evacuate building Repair fault Fire Steam leak Electrical fault Machine malfunction Chemical leak Gas leak Weather damage 2.39

54 2.40

55 Activity answer sheets: Fire Activity 1 Question p. 2.6 Add two more guidelines to this list to prevent fires starting in your laundry

56 Activity 2 Question p What does your fire alarm sound like? Is it a buzzer, bell, klaxon, etc? Is it continuous or intermittent? 2 What should you do if it goes off? 3 What should you do with the equipment or machine you are working with? 4 Which exit should you use? 5 What route should you take to the exit? 6 Should you carry out any tasks on the way to the exit? 7 What should you do when you get outside? 2.42

57 Activity 3 Question p. 2.7 Please ask your trainer for a plan. Activity 4 Question p. 2.7 A number of company policies and procedures should be in place to reduce the risk of injury to members of staff when the fire alarm sounds. Answer the following questions to determine the level of preparation for an emergency evacuation of your laundry or dry-cleaning plant. 1 When did you last take part in a fire drill/evacuation practice? 2 Are gangways to the fire exits marked on the floor? 3 Are gangways kept clear? 4 Are all fire exits kept clear on both sides? 5 Is all fire fighting equipment well maintained? 6 Are all fire exits clearly marked? 2.43

58 Activity 5 Question p. 2.8 Design a sign for fixing next to the telephones that can be used to ring the emergency services. You should include the following information: 1 The method of getting an outside line. 2 The number to be dialled. 3 A list of the services available. 4 The address and telephone number of the plant. 2.44

59 Self-check questionnaire Question p. 2.8 Use this self-check questionnaire to make sure that you now know all that you need to know about the fire section. When you have finished discuss the answers with your trainer. 1 Where are the fire exits in your laundry? 2 Where are the fire call points? 3 If you discovered a fire what would you do first? 4 Who would you tell? What would you tell them? 5 What should you do with any machinery? 6 What would you do with any doors and windows and why? 2.45

60 Self-check questionnaire (continued) Question p Where is the fire evacuation point for the laundry? 8 Why is a roll call taken? 9 When would you re-enter the building? 10 What is spontaneous combustion? How and why does it start? 11 What is good practice to avoid spontaneous combustion? 12 What types of work should you be particularly careful with? 13 How many types of fire extinguishers are there in your laundry? What types of fire are they used on? 2.46

61 Activity answer sheets: Accident and emergencies Activity 6 Question p Who is your trained first aider? 2 Where is your first aid box kept? Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about accidents and emergencies. When you have finished discuss the answers with your trainer. 1 Where are the first aid boxes?. 2 Who checks the boxes? 3 Who is the nominated first aider in your laundry? 2.47

62 Self-check questionnaire (continued) Question p What would you do if you had an accident? 5 What are the most likely accidents in the laundry? 6 How would you treat them? 7 What items would you find in the first aid box? 2.48

63 Activity answer sheets: Other hazards in the laundry plant Activity 7 Question p Identify and name a machine in your laundry or dry cleaning plant where you could come into contact with live steam. 2 Can you think of two other effects on productivity of reduced steam pressure? Activity 8 Question p Think of what could happen as a result of a water leak. 1 What risks do pools of water on the laundry floor pose to laundry staff? 2 What are the dangers of hot water dripping from an overhead pipe? 3 How can linen be damaged as a result of being allowed to become damp in storage? 2.49

64 Activity 9 Question p What would you do if you identified a water, steam or air leak on the piece of equipment you were working on? 2 If you came across a large pool of water in a gangway, what would you do to minimise the health and safety risks to your colleagues? Activity 10 Question p How should you deal with litter in the laundry? 2 What should you do to avoid an infestation of rodents in the laundry? 2.50

65 Activity 11 Question p Which of the following methods will reduce cross-contamination from soiled laundry? Tick the correct statements. Washing above 40 C. Washing above 65 C for 10 minutes. Sweeping floors regularly. Chemical disinfection of work surfaces. Encouraging frequent hand washing. Banning cigarette smoking from the laundry. 2.51

66 Activity 12 Question p Try to find out at least three ways used in your plant to reduce cross contamination. 2 What risks are there from contact with soiled linen? 3 What could be the result of sharp blades, syringes or swarf left in a soiled boiler suit pocket sent to the laundry? 4 What could be the result of a box of matches or a cigarette lighter left in a soiled boiler suit pocket sent to the laundry? 5 If fabric items that are contaminated with bacteria or viruses are sent to the laundry, how should they be packaged to protect the sorter? Tick the precautions which give protection. Bag labelled. Bag colour-coded. A hot water-soluble bag. Container labelled with details of contamination. Only packaged in cardboard boxes. Net bags used that can go directly into the wash. 2.52

67 Activity 13 Question p What protective clothing is available for you to use? Please tick the appropriate boxes. Smock coat Boilersuit Apron Rubber gloves Goggles Face mask Jacket/trousers Safety shoes Cotton gloves Other? Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about the other hazards in the laundry plant. When you have finished discuss the answers with your trainer. 1 What does a RED alginate bag contain? 2 How is the linen from a red bag handled and why? 3 What would you do if you found a needle or something similar? 4 What personal protective equipment (PPE) should the sorter wear? 5 What are the risks from coming into contact with soiled linen? 2.53

68 Self-check questionnaire (continued) Question p What do you think might happen if blades, syringes, etc are sent to the laundry? 7 What do you think might happen if matches or lighters are sent to the laundry? 8 Where do dust and lint come from? What are the potential risks from dust and lint in the laundry? Name six risks. 9 When was the lint and dust last cleared from all the machinery at your workstation? 2.54

69 Activity answer sheets: Electricity and machine safety Activity 14 Question p Choose a machine that you use regularly and identify which of the following safety devices are available for your protection. Machine: Safety guards Insulated pipes Emergency stop Warning signs Flashing light Cut-off device Button/audible alarm Electrical fuses Activity 15 Question p What would you do if a safety device stopped a machine for no apparent reason? Tick the box(es) you think are appropriate. Report incident to supervisor. Set out yourself with spanner and screwdrivers. Reset the safety device and continue to work. Report incident to an engineer. Ask a workmate to help you restart the machine. 2.55

70 Activity 16 Question p Look around you and give details of three posters or signs that help to make your work area a safer place. Write or draw the information on the signs onto paper and attach to the portfolio. 2.56

71 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about electricity and machine safety. When you have finished discuss the answers with your trainer. 1 Where are the emergency stop buttons for your laundry located? 2 Can you describe the various audible alarms that sound in the laundry? 3 Are there any warning signs in the laundry? Can you identify them? 4 If you came across defective electrical equipment what would you do? 5 There are 10 points that can protect you from electrocution can you list at least eight? 2.57

72 2.58

73 Answer sheets: COSHH Activity 17 Question p Identify two products that you use in your laundry that have a hazardwarning symbol on the label. 2 Write down the product name and detail the recommended safe handling advice given on the label. 3 Draw the hazard warning symbol exactly as it appears on the label. 2.59

74 Activity 18 Question p Go and find the Safe Handling Data Sheet for one of the chemicals you handle. Now answer the following questions: 1 Are there any restrictions on this chemical coming into contact with other chemicals? 2 Is there any information that should be given to the Fire Service if this chemical is in the vicinity of a fire? 3 What should you do if this product is swallowed by a workmate? Activity 19 Question p How should chemicals be stored safely? 2 You have to change a container of bleach, how should this be carried out? 3 What information would you find on a safety data sheet? 2.60

75 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about the Control of Substances Hazardous to Health. When you have finished discuss the answers with your trainer. 1 What do the letters COSHH stand for? 2 How many plastic chemical kegs can you stack one on top of another? 3 Where is the COSHH information kept in your laundry? 4 Identify two products that are used in the laundry that have a hazardwarning symbol on the label. What is the symbol and what does it mean? 5 Using a hazard data sheet for one of these products, list key points for storage, and so on. 6 List the potential COSHH hazards in the laundry. 2.61

76 Self-check questionnaire (continued) Question p Now carry out a full risk assessment in the laundry using the form provided by your trainer for cleaning a tumble dryer lint screen. 8 How do you deal with the following waste materials: polythene bags string waste fabric 9 Your colleague receives a bleach splash to his eye. What do you do? 10 To whom would you report hazards in the laundry? 2.62

77 Answer sheets: Security Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about the security section. When you have finished discuss the answers with your trainer. 1 How would you maintain the security of employees personal belongings? 2 How do you protect employees from risk of attack? 3 How can you prevent theft of laundry equipment for ex ample, a computer? 4 How would you deal with an unauthorised person entering the laundry during working hours? 5 How can a laundry protect commercial information such as customer lists or this training manual? 2.63

78 2.64

79 Notes 2.65

80 2.66

81 3 Dry Cleaning Operations Level 2 G8CC 22 Candidate Support Pack Section 3 F0JL 04 Classify items and make up loads for cleaning (LDC3)

82 ii

83 Contents Introduction About this Unit Key areas of knowledge and understanding Skills and techniques Regulations, rules and guidelines About this learning and teaching pack Sorting domestic, personal and specialist laundry Introduction Health and safety Linen handling Activity 1 Activity 2 Setting-up the workstation Activity 3 Activity 4 Closing down the workstation Activity 5 Counting and sorting Foreign bodies and lost property Foul and infected linen Activity 6 Activity 7 Marking Activity 8 Care labels for laundering Activity 9 Self-check questionnaire iii

84 Sorting contract laundry Introduction Health and safety Activity 10 Activity 11 Setting-up the workstation Closing down the workstation Activity 12 Activity 13 Sorting equipment Activity 14 Self-check questionnaire Classification Introduction Activity 15 Fibre type Activity 16 Activity 17 Item type Colour Activity 18 Activity 19 Soiling type Soiling levels Activity 20 Production requirements Disinfection Special fabric finishes Rewash Activity 21 Self-check questionnaire Activity answer sheets Sorting domestic, personal and specialist laundry Sorting contract laundry Classification Notes iv

85 Introduction About this Unit This Unit F0JL 04 Classify items and make up loads for cleaning (LDC3) is designed to help you prepare items and make up loads for cleaning. Your role will involve: handling items with care and removing those that are unsuitable for the cleaning process checking for foreign objects and dealing with them according to procedures sorting items according to the appropriate classifications making up loads of the correct weight labelling them clearly prioritising loads and storing them carefully As a competent person, you must: prepare items for classification prioritise work classify items and make up loads Key areas of knowledge and understanding This Unit will help you to develop the following key areas of knowledge and understanding: How to identify and handle items. The importance of removing items unsuitable for cleaning. Classification of loads. Weight capacity of machines. Why different types of items need different weight loads. Care labels. Understanding fibres and fabrics. Constructions of items. The importance of identifying delicate/sensitive items. 3.1

86 Skills and techniques After working your way through the Unit, you should be able to: handle items carefully redirect items unsuitable for the cleaning process deal with foreign objects make up, label and store loads deal with foul and infected items identify items requiring stain removal Regulations, rules and guidelines You should read and get to know the following regulations, rules and guidelines: The organisation's rules, codes, guidelines and standards Equipment operating procedures Machine and equipment capabilities Relevant responsibilities under the Health and Safety at Work Act and Control of Substances Hazardous to Health (COSHH) Manufacturer s instructions About this learning and teaching pack This part of the learning and teaching pack is designed to help you develop the knowledge and skills and generate the evidence required to pass this Unit. It is divided into the following sections: Sorting domestic, personal and specialist laundry Sorting contract laundry Classification Each section contains information and follow-up activities to help you apply what you have learned. At the end of each section there is a self-check questionnaire to help you check your knowledge and understanding so far. You should discuss your answers with your trainer. 3.2

87 Sorting domestic, personal and specialist laundry Introduction This section covers the counting, sorting and marking of domestic, personal and other specialist soiled fabric work for washing. Information specific to large commercial laundries is given later in this teaching pack under the sorting contract laundry section. Health and safety You should make full use of all the protective equipment supplied to you to protect yourself from the potential risks of handling soiled and contaminated fabrics. An overall and gloves are essential items. Your work will involve checking pockets on all types of garments from unknown sources. The increasing use of drugs in today s society and the risk of infection from prick injuries should give you the incentive to take every possible precaution when carrying out this task. You should report any cut, abrasion or prick injury you receive while working with soiled fabric to your supervisor or first-aider immediately, so that the appropriate action can be taken. Handling foul and potentially infected items should be carried out with care to limit the risks. Do not handle these items unless you are wearing an overall and gloves. Barrier creams may be available for your use. They are not as effective against bacteria as gloves and provide no protection against sharps. Barrier creams should only be used as an additional protective layer when handling foul and infected items. If you experience any mechanical or electrical problems with machinery that you are working on, you should report these to your supervisor, engineer or manager. You should not attempt to make any repair to faulty equipment unless you have been specifically trained to carry out this type of maintenance. The following diagrams give you advice on how to deal with difficult, awkward or heavy loads. 3.3

88 Difficult loads teaching points Linen handling Possible Problems Storage level difficulties Carrying excessive loads Bulk of material may obscure vision Awkward/heavy laundry bags Possible Solutions Re-assess storage provision Advise staff on breaking load down into lighter components and use of wheeled transport Review safe lifting levels for heavy laundry bags and advise staff on when two staff are required to lift Set guidelines on the load in the bag Correct lifting of laundry bag by one person Incorrect lifting of laundry bag Correct lifting of laundry bag by two persons 3.4

89 Incorrect lifting of laundry bag by two persons Correct lifting of linen basket from table Unsafe storage of linen 3.5

90 Here is a summary of the particular health and safety issues you should be aware of in sorting: Sharps be aware of these. Pat rather than poke. Manual handling injury always lift in correct way at correct height. Do not bend and twist. Do not overload. Do not lift more than you comfortably can. Get help if needed. Infection risk wear gloves. Tape up cuts and sores. Do not open red bags. Leave any foul items in a polythene bag. Wear smock coat. Wear facemask if work is foul or dusty. Fire ensure that soiled linen from kitchens, etc are kept separate because they will possibly contain fats and oils that can cause fires. Refer to Unit HS1 for further information about fire drill procedures. Activity 1 Answer sheets p Check if there are any hazards in your sorting area. Hazard check Answer Any red bags? Are they separate and securely fastened? Any broken glass? Any sharp edges on trolleys etc? Do trolleys wheel easily? Any floor slippage or trip hazards? Any bare wires or sparks or tingles? Any steam or water leaks? 3.6

91 Activity 2 Answer sheets p You see smoke coming from a pile of dirty laundry. What should you do first? Put it out with a hose. Tell your supervisor/manager. Put it out with an extinguisher. Evacuate and sound the fire alarm. 2 Where is the nearest fire alarm to your workstation in sorting? 3 Where is the nearest fire extinguisher for a linen fire? 4 How do you use this particular extinguisher correctly? 5 What would you do to open windows and why? What would you do if you were the last to evacuate the room and if so why? 6 How do you secure customers property so that it does not get mixed up and lost? 7 You cut your finger on a blade whilst checking pockets. What do you do? 8 What precautions do you take to avoid infection when sorting work? Setting-up the workstation The workstation and sorting area are likely to be planned around a marking machine, which will provide individual laundry marks for each piece of work processed. If this machine is not functioning correctly and customer works are lost during processing, the system will collapse, extra work will be generated and time lost trying to match items with customers. It is therefore important that you carry out a planned set-up routine at the start of your shift. Check the work you are expected to sort during your time at this workstation and plan what order you will carry out the task to meet the production requirements of the laundry. It is a good policy to check with your supervisor, the previous sorter or on an agreed memo board whether you need to carry out any special tasks for the day. If the workstation has been left in a tidy and clean state by the previous worker, no housekeeping jobs should be necessary. Preparation of containers for the sorted fabric items should include a check on their condition and cleanliness to prevent damaging sorted items. If everything appears all right, you should begin setting up your workstation by switching on the marking machine and allowing it to warm up. While this is happening carry out checks on the supplies of marking tape, ink, pens, documentation and any other items you are likely to need during the time you are working at this workstation. 3.7

92 The warming-up time and necessary equipment temperature (if these are visibly recorded) will be found in your inhouse work instruction manual or in the marking machine s operator manual. Ensure that the marking machine is working satisfactorily by fixing a number of test marks to a piece of fabric and checking for clarity of mark and adhesion. You should also check that no mark-off or damage has been caused to the fabric. Activity 3 Answer sheets p Answer the following questions on how you prepare your work area and equipment for operations. 1 Set-up procedures differ from laundry to laundry. Does your laundry have any special set-up instructions not covered above? If so, write down what they are. 2 Why do you clean down sorting surfaces at the start and end of the day? 3 Where do you dispose of the following: plastic waste string and tape paper waste textile waste other waste 4 How much of your waste is: recycled % sent for landfill % incinerated % Total 3.8

93 Activity 4 Answer sheets p Detail below the marking machine you are likely to use. What is the approximate warm-up time and the target operating temperature if visibly recorded? Machine... Warm-up time... Target temperature... Closing down the workstation Before closing down the workstation you should check that all the work that was supposed to have been completed has been completed. If it has not, your supervisor should be informed as soon as possible so that arrangements can be made to complete the work or to leave instructions for whoever is working next on the workstation. All paperwork generated by your sorting and marking activities should be completed and processed to required company procedures. Once your equipment is no longer required, you should switch it off. You are responsible for making your workstation tidy and for carrying out the necessary preparations to allow the next shift to begin sorting without having to complete your unfinished tasks first. All sorted items should be stored in a way that will not cause damage or allow any item to become damp and increase the risk of mildew and odours developing. If you have been using a Polymark machine, you should check the level of solvent in the machine before leaving the workstation. If additional supplies are required the reservoir on the machine should be topped up, following the manufacturer's instructions. Activity 5 Answer sheets p The Polymark solvent that is used automatically by the Polymark marking machine to fix numbered laundry tags to fabric is classified as a hazardous chemical, because it is flammable. Using the safe handling data sheet as a guide, detail the precautions that should be taken when topping up the machine s reservoir, the personal protective equipment (PPE) that should be worn or used and how the product should be stored. 1 Product name: 2 Hazard classification: 3 What PPE should be used when handling product? 4 Recommended storage: 3.9

94 Counting and sorting The counting, sorting and marking of work for washing should be carried out in priority order. If you are not sure about the order of the work, then ask your supervisor. Sorting work in the wrong order can upset work schedules in the laundry and transport departments, and can result in sorting bins that are overflowing with unwashed work. The sorting and classification procedure for domestic, personal and other specialist work is made more difficult by the additional attention that has to be given to each item. The workwear sorter can be responsible for counting in pre-marked items, checking them for general soiling level, damage, staining and for extraneous objects in pockets before classifying them for the correct washing process. This count can be carried out manually and recorded with pen and paper, or entered into a computer terminal. Some plants operate a bar code system where every item has to be individually scanned or, alternatively, passed through a hoop that records the number of garments electronically. Whichever method is used, the sorter is ultimately responsible for providing important statistics on which management will base garment monitoring and invoices. Some domestic laundries operate automatic pricing systems where the sorters count and mark the soiled work and produce a priced invoice. This then acts as the laundry list for the packing department. Foreign bodies and lost property Part of your sorting responsibilities will involve individually checking each garment or article for extraneous objects that may cause damage or be damaged during the wash process. You may find personal belongings in the pockets of garments, badges on lapels, fancy buttons or buckles which will need to be removed before the item is washed. These items should be labelled and stored safely for return to the customer. Some items will arrive at the sorting workstation with no indication of ownership. You should make some attempt to find out where they came from by asking workmates, delivery drivers and your supervisor. If you cannot establish ownership of an item or bundle it should be Polymarked and processed as normal with a no-name ticket made out detailing the items involved and any information that might help match it with a customer enquiry later on. Foul and infected linen If items arrive at your sorting workstation labelled as foul or infected, they should be washed as quickly as possible. If the items have no identification marks they should be washed on their own (ensuring that they are disinfected) dried and then Polymarked as normal or processed as an individually labelled load through to dispatch. Infected linen should be delivered to you sealed in a red water soluble bag or in a bag with water soluble stitching that can be placed straight into a washing machine, therefore avoiding any direct contact with laundry staff. 3.10

95 Disinfection of infected linen in the wash process should follow the NHS Executive recommendations of either thermal disinfection or chemical disinfection. Thermal disinfection is achieved by washing at a set temperature for a given period of time. The recommendations are as follows: Fabric Temp Time Polyester cotton 65 C 10 mins Cotton 71 C 3 mins Chemical disinfection can be used on fabrics that will be damaged by washing at 65 C. To achieve chemical disinfection, sodium hypochlorite should be added to the first rinse of the wash process. This rinse should have a medium dip and should be of at least five minutes duration. The sodium hypochlorite addition should be enough to give parts per million in the rinse liquor. This process or alternatives to it using accredited detergent/disinfectant should be set up by a chemical technician from your detergent supplier to ensure that they achieve all the correct parameters for chemical disinfection. Activity 6 Answer sheets p You are expecting two loads of daily laundry in taped or tied knotted plastic bags or linen bags to be sorted into six classifications in trolleys from your table. 1 What will you need to do to prepare for this? 2 What do you do with linen in red bags? 3.11

96 Activity 7 Answer sheets p Your choice of disinfection process should be influenced by fabric type, colour, finish and company policy. Tick the processes you would recommend to disinfect the following items. Item 65 C 10 minutes 71 C 3 minutes 40 C hypo bleach 40 C detergent disinfectant wool jumper white cotton sheet cotton flame retardant curtains Marking Being able to identify a particular item in a laundry that processes thousands of pieces per day and being able to allocate that item to a particular customer is all down to a good marking system. There are many systems in use within the laundry industry but here are the main ones: temporary marking used on domestic items permanent transfers used on hospital linen printed heat seal labels used on workwear bar code labels used on a variety of items transponders used on work wear Temporary marking Temporary marking in the laundry industry usually means a Polymark label. This is a small, coloured piece of fabric stamped with a code that features two letters and three numbers. It is attached to every item belonging to a particular customer, and it is also attached to the laundry list. A special glue is used which holds the tag in place throughout the washing and finishing process, but allows the tag to be pulled off after all the work has been brought together in the packing department, and before it is returned the customer. Most laundries have a Polymark machine and they have proved to be a reliable solution to the difficult problem of identifying an item temporarily without leaving a permanent mark on the washed item. 3.12

97 As with all systems, it is not without its faults and unless the Polymark machine operator is properly trained, it can damage some marked items. The Polymark machine must be set up carefully so that the ink stamp pressure is high enough to mark the Polymark label, but not so high that it forces ink through the label and onto the item being processed. At the same time as the mark is being stamped, the machine heats a special adhesive to fix the tag to the garment or article. Some heat sensitive fabrics such as acrylics, wool or silk can be damaged by the heat or by the removal of the label. For heat sensitive items it is best to fix the Polymark tag to a piece of tape and attach this to the garment or article with a safety pin. Permanent transfers Permanent transfers are usually used on fabric items that will be assigned to the same client for their serviceable life, and where a prominent mark is a deterrent to theft. This type of transfer is usually applied with a heat-seal machine and is most commonly found on healthcare linen. Printed heat seal labels These are usually used to permanently mark workwear garments. Readable information such as the customer s name, date issued, number of garments and so on is printed onto a label and then heat-sealed onto the garment or article. This system enables identification of the garment at the laundry and at the customer s site. Bar code labels Labels just like those seen on food packaging are sewn or heat-sealed to fabric items and can be used to keep an accurate account of how many times an item is processed. Customers working to specific rules and regulations on fabric life for example, cleanroom operatives in the pharmaceutical and electronics industries require this level of accuracy and garment control. Transponders These are small microchips sewn into the fabric, usually on workwear, which enable garments to be accurately logged into the laundry when they pass an electronic receiver. Activity 8 Answer sheets p Collect samples of the types of laundry marks used in your plant, then stick them onto a piece of A4 card. You can now put this presentation card into your file after this page. 3.13

98 Care labels for laundering There are British standard wash process symbols that are found on the care labels attached to most modern fabric items. These recommendations are given by the manufacturer of the garment or article to help the purchaser to clean it without causing any unwanted change to its appearance, shape, colour or fabric. You should use these labels to help you to decide the most suitable classification, but if you are unsure about your selection always confirm your choice by discussing it with your supervisor or manager. A fabric item that is permanently damaged by washing with the wrong classification will result in a customer complaint, or even a possible compensation claim. The laundry will have to wash a lot of standard pillowcases to make up for the lost profit paid out to compensate the heartbroken owner of a damaged, antique pillowcase, regarded as a family heirloom. That customer will probably be lost forever and they'll tell their friends about their experience. You should be able to understand and read the washing process symbols. The following pages detail these symbols and their meanings. The recommendation for processing fabrics classified as delicate will usually include a bar beneath the washtub, containing a recommended temperature. This bar is very important because it means reduced mechanical action, gradually reduced temperature (cool down) and reduced spin. The only chemical indication given on the care labels is for chlorine bleach or dry cleaning chemicals. You should consider the effects of industrial alkali detergents on some fabrics. Wool and animal hair fibres are extremely sensitive to alkali, which is the main ingredient of most industrial washing products. Some items may be washable but if you have a dry cleaning plant this may offer a better option of cleaning a garment or article successfully without causing damage. Always consult your supervisor before redirecting an item to the dry cleaning department, as the customer may need to be consulted. Some stains or heavily soiled areas on garments or articles that will not be given a heavy wash process may benefit from spotting or special treatment before they are washed. These treatments should be followed immediately by a normal wash to prevent possible chemical damage from the treatment chemicals. Badly soiled collars, rust and ink stains are typical problems that benefit from pre-treatment. 3.14

99 Care labels for laundering WASHING BLEACHING Symbol Brief meaning Symbol Brief meaning Handwash 40 Wash at 40 o C or Use of chlorine bleach permitted 40 Wash at 40 o C with reduced mechanical action 40 Wash at 40 o C with much reduced mechanical action (wool process) or Do not use chlorine bleach Do not wash IRONING DRYING Symbol Brief meaning Symbol Brief meaning Steam ironing may be risky. Cool iron 110 o C Tumble dry at low heat setting Medium temperature iron 150 o C Tumble dry at high heat setting Do not tumble dry Hot iron 150 o C Hang to dry Dry flat Do not iron. Steaming and steam treatments not allowed Drip dry 3.15

100 Washing The washtub symbolises the domestic washing treatment (by hand or machine) (see table 1). It is used to convey information regarding the maximum washing temperature and the maximum washing process severity, as shown in table 1. Symbol 40 Washing process maximum temperature 40 C mechanical action reduced rinsing at gradually decreasing temperature (cool down) spinning reduced Symbol Table 1 Washing process maximum temperature 95 C mechanical action normal rinsing normal spinning normal maximum temperature 95 C mechanical action reduced rinsing at gradually decreasing temperature (cool down) spinning reduced maximum temperature 70 C mechanical action normal rinsing normal spinning normal maximum temperature 60 C mechanical action normal rinsing normal spinning normal maximum temperature 60 C mechanical action reduced rinsing at gradually decreasing temperature (cool down) spinning reduced maximum temperature 50 C mechanical action reduced rinsing at gradually decreasing temperature (cool down) spinning reduced maximum temperature 40 C mechanical action normal rinsing normal spinning normal maximum temperature 40 C mechanical action much reduced rinsing normal spinning normal do not wring by hand maximum temperature 30 C mechanical action much reduced rinsing normal spinning reduced hand wash only do not machine wash maximum temperature 40 C handle with care do not wash be cautious when treating in wet stage Chlorine-based bleaching The triangle symbolises the bleaching process (chlorine process) table 2. Symbol Cl Table 2 Process chlorine-based bleaching allowed only cold and dilute solution do not use chlorine-based bleach 3.16

101 Activity 9 Answer sheets p A pastel blue and white stripe polycotton overall has a care label with the following symbols: 60 What does this tell you about the recommended wash process? Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about sorting domestic, personal and specialist laundry. When you have finished discuss the answers with your trainer. 1 What type of clothing should be worn in the sorting area? 2 Give three examples of why soiling is hazardous to health? 3 Describe how you would lift difficult loads in linen handling. 4 What is the care label symbol for wash at 40 C with reduced mechanical action? 5 What is the care label symbol for use of chlorine bleach permitted? 6 What is the care label symbol for tumble drying at high heat? 7 Can you name five types of marking systems used in the laundries? 3.17

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103 Sorting contract laundry Introduction Large commercial laundries that deal with big contracts usually have an area set aside specifically for sorting soiled linen and fabric items. Soiled linen, workwear garments and other fabric items enter the laundry in a soiled and contaminated state and, in most laundry operations, they have to be sorted and classified before being washed. This task can be very dirty, and potential dangers exist to laundry personnel responsible for sorting these items. The laundry will have carried out a risk assessment on all classifications entering the premises, and will consequently have established operating procedures to protect the health and safety of their staff involved in this task. Health and safety Your supervisor will advise you or your manager if there are any specific risks associated with the type of work your laundry processes and what special precautions are necessary. By following basic hygiene and safety policies within your sorting department, you should be able to carry out all the required activities safely and efficiently. All employees engaged in sorting soiled linen or garments should wear workwear. The level of body coverage required will depend on the contamination levels of the soiled linen or special requirements issued by your customer. Some customers for example, the food industry and clean room operations are concerned that you might be at risk of increasing contamination of their garments before they are washed. The following table gives you some indication of the level of protection you may need: Personal Protective Equipment Type of soiling/customer Coat/ overall Boilersuit Jkt/Trs Face mask Respirator Special footwear Hat hood Gloves Hospital linen Engineering workwear yes possible possible unlikely possible no yes yes possible no no possible no yes Hotel work yes possible no no no no possible Abattoir overalls yes possible possible no possible possible yes Food industry yes possible possible no possible possible yes Asbestos contamination no yes yes yes yes possible yes Cleanroom no yes yes no yes yes yes 3.19

104 Some types of soiled linen are subject to special regulations from government departments, to ensure that laundry staff are not put at risk. Any laundry that processes soiled linen or garments from hospitals has to follow the recommendations in a document called Hospital Laundry Arrangements for Used and Infected Linen HSG (95) 18. This document states that workwear must be worn by laundry sorting staff because of the potential risk of infection from blood, bacteria and viruses on soiled linen. A waterproof dressing must cover all cuts and exposed lesions on the skin, and gloves must be worn. Workwear should be changed at the end of every shift. Taking workwear worn in the sorting department home for washing is to be discouraged because of the risk of spreading bacteria, viruses and infections. Heavy-duty rubber gloves are a good barrier for protection against the sharp objects often found in soiled linen. These objects can range from syringes and scalpels left in hospital work to screwdrivers and swarf left in engineers overalls. If you find any sharp object while sorting linen, you should report this to your supervisor. They will assess the risk and, if the customer can be identified, inform them of the possible consequences of their carelessness. If an injury is caused by a sharp in soiled linen, it should be treated as a potential infection and medical advice should be sought. Personal hygiene is very important if you have been handling soiled linen or workwear. Even if you have been wearing gloves, you must ensure that you wash your hands before carrying out any other activities. Handling and eating food without washing your hands could lead to infection and serious illness. Working in the sorting department often involves lifting and moving quite heavy objects. You should be aware of the risks to your back and try to follow the recommendations given in safe lifting manuals. Activity 10 Answer sheets p Carry out a risk assessment in your sorting department. 2 Highlight four activities or substances that may be potentially hazardous. 3 Detail what procedures or precautions are in place to reduce the risk. Activity 11 Answer sheets p Many advisory leaflets are available with good manual handling advice. Obtain some of these leaflets or refer to textbooks to add a number of pages of useful reference information to this manual. 3.20

105 Setting-up the workstation The sorting area will generate a large amount of debris and litter that can be seen, as well as bacteria, that often can't be seen. The workstation should be as clear of all this contamination as possible before work starts each morning. There should be a cleaning programme in place that involves the clearing of all debris from sorting areas, tables, troughs, etc and the emptying of all waste bins at the end of each shift. Dustbins, sweeping brushes, dustpans and bin bags with ties are all essential in the sorting department. Once the dust has settled, all work surfaces should be wiped down with a damp cloth soaked in a detergent/disinfectant to provide a degree of bug-kill. The disposal of waste generated by the sorting department should be given consideration as it is potentially infected. Preferably it should be incinerated and steps taken to prevent it blowing around the site where it could infect clean linen or work surfaces. If the workstation has been left clean and tidy from the previous shift s sorting, then preparing for your day s work should be relatively straightforward. Every plant is slightly different in the way they set-up their sorting department, but an assessment of workload prior to starting work should enable you to provide yourself with all the space, equipment and trolleys you need to carry out your work efficiently. If you use any electrical or mechanical equipment, you should check this for any signs of damage, and then if all appears well you should switch it on and test it prior to beginning work. You should check that any marking machines you use have sufficient labels, marking ink and adhesive to allow uninterrupted production during your shift. Closing down the workstation When you close down your workstation, you should leave it as you would like to find it at the start of your shift. For more information about what you should do, refer back to the Closing down the workstation section on page

106 Activity 12 Answer sheets p Why do you think it is important to keep debris to a minimum in the sorting area? Tick the answer(s) you think are correct. Reduced fire risk. Stops bacteria multiplying. Reduces cross-contamination of linen. Less risk of staff tripping up. Keeps string and other unwanted items out of the washing machine. Less attraction for rodents. Reduces risk of linen getting stained. Improve the working environment. Good image for visitors. Activity 13 Answer sheets p Produce a list of activities you would complete at the end of your shift to close down your sorting workstation. Sorting equipment Linen and workwear often arrive for washing packaged in a variety of ways. Sorters might well have to use knives or scissors to remove this packaging. You should be careful when you are using these sharp instruments, because they could damage the linen or garments, or find their way into washing machines where they can cause irreparable damage to the items being washed and to the washing machine itself. Soiled linen is transported in barrows, cages and bags and these should be in good condition to prevent damage to the soiled linen or garments, and to help the sorters carry out their duties safely. Cages and barrows should be checked daily for sharp edges, and cleaned and disinfected to prevent cross-contamination and soiling mark-off between different classifications. Wheels should be clear of string and other debris. If fabric bags are used for soiled linen, they should be free of holes and have all fixings and handles in place. Overfilled bags may well exceed a safe lifting weight for one person, so you should ask for help when necessary and inform customers of the problem. 3.22

107 Sorting tables should be used when available. They enable sorting to take place at a safe height and keep soiled linen off the floor. Weighing scales are an important piece of equipment. They enable the sorter to accurately measure the weight of each load. Accuracy is important if optimum production is to be maintained through the washing machines. An unbalanced load will probably not extract properly and over- and underloading of the washing machine reduces the wash quality, and can damage the machines. Production control figures for the washroom are usually based on the weight of work processed. Recording production throughput accurately provides management with statistical information on which they can base their business plans and development programmes. Activity 14 Answer sheets p What are the possible consequences of sorting work on the floor? Work might pick up additional soiling. A chemical spillage might contaminate it. The factory cat might sleep on the pile. People might trip over the pile. It might get stood on or run over by a trolley. Work can get damaged. Picking work up off the floor may injure the sorter. Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about sorting contract laundry. When you have finished discuss the answers with your trainer. 1 Document HSG (95) 18 describes what action should be taken with healthcare linen. Can you explain what these are? 2 What checks should be made to the cages/barrows and bags used in the laundry? 3 What are the advantages of using weighing scales? 4 What are the nine factors you should take into account when assembling wash loads? 3.23

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109 Classification Introduction Life would be so easy if there was only one classification, and all soiled fabrics could be washed together in a washing machine, with the same chemicals, temperature, mechanical action, process time, process formulation, extraction, drying time and finishing process. Unfortunately, there are quite a few reasons why soiled fabric has to be classified, and then each classification washed, dried and finished differently. Some laundries try to keep their classifications to a minimum. But classification is still necessary even for a linen hire company with a white-cotton-only policy* for their bed linen, table linen and towelling. The sorter is a key figure in providing information on the classifications available for washing and therefore on what the laundry throughput is likely to be over a set period. Information will come to the sorter from other departments about which classification or customer s work is required, and they must respond positively as a member of the production team. With the time delay between sorting and packing, requests between departments often overlap shift patterns. It is therefore important that messages are left if personnel carrying out the work are about to change and equally important that the new shift sorter looks for and reacts to any information or message left. Activity 15 Answer sheets p Complete the following table to see how many different classifications the linen hire company with the white-cotton-only policy* would need: Laundry service Bed linen Washing classifications Sheets Towelling Bath towels Hand towels Bath mats Dressing gowns Face cloths Table linen Banquet cloth * The linen hire company s policy is to purchase white linen and towels as these can be easily laundered and cleaned with a minimum of effort by the company. 3.25

110 Despite having only one fabric type in one colour, this laundry could potentially need the soiled fabric sorted into more than 15 different classifications! And this particular job could need even more sub-classification if the laundry has a continuous batch washing machine that requires a process number for each batch loaded and this in turn controls the wash process parameters, chemical additions, press pressure and the tumble dried finish! The number of classifications and programmes starts to increase when you consider all the possible influences on process selection. fibre type natural or man-made? item type finishing requirements colour loose dyes soiling type oily or protein? soiling level heavy, medium or light? production requirements priority and sequencing? disinfection thermal or chemical? special fabric finishes fire retardant rewash for what reason? Fibre type There are hundreds of different fibre types available to textile manufacturers, but only a few of these are typically found in commercial laundries. Fibres can be divided into two groups natural and man-made. The most common natural fabrics are made from vegetable matter (eg cotton) and from animal byproducts (eg wool). The most common man-made fibre is polyester. Cotton is a very popular fabric with linen hire and flatwork rental companies because it can be finished in a commercial laundry to a high standard and will withstand a wellbalanced industrial wash process well. It is very resistant to alkalis and the way the cotton fibres swell in an alkali wash solution helps to loosen dirt and make it easier to remove. Also, because of its high water absorption capacity, cotton is a very comfortable fabric next to the skin, and is therefore used extensively for hotel bed linen and towelling. Cotton is susceptible to chemical attack from acids and from sodium hypochlorite. Great care should be taken when bleaching cotton with sodium hypochlorite, as low concentrations cause some damage and high concentrations make the cotton fibres extremely weak. Even low concentrations will cause accelerated rotting in the hot wash. Cotton can also be damaged by micro-organisms that find their way into the hollow fibres and multiply in damp and warm conditions to form mildew. Wool and other fabrics made from animal derivatives are rarely seen in commercial laundries these days. Despite having many qualities, they do not respond well to alkali, 3.26

111 wash temperature or mechanical action in the washing machine. The classification of domestic and personal soiled fabric items involves a greater awareness of fabric types. You must be aware of what each item is made of and how this fabric will respond to the wash process your classification will give it. The added difficulty with domestic and personal items is that they are often made up of mixed fibres and are not of a standard quality. You will be expected to use your skill gained from training and experience to assess items for their washability as you count and mark them. Polyester has taken over from natural fibres as the most common fibre in use today. Polyester was first patented in 1941, and since then there have been many types developed from different base chemicals. Polyesters are very hard wearing and can withstand misuse. But they can be cold next to the skin and are not suitable for all applications. For example, sparks from welding would make a polyester overall melt and polyester sheets are uncomfortable to lie on for long periods. They are resistant to acids and all types of bleaches, but can be damaged by very strong alkalis. Polyester, however, has several major drawbacks. It attracts oily and fatty soiling, tends to generate static electricity when agitated and forms creases that detract from the laundered finish. A polyester fibre is a type of plastic, and when it is heated in the laundry process it can be bent, which causes a crease in the fabric. There are two main reasons for these creases: Thermal shock creasing is caused when the hot pliable polyester fibres are cooled down quickly, setting the fibres in a bent and twisted state. To overcome this problem the wash and drying process has to include a cool down period where the temperature is slowly reduced to about 52 C slowly (at approx 4 C per minute). Pressure creasing can be caused by the weight of the work during the hot wash in a large capacity machine and by over-extraction or extraction when items are still hot. Any polyester items left in barrows or cages after washing will develop creasing. To try to gain the benefits of both types of fibres, many items are manufactured from a mixture of cotton and polyester. It should be noted that the cotton in these polycotton items would be damaged if hypochlorite bleach were used. Activity 16 Answer sheets p List the natural fibres used to make up fabrics washed in your laundry. 3.27

112 Activity 17 Answer sheets p How would you prevent polyester garments from creasing during processing in the laundry? Item type Classification by item type is required due to different finishing techniques later in the laundry process. A lightly soiled white cotton pillowcase and towel will be classified separately. The pillowcase will only require conditioning in the tumble dryer and will then be ironed. The towel will be fully dried and folded. It is usually more efficient to separate different item types before washing rather than after. Colour White and coloured items should not be washed together. Dye transfer will occur at any temperature. At best, whites will become dingy and at worst they will take up a pale colour. Colours should also be classified carefully, with pastel shades kept separate from dark colours. Even if the dyes are relatively stable there can be a problem with coloured lint contaminating lighter coloured work. Activity 18 Answer sheets p Imagine that you are holding a soiled chef s jacket with red trimming. What would you have to consider before classification? Activity 19 Answer sheets p Cotton pillowcases are probably washed in their thousands in your laundry, but if you receive a very old linen pillowcase with delicate lace trim and coloured embroidery in a domestic parcel, it would probably be ruined if classified as a standard pillowcase. This example would probably not even carry a care label to help you decide the most suitable process classification. What would you do with this pillowcase? 3.28

113 Soiling type The influence of soiling on the sorting operation will depend on the type of laundry you work in. A linen rental company will give little attention to soiling type, as their wash processes will be designed to cope with both protein and oily type soiling. This general process will include a wash below 40 C to breakdown protein stains and a second wash at high temperature (70 80 C) to emulsify oily and greasy soiling. The workwear plant will make a major distinction between engineers garments soiled with mineral oil and food industry garments contaminated with protein based soiling, even if the garments themselves are exactly the same. The protein stained garments will be given a process similar to that used by the linen rental company, but they may use a biological enzyme detergent and low temperatures pre-wash to help release all the protein soiling from the fabric before the high temperature wash. Any protein soiling left in the fabric at the high temperature stage of the wash will be set in and be very difficult to remove. The removal of mineral oil soiling is achieved by taking the first wash straight up to high temperature where the alkali detergent and possibly a special emulsifying detergent will breakdown the oily soiling and remove it from the fabric. This type of process also allows the wash process to start at high temperature and to reduce in stages through washes and rinses to prevent thermal shock creasing a polycotton work wear. Soiling levels With classifications that vary a lot in soiling level, it is quite common for the sorter to subclassify work into light, medium and heavy soiling, all with a different process. It is quite normal for workwear plants to classify in this way. The sorter must be aware of soiling levels on all classifications, because just one grossly soiled item washed with a load of lightly soiled items can result in cross-contamination and increased staining and rewash. Very heavily soiled items should be classified separately and given a special wash process. Activity 20 Answer sheets p Give two reasons why white and blue overalls should not be washed together. Production requirements The sorter must process the soiled work in priority order, being led by the requirements of the wash room, finishing and packing departments. If the sorter is responsible for loading and programming a monorail bag storage system for a continuous batch washer, then consideration must be given to sequencing. This is the term given to batching work of similar type for processing as consecutive batches through the CBW. It can take over 20 minutes for the wash conditions in a batch washer to 3.29

114 change to a new set of parameters and this can cause problems like dye transfer, thermal shock and unwanted bleaching if the sequencing is not right. Disinfection Decisions on classification by a sorter will not usually include reference to disinfection of fabric items. The one time this may be necessary is if an item is labelled as infected, and a thermal or chemical disinfection process must replace the normal wash process for that classification. Special fabric finishes Most fabric finishes on commercially washed items will be washed off during the first few washes. This includes the special stiffness manufacturers put on new fabrics to make them feel crisp and new. The sorter may be asked to give new items a heavier wash classification to speed up this process. One finish that should not be removed and therefore should be given a special classification by the sorter is fire retardant finish. You may hear these fabrics referred to as FR curtains, FR blankets or by a treatment trade name such as Proban. There are two main processing risks to this treatment: The treatment is destroyed by contact with sodium hypochlorite bleach, although not by perborate or percarbonate bleaches. The treatment is accidentally coated as a result of the wash process. This can occur if you are washing in hard water and alkali/detergent residue are left on the fabric by poor rinsing. Good oily soil removal is also required, or the soiling might mask the fire retardant properties of the fabric finish. Fabric finishing agents such as fabric conditioners and starch should not be used on FR fabrics. A mistake in classification with FR fabrics could result in the injury or death of someone caught in a fire. Rewash Classifying work for rewash is often done in the finishing and packing departments. In most laundries this work is done without needing to determine the reason for its rewash status. To prevent work going round in circles or getting into the wrong process, the sorter should use their skill to sub-classify the rewash. A large proportion of items might just need the standard process, but some will need special treatment and some condemning. 3.30

115 Activity 21 Answer sheets p Some flame retardant curtains were sent to the laundry heavily contaminated with atmospheric soiling, and after a good wash with lots of mechanical and detergent action they still had stains on. Which bleaching agents could you use on a rewash process? 2 Complete the following table to show which fabric resists damage from alkali, acid and hypochlorite bleach. Fibre Strong alkali Strong acid Hypochlorite bleach Wool & Hair Fibres Weakened Weakened, but slowly Resists attack Cotton Polyester 3 Which of the following process classifications would you use for a heavily bloodstained white boilersuit and at what temperature would the first wash be? Process Selection or 1st wash temp White oily soil White protein soil White protein soil with enzyme detergent White mineral oil with peroxide bleach White protein with hypochlorite bleach rinse 3.31

116 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about classification. When you have finished discuss the answers with your trainer. 1 What types of stains will not wash out in the wash process? 2 How would you document any damaged item at classification? 3 What could happen if you failed to remove extraneous objects? 4 Why is it important to identify existing damage to garments in sorting? 3.32

117 Activity answer sheets: Sorting domestic, personal and specialist laundry Activity 1 Question p. 3.6 Check if there are any hazards in your sorting area. Hazard check Answer Any red bags? Are they separate and securely fastened? Any broken glass? Any sharp edges on trolleys etc? Do trolleys wheel easily? Any floor slippage or trip hazards? Any bare wires or sparks or tingles? Any steam or water leaks? 3.33

118 Activity 2 Question p You see smoke coming from a pile of dirty laundry. What should you do first? Circle the correct answer(s). Put it out with a hose. Tell your supervisor/manager. Put it out with an extinguisher. Evacuate and sound the fire alarm. 2 Where is the nearest fire alarm to your workstation in sorting? 3 Where is the nearest fire extinguisher for a linen fire? 4 How do you use this particular extinguisher correctly? 5 What would you do to open windows and why? What would you do if you were the last to evacuate the room and if so why? 6 How do you secure customers property so that it does not get mixed up and lost? 7 You cut your finger on a blade whilst checking pockets. What do you do? 8 What precautions do you take to avoid infection when sorting work? 3.34

119 Activity 3 Question p. 3.8 Answer the following questions on how you prepare your work area and equipment for operations. 1 Set-up procedures differ from laundry to laundry. Does your laundry have any special set-up instructions not covered above? If so, write down what they are. 2 Why do you clean down sorting surfaces at the start and end of the day? 3 Where do you dispose of the following: plastic waste string and tape paper waste textile waste other waste 4 How much of your waste is: recycled % sent for landfill % incinerated % Total 3.35

120 Activity 4 Question p. 3.9 Detail below the marking machine you are likely to use. What is the approximate warm-up time and the target operating temperature if visibly recorded? Machine... Warm-up time... Target temperature... Activity 5 Question p. 3.9 The Polymark solvent that is used automatically by the Polymark marking machine to fix numbered laundry tags to fabric is classified as a hazardous chemical, because it is flammable. Using the safe handling data sheet as a guide, detail the precautions that should be taken when topping up the machine s reservoir, the personal protective equipment (PPE) that should be worn or used and how the product should be stored. 1 Product name: 2 Hazard classification: 3 What PPE should be used when handling product? 4 Recommended storage: 3.36

121 Activity 6 Question p You are expecting two loads of daily laundry in taped or tied knotted plastic bags or linen bags to be sorted into six classifications in trolleys from your table. 1 What will you need to do to prepare for this? 2 What do you do with linen in red bags? Activity 7 Question p Your choice of disinfection process should be influenced by fabric type, colour, finish and company policy. Tick the processes you would recommend to disinfect the following items. Item 65 C 10 minutes 71 C 3 minutes 40 C hypo bleach 40 C detergent disinfectant wool jumper white cotton sheet cotton flame retardant curtains 3.37

122 Activity 8 Question p Collect samples of the types of laundry mark used in your plant, then stick them onto a piece of A4 card. You can now put this presentation card into your file after this page. Activity 9 Question p A pastel blue and white stripe polycotton overall has a care label with the following symbols: 60 What does this tell you about the recommended wash process? 3.38

123 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about sorting domestic, personal and specialist laundry. When you have finished discuss the answers with your trainer. 1 What type of clothing should be worn in the sorting area? 2 Give three examples of why soiling is hazardous to health? 3 Describe how you would lift difficult loads in linen handling. 4 What is the care label symbol for wash at 40 C with reduced mechanical action? 5 What is the care label symbol for use of chlorine bleach permitted? 6 What is the care label symbol for tumble drying at high heat? 7 Can you name five types of marking systems used in the laundries? 3.39

124 3.40

125 Activity answer sheets: Sorting contract laundry Activity 10 Question p Carry out a risk assessment in your sorting department. 3.41

126 Activity 10 (continued) Question p Highlight four activities or substances that may be potentially hazardous Detail what procedures or precautions are in place to reduce the risk. Activity 11 Question p Many advisory leaflets are available with good manual handling advice. Obtain some of these leaflets or refer to textbooks to add a number of pages of useful reference information to this manual. List the titles of these leaflets here. 3.42

127 Activity 12 Question p Why do you think it is important to keep debris to a minimum in the sorting area? Tick the answer(s) you think are correct. Reduced fire risk. Stops bacteria multiplying. Reduces cross-contamination of linen. Less risk of staff tripping up. Keeps string and other unwanted items out of the washing machine. Less attraction for rodents. Reduces risk of linen getting stained. Improve the working environment. Good image for visitors. Activity 13 Question p Produce a list of activities you would complete at the end of your shift to close down your sorting workstation. 3.43

128 Activity 14 Question p What are the possible consequences of sorting work on the floor? Work might pick up additional soiling. A chemical spillage might contaminate it. The factory cat might sleep on the pile. People might trip over the pile. It might get stood on or run over by a trolley. Work can get damaged. Picking work up off the floor may injure the sorter. 3.44

129 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about sorting contract laundry. When you have finished discuss the answers with your trainer. 1 Document HSG (95) 18 describes what action should be taken with healthcare linen. Can you explain what these are? 2 What checks should be made to the cages/barrows and bags used in the laundry? 3 What are the advantages of using weighing scales? 4 What are the nine factors you should take into account when assembling wash loads? 3.45

130 3.46

131 Activity answer sheets: Classification Activity 15 Question p Complete the following table to see how many different classifications the linen hire company with the white-cotton-only policy* would need: Laundry service Bed linen Washing classifications Sheets Towelling Bath towels Hand towels Bath mats Dressing gowns Face cloths Table linen Banquet cloth Activity 16 Question p List the natural fibres used to make up fabrics washed in your laundry. 3.47

132 Activity 17 Question p How would you prevent polyester garments from creasing during processing in the laundry? Activity 18 Question p Imagine that you are holding a soiled chef s jacket with red trimming. What would you have to consider before classification? 3.48

133 Activity 19 Question p Cotton pillowcases are probably washed in their thousands in your laundry, but if you receive a very old linen pillowcase with delicate lace trim and coloured embroidery in a domestic parcel, it would probably be ruined if classified as a standard pillowcase. This example would probably not even carry a care label to help you decide the most suitable process classification. What would you do with this pillowcase? 3.49

134 Activity 20 Question p Give two reasons why white and blue overalls should not be washed together. Reason one: Reason two: 3.50

135 Activity 21 Question p Some flame retardant curtains were sent to the laundry heavily contaminated with atmospheric soiling, and after a good wash with lots of mechanical and detergent action they still had stains on. Which bleaching agents could you use on a rewash process? 2 Complete the following table to show which fabric resists damage from alkali, acid and hypochlorite bleach. Fibre Strong alkali Strong acid Hypochlorite bleach Wool & Hair Fibres Weakened Weakened, but slowly Resists attack Cotton Polyester 3 Which of the following process classifications would you use for a heavily bloodstained white boilersuit and at what temperature would the first wash be? Process Selection or 1st wash temp White oily soil White protein soil White protein soil with enzyme detergent White mineral oil with peroxide bleach White protein with hypochlorite bleach rinse 3.51

136 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about classification. When you have finished discuss the answers with your trainer. 1 What types of stains will not wash out in the wash process? 2 How would you document any damaged item at classification? 3 What could happen if you failed to remove extraneous objects? 4 Why is it important to identify existing damage to garments in sorting? 3.52

137 Notes 3.53

138 3.54

139 4 Dry Cleaning Operations Level 2 G8CC 22 Candidate Support Pack Section 4 F0K4 04 Remove stains by dry cleaning (LDC12)

140 ii

141 Contents Introduction About this Unit Key areas of knowledge and understanding Skills and techniques Regulations, rules and guidelines About this learning and teaching pack Stain Removal Introduction Health and safety: chemicals Health and safety: steam gun A short history Some terms and definitions What to use when? Methods of stain removal Procedures for stain removal Factors influencing stain removal Pre-spotting equipment Post-spotting equipment Ancillary equipment Kit spotting chemicals Lighting Self-check questionnaire Activity answer sheets Stain removal 4.19 Notes 4.23 iii

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143 Introduction About this Unit This Unit F0K4 04 Remove stains by dry cleaning (LDC12) is designed to help you identify and remove stains in dry cleaning. Your role will involve: applying stain removal procedures working on the spotting table inspecting garments and detecting stains using chemicals As a competent person, you must: set-up and close-down the workstations protect items during treatment remove stains deal with soiling and staining Key areas of knowledge and understanding This Unit will help you to develop the following key areas of knowledge and understanding: Services required for the operation of stain removal equipment. The difference between cold spotting and steam spotting tables. The correct steam, water, pressure and lighting requirements. The different fabric/fibre types and the characteristic problems when they are brought into contact with certain chemicals. The requirements of ventilation air extraction. Types of absorbed staining, built-up staining and compound staining. The objectives and limitations of stain removal. The definition of pre-spotting to treat items and garments for stains, ingrained soiling and marks likely to be resistant to the dry cleaning/wet cleaning process. The risks associated with the dry cleaning of garments containing water after wet side removal treatments or slab spotting. How to interpret care labels. Why certain stains need additional treatment or special precautions. The properties of main fibres protein, vegetable (cellulose) and synthetic. Fabric construction and dyed and printed textiles. Relevant simple testing to identify fabrics. Limitations and uses of bleaching chemicals. Correct use of stain removal chemicals and other techniques. 4.1

144 Skills and techniques After working your way through the Unit, you should be able to: set-up and close-down workstations for stain treatment and/or removal, garment inspections, pre-spotting and slab spotting protect delicate items and accessories during treatment procedures identify wetside and dryside staining identify protein, albumin and tanning staining use mechanical action, dissolving, softening and lubrication, digestion and chemical reaction flush out applied chemicals deal with heavy soiling, staining content, added on trims and buttons, manufacturers faults, wear damage and other damage caused by previous treatments use stain removal equipment to remove any stains without damaging fabric carry out garment inspection and stain detection and identify staining type or possibilities using feel, odour, colour, appearance and location handle items that have been contaminated, stained with blood or unpleasantly soiled test to ascertain colour fastness to spotting reagents and chemicals apply and treat using wetside and dryside proprietary chemicals use acid and alkali wet treatments. Regulations, rules and guidelines You should read and get to know the following regulations, rules and guidelines: The organisation s rules, codes, guidelines and standards. Equipment operating procedures. Relevant responsibilities under the Health and Safety at Work Act and Control of Substances Hazardous to Health (COSHH). Personal protection measures when using hazardous chemicals. Duty of care regulations and requirements. Hazardous substances warning labels. Manufacturers instructions. 4.2

145 About this learning and teaching pack This part of the learning and teaching pack is designed to help you develop the knowledge and understanding and generate the evidence required to pass this Unit. It has one section: Stain removal This section contains information to help you apply what you have learned. At the end of the section there is a self-check questionnaire to help you check your knowledge and understanding so far. You should discuss your answers with your trainer. 4.3

146 4.4

147 Stain removal Introduction Many types of stains and ingrained soiling can be removed during the cleaning process, provided that they are treated/conditioned prior to being put into the machine. This is normally the easiest and quickest method, and further treatment should not be necessary. In some specific cases, stains need to be removed completely before cleaning, to make sure that the stain is removed and that the garment and fabric are safe. A good inspection and pre-spotting procedure is essential where service times are very short and there is only enough time to clean the garment once. This particularly applies to water based stains/soiling. Stains can sometimes still remain once a garment has been cleaned, and then postspotting has to be carried out. If, however, pre-spotting has been carried out effectively, a pass-up figure of approximately 80 per cent can be achieved. This means that probably only 20 per cent of the garments leaving the machine will require post-spotting. Ideally, garments should receive a detailed inspection in front of the customer, who should be able to indicate the nature of any particular stains. This also provides a good opportunity to return any items that may have been left in the pockets. However, even if garments have been inspected on the counter, you must still carry out a detailed inspection, then treat stains and soiling as necessary before cleaning. The cleaner should always remember that the garment is the customer s responsibility no blame can be attached if the stains and soiling cannot be removed. On the other hand, if a cleaner attempts to remove a stain from a garment and damages the garment in the process, then it is the cleaner s responsibility, and could well lead to a legitimate claim. Health and safety: chemicals You must always be careful when using chemicals. If in doubt, refer to Unit HS1 and COSHH, or consult your trainer. Here are some do s and don ts to help keep you safe while working with chemicals: Do keep your spotting equipment clean spotting chemicals can easily migrate from equipment to sensitive garments always wear eye protection when using rust removers and bleaches. All spotting chemicals and particularly rust removers and bleaches can cause extreme pain and irritation if splashed in the eye. In the case of rust removers and bleaches there is a high risk of blindness if the eye is not promptly flushed with cold water for at least 10 minutes. Medical advice should always be sought following eye contact. always wear gloves when dealing with spotting chemicals prolonged or regular skin contact with any spotting chemical may cause a range of skin problems including rashes, dermatitis and eczema. 4.5

148 tamp gently with an appropriate spotting brush on sensitive fabrics it is safer than using a spatula use absorbent material when treating stains that liberate a lot of colour check the gauze on the spotting table for sharp wire ends, which can cause serious fabric damage apply reagents around stains rather than dropping the chemical on the centre this helps to prevent heavy stains like burst biro pens spreading spot stain fabrics on the reverse Don t fill the spotting bottle to more than 70 per cent of its capacity to avoid the risk of chemicals being inadvertently ejected through the nozzle tamp or use the spatula over the wire gauze this can cause fabric damage as the textile is not fully supported apply soaps to areas that are neither soiled or stained flush out stains with a steam gun, apply soap to the wet area and clean this is a dangerous cleaning practice use the edge of the spatula to work stained areas use bleaches on coloured textiles without first testing the colour rub stains on delicate fabrics this can easily cause abrasion damage on silk attempt to treat stains on silk and acetate pile fabrics 4.6

149 Health and safety: steam gun You must always be careful when using the steam gun. If in doubt, consult your trainer or supervisor. Here are some do s and don ts to help keep you safe while using the steam gun: Do clear the condensate into a bucket or other container before using the gun hold the gun at a safe distance from the fabric to minimise the risk of yarn slippage adjust the steam to an appropriate pressure to reduce the risk of fabric damage test cellulostic fabrics in particular, cotton, linen, viscose etc for colour fastness test for colour/fabric safety when using the gun in conjunction with spotting chemicals feather out and dry from the outside of the wetted area after removing stains this reduces the risk of swelling use eye protection and gloves when using the gun in conjunction with spotting chemicals Don t hold the gun at a shallow angle to the fabric there is a significant risk of yarn slippage flush out blood or albuminous stains such as egg with the gun it may set them in the fabric use the gun on acrylic, silk and acetate use the gun to flush out rust remover this chemical must first be neutralised with five per cent ammonia flush out stains with the gun and then apply soap before dry cleaning there is a high risk of shrinkage in particular on animal hair fabrics use the gun on moiré effects without first testing some are adversely affected by water A short history It s useful to understand how stain removal has evolved. Up to the late 1950s the vast majority of dry cleaning was carried out in factory operations. In those days pre-spotting was generally confined to the removal of stains subject to heat setting such as blood and albuminous stains. These stains were removed on a specialist spotting table and the fabric dried completely before the item was cleaned. The majority of stains were removed once the garment had been cleaned. This is called post-spotting. Post-spotting procedures were therefore the norm and the staff involved were highly skilled specialists. They often had a range of 20 or more chemical reagents at their disposal. When dry cleaning moved onto the High Street, cleaners had to become multi-skilled. This inevitably gave rise to a simplification of stain removal methods, and resulted in the use of the kind of kit chemicals that we are all familiar with today. Because of this decline in the 4.7

150 use of pure chemicals, many High Street dry-cleaners are now using no more than a three bottle spotting kit, and this has substantially reduced the need for in-depth and extended training periods. Consequently, however, this has also led to an inadequate knowledge of stain removal and a reliance on cold spotting tables and spotting kits, which do not contain either a metal stain remover or bleach. The dry cleaning industry today has now reached the stage where the vast majority of garments that are still stained after dry cleaning are now pre-spotted and re-cleaned rather than the stains being removed on the post-spotting table. In fact, many dry-cleaners today do not use post-spotting methods, because unnecessary re-cleaning wastes solvent and a considerable amount of machine time. This is particularly the case during busy periods. Some terms and definitions Stain removal includes a number of technical terms and definitions, and you have to know and understand these. So here they are. Stains A stain is the presence of a substance on a fabric that alters that part of the fabric s colour and/or appearance. Stains can be classified into the following groups: Dryside stains These are stains which, in many cases, are soluble in organic solvents, eg perchloroethylene, paint removers, etc Wetside stains These are stains which, in many cases, are soluble in inorganic solvents, eg water ammonia, acetic acid etc Compound stains Compound stains are stains such as lipstick which contain both oily components as well as water solubles. Dye stains Hair dye, home fabric dyes, mark-off from fugitive colours, food colourings. Metal stains Rust, verdigris, last residue from blood and some water based inks. 4.8

151 Spotting The removal of individual stains from textiles is generally referred to as spotting. The primary objective of spotting is to remove stains without damage to the fabric, the finish or the colour. Here are three terms that you should know and understand about spotting: Pre-spotting In pre-spotting, one or more of the following is applied to the stain on the fabric before it goes on to be cleaned: soaps soap/water mixtures and/or specific wet side/dry side chemicals designed for pre-spotting The soaps and mixtures are normally used to treat ingrained soiling and/or extensively stained areas this is sometimes referred to as slop spotting. Specific wetside/dryside kit chemicals are worked into stains and are then left on the fabric to be flushed out during the dry cleaning process. Post-spotting The term post-spotting refers to the removal of stains from garments that have already been cleaned. Effective pre-spotting gets rid of most stains. Up to 70 per cent of the stains that are left in after pre-spotting can be tamped out with water, or removed with a high pressure water spray. So the stains that are left to be post-spotted are fairly stubborn! In post-spotting, the chemicals are flushed out on the spotting table, and fabric dried. Pre-cleaning stain removal Pre-cleaning stain removal is slightly different from pre-spotting and post-spotting. In precleaning stain removal the chemicals are applied to the stain before it gets cleaned but unlike pre-spotting they are not then left on the fabric to be flushed out during the dry cleaning process. Instead, the chemicals are flushed out on the spotting table and the fabric is completely dried this is vital for the safety of the fabric. What to use when? Here are some general guidelines for what to use when: Consider stain removal rather than pre-spotting on whites. Alternatively, pre-spot whites just before loading the machine. If possible do not allow pre-spotted garments to stand for more than half-an-hour before cleaning. This is more likely to happen at lunch breaks and particularly at the end of the day. Stain removal is usually the safest option on sensitive fabrics. Consider stain removal if fugitive colour is suspected it is the safest option. 4.9

152 During pre-spotting do not place sensitive items in the same pile as pre-spotted items. To avoid re-cleaning and also setting during dry cleaning, it is important that the following stain types are pre-spotted prior to cleaning. This list is not exhaustive. Albuminous egg, milk, blood, ice-cream and similar stains Tannin based tea, coffee Paints oil-based and emulsion Drinks soft drinks, beer, wine Oil-bound cosmetics, lipstick, ball-point inks Ingrained soiling hems, collars, cuffs, sleeves Methods of stain removal There are five main methods of stain removal: Mechanical action Mechanical action refers to the application of stress to a stain. It is generally applied by using a spatula or occasionally, by tamping with a spotting brush. The latest method involves ultra sonic vibration using a Sono Flash gun. This is a very safe and effective method of applying mechanical action. However it should be appreciated that mechanical action is also applied when the steam, air gun and high pressure water sprays are used. Under normal circumstances mechanical action applied by the spatula, brush or Sono Flash should only take place when the item is on the main body of the spotting table. Here is some guidance on how to use a spatula and spotting brush. How to use the spatula Applying pressure with the spatula flat against the fabric spreads the pressure, and substantially reduces the risk of fabric damage subject to the pressure applied. 2 If the spatula is used at a high angle to the fabric as above, the pressure is focused in a very narrow area and the risk of fabric damage is increased substantially. 4.10

153 Applying the tamping technique with a spotting brush Tamping stains using an appropriate spotting brush is one of the safest and most effective methods of applying mechanical action to stains. When tamping, it is important to ensure that the brush rises and falls accurately in a constant horizontal plane to the fabric, as shown above. If used as shown below, many of the bristles will not strike the fabric and there may be little or no mechanical action in the stained area. If tamping is performed correctly, a considerable hydraulic effect is created due to the spotting chemical being driven quickly through the fabric. You therefore need to ensure that there is always plenty of the spotting chemical in the region of the stain. Solubilisation This method of removing stains relies on solvent action wet or dry to dissolve stains. This therefore allows them to be flushed out of the fabric. Softening Many stains oxidise or harden with age, and have to be softened before they can be removed. The steam gun can often be used to help soften stains. Chemical action This method of removing stains relies on a chemical reaction between the reagent used and the stain. Bleaches and rust removers function by means of chemical action. Digestion Some protein stains change under the influence of heat and become insoluble. Once this change has taken place, the stains have to be treated with a digester which employs enzymes to convert protein/albumin stains back to a soluble form. They can be flushed out of the textile with water. 4.11

154 Example stain removal method for heavy biro Here is an example of how to remove heavy biro from fabric. 1 Place absorbent cloth underneath the stain. 2 Surround the stain with glycerine. 3 Apply paint remover and pad off the stain. The above method should also be used for other heavy stains such as dye and some paints. In cases where the ink has soaked into several layers of fabric for example where a biro has leaked in a jacket pocket it will normally be necessary to unpick part of the lining to gain access to the inside of the garment and the interlining, where most of the ink will be located. If there is a lot of ink in the pocket lining, the most practical solution is to cut out the lining and renew the pocket. Absorbent material should then be placed inside the lining to soak up the ink from the interlining and the outer fabric. Any ink in the lining of the jacket should be removed separately. Procedures for stain removal It is important to know about the correct procedures for stain removal. Location and identification of stain Before stains can be removed, they must first be located and identified. Very often obvious stains are missed by the cleaner simply because the garment has not been inspected properly. The next step is to identify the stain. Identification is based on the following mnemonic, or memory aid: FOCAL Feel Odour Colour Appearance Location It is important to identify the stain, or at least to establish the basic nature of the stain for example, dryside or wetside because you need to be able to select an appropriate stain removal reagent. 4.12

155 Stain removal reagents The most widely used stain removal reagents are proprietary kits containing as few as three and as many as eight bottles. The main advantage of kit chemicals is that they streamline stain removal, allowing many stains to be conditioned/solubilised prior to cleaning. They are then subsequently removed in the machine. This can save a considerable amount of time and substantially reduce the need to re-clean the garments. Many cleaners supplement kit chemicals with straight chemicals such as ammonia, acetic acid and amyl acetate. Straight chemicals unlike kit chemicals are pure chemical compounds. They are completely volatile and can easily be removed from textiles without leaving any non-volatile residue. Reagents that are used in stain removal fall into two main groups: dryside reagents and wetside reagents. The former are mainly organic solvents that are soluble in dry cleaning solvent. The latter are reagents that are miscible with water. These two groups of reagents should not normally be mixed during stain removal. It is not recommended that straight wetside chemicals are used for pre-spotting. If they are, the chemicals should be rinsed out and the fabric dried completely to avoid any risk of fabric damage during the cleaning process. Factors influencing stain removal When stains do not respond to treatments, it is often due to one or more of the following factors being overlooked. If a difficult stain is encountered or if it is vital that a stain is removed, go through each of these factors, asking the following questions: Time Has sufficient time been allowed for the reagent to react fully with the stain? Do not expect stains to respond immediately very often it may take a little time for reagents to fully penetrate stains and for them to work effectively. Temperature Has the steam gun been used to raise the temperature? Would raising the temperature be appropriate? Most chemicals become more reactive as temperature increases. Therefore raising the temperature by means of the steam gun can often help to release stains. Reagent Has the correct reagent been applied to the stain? Has the stain been identified correctly? Stains will only respond to an appropriate reagent. It may be that a stain that is not responding has not been identified correctly, in which case it will be necessary to consider the use of other reagents. Mechanical action Would an alternative form of mechanical action help to release the stain? Most spotters employ the spatula to apply mechanical action and rarely if ever use a spotting brush to tamp stains. Tamping is generally much safer than using a spatula, and it is usually more effective as more stress is generated. 4.13

156 Fibre/fabric type Has the stain an affinity for textile? In other words, do the textile and the stain have particular chemical/physical properties that tend to bind them together, therefore making the stain more difficult to remove? The type of textile on which a stain is present may well dictate how the stain responds to treatment or what methods/techniques can be employed. For example oil which usually responds well to spotting and dry cleaning might be difficult or even impossible to remove from a polyester fabric, which is a textile that has a strong affinity for oil. The sensible application of all these factors by experienced staff will often enable deep seated and difficult stains to be successfully removed. One of the most difficult aspects of stain removal for both experienced and inexperienced staff alike is to learn when to stop trying. Even highly skilled staff are occasionally tempted against their better judgement to continue their efforts to remove a stain. This is when mistakes are made and the fabric is damaged or its colour affected. Pre-spotting equipment Having access to good equipment is vital if stains are to be treated effectively and efficiently. Today there are a number of equipment options available. The type used by your organisation will depend on the skill level of the staff and the space available. Good lighting (500 lux) is essential in all areas where inspection, pre- and post-spotting are carried out. There are two main options for pre-spotting equipment: Domestic type table A domestic type table at least 60cm x 90cm is ideal for inspection and pre-spotting purposes. A laminate surface is essential to ensure that the working area is not affected by chemicals. If space is very limited a hinged, pre-spotting table that drops down onto the top of the post-spotting equipment is an alternative to a domestic table. Tables are generally most suitable where soaps and detergents are applied by brush. If products are used that are designed for spray application a suitable air extraction system should be provided. Stainless steel pre-spotting cabinets This type of table is particularly suitable for the spray application of pre-spotting products. The equipment is usually supplied with a high-pressure pump and a carbon filter extraction system. A hot and/or cold spotting module can normally be fitted to this type of equipment if a single pre-spot, post-spotting unit is required. This arrangement can be worth considering in units where space is very limited. 4.14

157 Post-spotting equipment There is a wide range of post-spotting equipment available. Apart from the dimensions of the spotting table the fundamental choice is between a hot or cold system. Basically, apart from capital cost the choice should be dictated by the following: stain removal skills of the staff who will use the equipment whether it is going to be used to provide training if skill levels are low Cold spotting tables Cold spotting tables are normally supplied with two high pressure sprays. The tables are usually fitted with a vacuum unit and an air gun. A compressed air supply needs to be provided. The tables are available in a variety of specifications. Typically a cleaner will be able to choose between space-efficient equipment with a small spotting arm and much larger tables fitted with a sleeve arm and adjustable for height. Steam spotting tables This type of table is fitted with a steam gun and in many cases a high-pressure water spray(s). Steam is generally supplied to the gun through a heat exchanger that heats the compressed air used for drying. Significantly higher production rates are possible in this type of equipment as many stains can be solubilised quickly with steam, and the fabric dried rapidly with hot air. Progressive manual steam valves are strongly recommended for steam guns (as opposed to electrically operated valves which give no progressive control over the steam). If the table is fitted with solenoid valves that do not give progressive control of the steam, it is essential that hand control valves are fitted to enable the spotter to reduce the volume of steam. An example of good pre- and post-spotting equipment. 4.15

158 The use of steam and heat greatly increases the versatility of spotting equipment and in the hands of an expert spotter a much greater range of difficult stains can be successfully removed. However, as the P care-label only allows the use of cold water for stain removal, the cleaner must take full responsibility if the dye or fabric is adversely affected by steamgunning and the use of heat. The steam-gun can easily cause major fabric damage in the hands of a novice. A cold spotting system is therefore the safest option if you do not intend to develop your staff s expertise in stain removal. For the professional cleaner working to high standards, however, a steam-spotting table fitted with high pressure water sprays is essential. Ancillary equipment The following ancillary equipment is essential for stain removal: plastic or bone spatula spotting guns various types such as Krebbs and Sono Flash spotting brushes soft, medium and hard bowls absorbent cloths goggles and gloves Kit spotting chemicals The vast majority of dry-cleaners now use kit spotting chemicals as opposed to straight chemicals such as ammonia and acetic acid many in the mistaken belief that they can be used more safely on fabrics and dye-stuffs. In fact, the reverse is true but that particular debate is outside the scope of this pack! The overwhelming advantage of pre-spotting kit products is that they can be applied to stains and left on the fabric to be flushed out during dry cleaning. However, not all the products can be used with both perchloroethylene and hydrocarbon solvents. Conversely, there are products that can be used with perc, hydrocarbon and water based systems. It is therefore important that you check with your chemical supplier regarding their recommendation for specific products. If in doubt, it is better to opt for a kit product that is specific to one solvent. It is worth remembering that in wet cleaning you need to focus mainly on oily and greasy stains. 4.16

159 Kit chemicals Wetside protein removers/tannin removers Dryside paint/tar/oil removers Note that spotting chemical kits often contain chemicals for the removal of specific stains such as perspiration. Chemical reagents Wetside Dryside water perchloroethylene neutral lubricant paint remover bar soap (alkaline) amyl acetate 5 per cent ammonia (alkaline) methylated spirits 10 per cent acetic acid hydrofluoric acid digester sodium perborate/5 vol peroxide odium hydrosulphite Bar soap (Fairy Green is ideal) is normally used with ammonia and the steam gun to flush out a wide range of stains. It should not be used with any acidic spotting chemical. Acid and alkaline chemicals should not normally be used together during stain removal. The only exceptions are neutralisation and the correction of PH sensitivity. The above list is not exhaustive. Lighting Good lighting in the region of spotting tables (min 500 lux) is vital if inspection is to be really effective, with a high percentage of stains detected. 4.17

160 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about stain removal. When you have finished discuss the answers with your trainer. 1 What problems can be expected if the spotting table is not kept in a clean condition? 2 What ancillary equipment would you expect to find with a spotting table? 3 When the steam gun is parked or picked up, the nozzle should be directed at the floor. Why? 4 Spatulas must not be made of metal. Why? 5 Chipped spatulas must not be used. Why? 6 What are the factors that help to identify the nature of stains? 7 What is the objective when removing stains? 8 Explain the difference between wetside and dryside spotting reagents? 9 Name two wetside and two dryside spotting reagents? 10 What particular stain contains large amounts of albumin? 11 What benefits derive from pre-spotting? 12 How long should garments that have been pre-spotted be allowed to stand before being dry-cleaned? 13 What are the factors that influence the removal of stains? 14 What are the various methods of stain removal? 15 How would you remove a heavy biro stain? 4.18

161 Activity answer sheets: Stain removal Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about stain removal. When you have finished discuss the answers with your trainer. 1 What problems can be expected if the spotting table is not kept in a clean condition? 2 What ancillary equipment would you expect to find with a spotting table? 3 When the steam gun is parked or picked up, the nozzle should be directed at the floor. Why? 4 Spatulas must not be made of metal. Why? 5 Chipped spatulas must not be used. Why? 4.19

162 Self-check questionnaire (continued) Question p What are the factors that help to identify the nature of stains? 7 What is the objective when removing stains? 8 Explain the difference between wetside and dryside spotting reagents? 9 Name two wetside and two dryside spotting reagents? 10 What particular stain contains large amounts of albumin? 11 What benefits derive from pre-spotting? 12 How long should garments that have been pre-spotted be allowed to stand before being dry-cleaned? 4.20

163 Self-check questionnaire (continued) Question p What are the factors that influence the removal of stains? 14 What are the various methods of stain removal? 15 How would you remove a heavy biro stain? 4.21

164 4.22

165 Notes 4.23

166 4.24

167 5 Dry Cleaning Operations Level 2 G8CC 22 Candidate Support Pack Section 5 F0JN 04 Clean items by dry cleaning processes (LDC13)

168 ii

169 Contents Introduction About this Unit Key areas of knowledge and understanding Skills and techniques Regulations, rules and guidelines Workplace skills About this learning and teaching pack Fabric soiling and staining Introduction Classification of soils Classification of stains Removal of soils and stains Self-check questionnaire Dry cleaning solvents Introduction Main solvents used in the UK Efficient use of solvents Typical properties of dry cleaning solvents Self-check questionnaire The dry cleaning machine Introduction Component parts Operation and routine maintenance Activity 1 Self-check questionnaire iii

170 Detergents Introduction Wet-cleaning and washing detergents Activity 2 Dry cleaning detergents Activity 3 Self-check questionnaire Dry cleaning systems, processes and key facts Introduction Dry cleaning systems Systems for applying dry cleaning detergents Dry cleaning processes Key facts Self-check questionnaire Application of textile finishes Introduction Retexturing Reproofing Softeners Self-check questionnaire Activity answer sheets Fabric soiling and staining Dry cleaning solvents The dry cleaning machine Detergents Dry cleaning systems, processes and key facts Application of textile finishes Notes 5.49 iv

171 Introduction About this Unit This Unit F0JN 04 Clean items by dry cleaning processes (LDC13) is designed to help you to clean items using dry cleaning processes, and prepare the work required. Your role will involve: preparing and maintaining dry cleaning equipment dry cleaning items operating the dry cleaning machine safely handling solvents safely dealing with spillages and fume leaks setting-up the work required for dry cleaning processes As a competent person, you must: prepare the equipment plan the work required fill solvent tanks dispose of waste materials maintain the equipment operate the machine according to the manufacturers instructions load and unload items make the best use of the resources available identify any problems that might arise in carrying out the work brief colleagues and check that they understand what they are required to do prepare equipment monitor pressure and temperature identify and deal with items that are unsatisfactory or damaged Key areas of knowledge and understanding This Unit will help you to develop the following key areas of knowledge and understanding: How to select and use solvents and chemicals. Understanding wash cycle, dry cycle and distillation cycle. What services are required to make machines work. Care labels. The properties of textiles. Understanding fibres and fabrics. Operating pressures and temperatures of machines. 5.1

172 Which items are unsuitable for dry cleaning. Whom to report faults to. What dry cleaning processes might be required. How to dry-clean different types of items. Waste water management. Safe use of solvents. Monitor solvent emissions. The use of dry cleaning detergents. Skills and techniques After working your way through the Unit, you should be able to: start-up and shut-down the machine and engage relevant utilities clean out traps and check water collectors dispose of solvents and waste materials, and deal with spillages identify and deal with faults and concerns use and handle solvents, chemicals and machinery keep records select machine programmes operate machines and monitor operations unload and handle items deal with unsatisfactory items receive, check and confirm the supervisor s instructions plan how to carry out these instructions check that plans are in line with the supervisor s instructions identify any problems in dry cleaning work or in carrying out the supervisor s instructions and get advice brief colleagues on what they must do and check that they have understood check solvent consumption Regulations, rules and guidelines You should read and get to know the following regulations, rules and guidelines: The organisation s rules, codes, guidelines and standards. Equipment operating procedures. Relevant responsibilities under the Health and Safety at Work Act and Control of Substances Hazardous to Health (COSHH). Personal protection measures when using hazardous chemicals. Duty of care regulations and requirements. Hazardous substances warning labels. Manufacturers instructions. 5.2

173 Workplace skills The general workplace skills you will acquire through this SVQ have already been outlined in the general introduction. However, as a result of working through this Unit, you should also be able to: plan work, making the best use of resources available brief colleagues clearly identify any possible problems at the planning stage, and understand why you should report these to your supervisor About this learning and teaching pack This part of the learning and teaching pack is designed to help you develop the knowledge and understanding and generate the evidence required to pass this Unit. It has six sections: Fabric soiling and staining Dry cleaning solvents The dry cleaning machine Detergents Dry cleaning systems, processes and key facts Application of textile finishes Each section contains information and follow-up activities to help you apply what you have learned. At the end of each section there is a self-check questionnaire to help you check your knowledge and understanding so far. You should discuss your answers with your trainer. 5.3

174 5.4

175 Fabric soiling and staining Introduction Soil can be defined as any material deposited on fabrics that impairs their appearance. If garments are to be cleaned effectively and efficiently, we need to know something about the nature of soiling and how fabrics become soiled. Soiling from the atmosphere is constantly being deposited on our clothes, resulting in a progressive build-up of soil on the fabric. Over a prolonged period of time this type of soiling can become ingrained, particularly on the most exposed parts of garments. Dirt is also deposited on fabric by direct transfer through contact with dirty surfaces or by constant contact with the skin particularly in areas such as the collar and cuffs. Synthetic fibres have low regain, which generates static electricity. This in turn can attract soil. Such hydrophobic fibres can therefore tend to become soiled more quickly. When food or drink (not normally regarded as soil) are spilled on garments, they impair the appearance of the fabric and are therefore considered to be soiling agents. Dark coloured clothes become soiled at the same rate as white or light coloured fabrics. However, in the case of dark coloured garments, the dirt is not as noticeable, and therefore these are normally more heavily soiled than light coloured garments. This variation in the degree of soiling can have serious consequences if dark and light garments are cleaned together, as it is possible for soiling from dark garments to be picked up by light colours or whites. Sample of analysis of soil taken from an urban environment Moisture 3% Sand and clay 45% Gypsum limestone 5% Hair, wool and other fibres 5% Wood, paper and other cellulosics 12% Alcohol-soluble resins, gums and fatty acids 12% Ether-soluble fats, oils, rubber and asphalt 6% Undetermined 12% Total 100% (Note the low percentage of solvent solubles at 18 per cent of the total.) 5.5

176 Classification of soils Soils fall into a number of different classifications. General soiling General soiling happens as a result of the following: Atmospheric pollution the atmosphere always contains small particles of soil from a wide variety of sources such as motor vehicle exhausts and industrial processes. These particles become trapped in the fabric/fibre structure. Many particles have a surface layer of oil which causes them to stick to fabric. During wear, soil particles may be rubbed into the fabric structure, giving rise to ingrained soiling. Direct transfer clean and dirty surfaces rubbing together dirty seats and walls often give rise to this type of general soiling. Oils and grease. These come from the following sources: Oily soils are a result of atmospheric pollution. Body fats oil components from perspiration. Accidental contamination salad oil, butter, and so on. Natural oils present in or added to textile fibres during blending or spinning. Wet soiling This is water-borne soiling from, for example, mud or rain splashes. Water provides a vehicle to carry the soil deep into the fabric. Water may also cause the textile fibres to swell and trap dirt particles. Due to the penetration of the soiling and the swelling of the textile wet soiling can often be very difficult to remove, except by using a wet process. Perspiration The release of perspiration is part of the body s cooling mechanism. Perspiration is released over the whole skin area, but normally concentrated in areas such as the armpits. Perspiration may often induce a permanent colour change in the textile. Substances present in perspiration often encourage bacterial growth, which is largely responsible for the unpleasant odour associated with underarm stains. 5.6

177 Classification of stains The variety of materials capable of staining fabrics is infinitely variable. However the stains found on garments can be classified into the following groups. Localised stains These are often caused by accidental contact or a spillage, and often look worse than general soiling. Water-based stains These include most food and drink stains, dyes and washable inks. Oil stains These include motor oils and greases and oils in foodstuffs. Albuminous stains Stains such as blood, egg and milk contain albumin, which can easily be set by heat. Once they have been heat-set, albuminous stains may require specialised stain removal methods to treat them. Oil-based stains Paints, varnishes, biro ink and similar stains are not soluble in water. Paints, varnishes and other oil-based stains that oxidise are only solvent when fresh, and before oxidation has taken place. Once stains of this nature are dry, specialised chemicals are required to remove them. Removal of soil and stains There are three factors to be considered when deciding on whether to use a wet or dry process to remove soil and stains: type of soiling type of fabric/fibre types colour In addition, certain stains may have to be removed using either pre- or post-specialised treatment methods. 5.7

178 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about fabric soiling and staining. When you have finished discuss the answers with your trainer. 1 What is atmospheric pollution soiling? 2 What are the different types of oils and grease soiling? 3 Describe perspiration soiling. 4 What are the five classifications of stains? 5 What have you to consider when deciding to use wet or dry process stain removal? 5.8

179 Dry cleaning solvents Introduction The ideal dry cleaning solvent does not exist. All the solvents in use today have certain limitations, and they certainly don t fulfil all the criteria of the following ideal properties list: No harmful effects on textiles. No harmful effects on dyes and special finishes. Should be non-toxic. A good solvent for oils, fats and greases. Should not corrode metals. Easy to distil and recover. Should be removed completely in drying without high temperatures. Must not be liable to catch fire or explode during normal use. Should have no residual odour. Should be readily obtainable at a reasonable price. Main solvents used in the UK Perchloroethylene, hydrocarbon and siloxane are the main solvents in use in the UK, and they fall short of the ideal in many respects. They are, however, relatively safe and reliable solvents provided that dry cleaning machines are well maintained and staff are properly trained. Comparative volatility Boiling point KB value * Perchloroethylene low 121 C 90 Hydrocarbon Solvent very low 150 C 215 C Siloxane very low N/A *The KB value gives an indication of the solvent power in terms of the ability of the solvent to remove oils, greases, tars, waxes, etc. The higher the value the stronger the solvent. 5.9

180 Efficient use of solvents The following checks need to be carried out regularly to ensure that solvents are used efficiently: Keep plant and equipment clean so that the drips can be easily observed, and the cause corrected. Check the condition and seating of all gaskets and seals. Remove lint, rust, etc from all water separators. Ensure that distillation is complete before closing down the still: check that the steam pressure does not exceed 70 psi and that the temperature of water from the still condenser does not exceed 50 C. Check the temperature of solvent/water in the separator it should be about 25 C never over 35 C. Try to avoid machine overloading or underloading and minimise the number of recleans. Classify garments of similar-type density so that drying times and temperatures can be related to the load. Check temperatures outlet air temperature should not exceed 60 C (140 F) for 0+0 or 50 C (120 F) for 0+0. Solvent leaks are wasteful. They also have a health and safety implication. Check the following important areas for solvent vapour leaks, using a halide lamp or otherwise, with the machine on dry : main door seal inspection covers main bearing seal still vent pipe filter seals after cleaning cooling coil seal all glands and valves dust bag door button trap lid sight glasses heating coil seals fan housing pub housings 5.10

181 Solvent clarity If the solvent is to be maintained in good condition, the filter must be working efficiently. In addition, the volume of solvent that is distilled must be sufficient to maintain soluble contaminants at an acceptable level a minimum of 2.5 litres of solvent should be distilled per kilogram of work processed when cleaning with perc. Typical properties of dry cleaning solvents The following table illustrates the properties of dry cleaning solvents. Perchloroethylene (Perc) Siloxane Exxon Dryclean 56 1 Flammability Non-flammable Flammable Flammable 2 Flashpoint N/A 77 C 56 C 3 Density (SG) Boiling point/range 121 C 210 C C 5 KB Value Solubility of water in solvent (ppm) Solubility of solvent in water (ppm) 80 N/A N/A 3 8 Occupational exposure 50 ppm 100 ppm N/A 350 ppm 5.11

182 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about dry cleaning solvents. When you have finished discuss the answers with your trainer. 1 What would be an ideal properties list for a dry cleaning solvent? 2 What are the main solvents used in the UK? 3 What checks must be carried out to ensure solvent is used efficiently? 4 What and where would you check for solvent vapour leaks? 5.12

183 The dry cleaning machine Introduction Perchloroethylene, hydrocarbon and siloxane are now the main types of solvents used in dry cleaning machines operated in the UK. Hydrocarbon machines can be operated with either hydrocarbon solvent or siloxane. However, it is vital that the machine supplier is consulted before a change of solvent is initiated. Dry cleaning solvents are toxic and very expensive, and they can therefore only be used in a very controlled environment. The dry cleaning machine can be regarded as a selfcontained cleaning and solvent processing plant. It is capable of cleaning garments and also purifying the solvent it uses, so that the solvent can be used repeatedly to clean garments. This is in contrast to washing machines, where the contaminated water is disposed of down the drain. Component parts It is important that you know about the component parts of a dry cleaning machine, and that you understand what they do. Drum The design of the drum or cage can vary particularly the depth and the width. The capacity of machines normally found in unit shops ranges between 10Ibs (4.5kg) to 60Ibs (27kg). Maximum cleaning efficiency is normally obtained when a machine is fully loaded to its rated capacity. The cleaning time should therefore be extended when small loads are cleaned, subject to the nature of the load and fabric types. Filter pump The pump is always of the centrifugal type, and its main function is to pump solvent through the filter. It is also used to pump solvent to the still and to the base tank in many machines. The flow rate of filtered solvent is infinitely variable, and is dictated by the resistance of the filter. Maximum flow rates are achieved when the filter is clean. Very poor flow rates are normally caused by excessive amounts of dirt on the filter tubes/cartridges/discs or blocked button traps. As dirt builds up in a filter, it progressively reduces the solvent flow rate and consequently the efficiency of the cleaning process. Filter There are three main types of filter fitted to dry cleaning machines: regenerative, powderless and cartridge. 5.13

184 Regenerative Regenerative filters are still quite common and are constructed from fine wire mesh tubular springs or closely woven fabric. Filter powder is always used in this type of filter. The powder is very fine and white, and is manufactured from the fossilised remains of diatoms. The powder is used to coat the filter tubes or screens a process known as pre-coating. This forms a very fine, but porous filtering medium. Note that a dust mask should always be worn when handling filter powder. This type of filter can be shaken or scrambled to regenerate the filtering medium and maintain its porosity. As the filter pressure rises due to the build up of dirt, a point is reached when the filter will not operate efficiently. The contents of the filter are then discharged to the still. Regenerative filters only remove particulate soil from the solvent. All soluble impurities such as colour and dissolved oils and greases pass through the filter. Powderless Most new dry cleaning machines are now being fitted with powderless filters. This type of filter is constructed using fabric discs, which are mounted on a central manifold pipe that runs through the middle of the filter. The fabric discs act as strainers and filter out particulate soiling from the solvent passing through. There is no need for filter powder, and consequently the rake-out from the still is usually in liquid form. The contents of the filter are periodically discharged to the still to remove the accumulated dirt. Cartridge Cartridge filters rely on an outer layer of corrugated material to remove particulate soil. Some cartridge filters have an internally activated carbon core, which is capable of absorbing some soluble impurities - in particular colour. Dirt is removed from some filters by reversing the solvent flow through the filter into the still a process known as backwashing. Filter pressure gauge The filter pressure gauge registers the back pressure exerted by the filter on the solvent flow. It therefore tells the operator about the condition of the filter. The gauge is connected to the filter by a flexible pipe or, in some cases, it is mounted directly on to the body of the filter. It is important that the filters are not operated at pressures in excess of those recommended by the machine manufacturer. High filter pressure results in poor flow rates, and can seriously impair the efficiency of the filter. Still Most but not all dry cleaning machines are fitted with a still. The still boils and vaporises the solvent. This process is known as distillation. Distilling solvent removes both soluble and insoluble impurities and, as far as the drycleaner is concerned, distillation restores the solvent to a state of purity comparable to new solvent. 5.14

185 The design of stills varies considerably for example, many of the more modern stills are fitted with a porthole through which the boiling solvent can be observed. This can be a very useful feature if distillation problems arise. The heat that is required to operate a still is provided by either steam or electricity. Steam The stills on most perchloroethylene machines and hydrocarbon machines are heated by steam, which normally gives good distillation rates. The maximum recommended steam pressure for steam-heated perchloroethylene stills is 70 psi. Above 70 psi there is a risk of the solvent being broken down into corrosive by-products. Hydrocarbon stills operate under vacuum to reduce the boiling point of the solvent. Electricity Some stills are electrically heated. Electrically heated stills can give good distillation rates. However, a drawback can be the high cost of this form of energy. In some electric stills the electricity is used to generate steam, which is then used to heat the still. Live steaming and stripping During operation, soil and cleaning products such as soap and spotting chemicals collect in the still. The gradual build-up of impurities slows the distillation rate, and it eventually becomes necessary to remove the impurities that have accumulated. In perchloroethylene stills, some solvent remains in the residue after distillation has ceased. In some machines (not those with automatic still pump-out), live steam is injected into the residue to recover the remaining solvent. This has the effect of lowering the boiling point of the solvent, and enables it to be vaporised and recovered. This process is known as live steaming or stripping. In some electrically heated stills this is achieved by adding a small quantity of water to the still. Stills are not normally stripped on machines fitted with powderless filters. On hydrocarbon machines where the still is cleaned after all the solvent has boiled over, there is no steaming or stripping of the still. Still safety device As perchloroethylene is a high boiling point, volatile solvent on all stills, percholorethylene machines are fitted with a pressure relief device. On modern machines, the device normally discharges into the main solvent tank. On some older machines an external safety seal is fitted. Still preheater This is a heat exchange system that can be integrated into the still vent pipe between the still and the still condenser. The preheater transfers latent heat from the hot solvent vapour to a tank of cold solvent awaiting transfer to the still. The cold solvent is normally preheated to at least 80 C before being dropped to the still, therefore saving a considerable amount of heat energy. 5.15

186 Still condenser The still condenser condenses the solvent vapour from the still. The condensed distilled solvent passes from the condenser to the water separator. Still condensers are cooled by cold water. Water separator During distillation and also during drying, small quantities of water are usually present in the condensed solvent. As water can seriously affect some textile fibres and can also cause colour bleeding, it is vital that the water is separated from the solvent. Solvent and water are not miscible. Because of its higher specific gravity, perchloroethylene sinks to the bottom and the water rises to the top in the water separator. In the case of hydrocarbon and siloxane the situation is reversed. New perchloroethylene machines are all fitted with two water separators to improve the removal of solvent. The solvent in the lower half of the separator continuously drains to the distilled solvent tank, and the water from the second separator is drained to the contact water purifier. Over a period of time, dirt and sludge tend to collect at the solvent/water interface. It is therefore important that the water separator is drained and cleaned regularly to ensure that it operates efficiently. Contact water purifier The contact water purifier is designed to remove the small quantities of solvent that remain dissolved in the water that is discharged from the secondary water separator. The contact water is passed through a perforated cylinder containing activated carbon, which absorbs the dissolved water. The activated carbon needs to be replaced on a regular basis when it becomes saturated with recovered solvent. Drying system Following the end of the final extraction period, garments still contain an appreciable quantity of solvent that has to be removed and recovered. All dry cleaning machines have an integrated drying system designed to do just this. On most machines with an electric boiler, the still vapour pipe is ducted through the air heater. This reduces the electric load during the drying stage substantially. This is referred to as still assisted drying. Fan The fan is located in the recovery ducting and its function is to circulate air through the cage and the recovery system during the drying cycle. On open machines the fan is also used to ventilate the machine at the end of drying, and to draw air through the cage during loading/unloading. Warm air is drawn into the cage by the fan and it evaporates solvent from the garments. The solvent-laden air is drawn from the cage and passes through a dust filter before entering the cooler. The solvent vapour in the air condenses in the cooler and passes via a water separator to the storage tank. The cooled air then passes directly into the air heater and from the heater back to the cage, 5.16

187 therefore completing the cycle. The air heater is thermostatically controlled to maintain the correct air temperature. The constant circulation of air around the system continues until all the recoverable solvent has been evaporated from the load. Dust filter Dust filters usually take the form of a woven bag or a foam pad. Supplementary lint screens are fitted to some machines, immediately in front of the cooler. It is most important that air filters are checked and cleaned on a regular basis. Failure to do this can lead to a build-up of lint and debris in the cooler and the air heater. Coolers Closed machines are normally fitted with refrigerated coolers. Water cooling is usually used in open machines, with a cooling tower installed to conserve water. If the efficiency of the drying system is to be maintained, it is important that coolers are kept free of dirt and debris. Air heater Air heaters are either steam or electrically operated. It is most important that air heaters are kept clean as a build-up of dirt or debris can seriously affect the efficiency of the drying system. Carbon recovery systems These are ancillary systems that can be fitted to percholoethylene machines to improve their solvent economy. Carbon recovery units use a bed of activated carbon to absorb solvent vapour from the air in the machine, at the end of the drying cycle. Free steam is used to strip the solvent from the carbon bed. After passing through a water separator, the solvent passes to a distilled solvent tank, where steaming hot air is blown over a carbon bed to dry it out. Cooling towers Water cooled dry cleaning machines use large quantities of water. A cooling tower cools the hot water from the machine and returns cold water to a storage tank. Cold water is drawn from the storage tank and returned to the machine. The only losses in the system occur through evaporation in the cooling tower. The volume of water in the system is maintained at a constant level by a ball valve located in the base of the cooling tower. Cooling towers can lead to machine problems during very hot weather when high ambient air temperatures can seriously reduce their efficiency. In this case, it might be necessary to temporarily transfer machines to the mains water supply to ensure adequate cooling. Cooling towers are normally installed with the facility to quickly change over to mains water when required. A biocide must be used in all cooling towers and they must be cleaned and maintained on a regular basis. 5.17

188 Water separator Failure to clean the water separator may result in dirty solvent. It may also result in solvent passing out of the separator with the water. Button trap This should be checked after every load. This is particularly important after cleaning household pile fabrics, suedes and boiler suits. Blocked button traps can lead to: inadequate cleaning re-deposition of soil extraction with cage full of solvent giving rise to linting/staining and fabric damage dip of solvent in cage during drying resulting in high solvent consumption and incomplete drying Dust bag lint screens These should always be cleaned using the machine manufacturer s recommendations. In addition, always examine the dust bag/lint screen after cleaning loads such as household pile fabrics, suedes and boiler suits. Extraction and drying The solvent that is left in the load after it has been drained at the end of the dry cleaning wash cycle is removed in two stages. The majority is removed by centrifugal extraction, commonly known as hydroing. The remaining solvent is then evaporated by tumbling the articles in warm air. It's generally a good idea to reduce the solvent content of the load as much as possible during extraction for the following reasons: When the solvent is evaporated, any remaining impurities are deposited on the garments so the less solvent (and, potentially, the less impurities) the better. The amount of solvent left after extraction also has some influence on the time required to dry the load. So thorough extraction is generally desirable except in special cases, where the type of work being cleaned would be expected to be sensitive to pressure during extraction and might become severely creased. Levels of solvent content In some special cases, there might need to be a higher residual solvent content after extraction to ensure the uniform application of a finish. Many factors influence the amount of solvent retained after extraction. Some are largely predetermined by the machine design and by the properties of the textile in the load. Others can be controlled to some extent by the machine operator. These factors are outlined below: The speed rotation of the cage is very important during extraction. There should be periodic checks that drive belts are correctly tensioned. 5.18

189 If the solvent extracted cannot drain away quickly enough it will form a dip and be thrown back onto the load. This can cause serious fabric damage. The button trap must be clean. The machine must not be overloaded as garments in the centre of the load may be exposed to significantly lower centrifugal force. In addition, if the garments are too tightly packed, the drying process will be extended and mechanical action during the wash cycle will be reduced. The solvent retention varies with extraction time. For example, if the extraction time is short, more solvent will be left in the load and the drying time will therefore be lengthened. On the other hand, there is little point in extending the extraction time beyond the stage where very little solvent is being removed, as the extra time does not provide any significant benefit. If these points are noted, the extraction time recommended by the machine manufacturer will generally be satisfactory. However, on many occasions, extending the extraction time can be beneficial, and the extra time spent in extraction will be more than compensated for by a reduction in drying time. If the dry cleaning machine is being run continuously, even an odd minute saved per cycle can be of value. It can be worthwhile to check the effect that an additional half or even one minute extraction has upon the drying time. Operation and routine maintenance You only get quality cleaning if you pay close attention to the correct operation and routine maintenance of the dry cleaning machine. Filter Filter powder should be applied correctly, and in the recommended quantities. Filter pressure must be kept at the correct level to allow the flow of solvent to clean effectively and efficiently. The process structure must allow the filter to operate efficiently. Still The still must be cleaned or pumped out on a regular basis. As a guide, most machines should have no more than two filter drops before the still is cleaned out. Bear in mind that: excessive still residue substantially reduces the rate of distillation, and can leave insufficient distilled solvent available to process the following load blacking over may be caused by: overfilling the still with solvent steam pressure that is too high contamination of the still with silicone or quantities of water Note that some of the chemicals used to apply flame retard finishes to furnishing fabrics can create a transparent coating on to the base and sides of the still. This usually results in an immediate and dramatic reduction in the distillation rate. The coating can only be removed by abrasive or chemical treatments. 5.19

190 Activity 1 Answer sheets p What are the machine types used in the UK? 2 Name all the component parts of a machine. 3 What type of pump is fitted to a machine? 4 What is a regenerative filter? 5 What is the purpose of the still? 6 What devices are fitted to a still? 7 What is a carbon recovery system? Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about the dry cleaning machine. When you have finished discuss the answers with your trainer. 1 What is the purpose of the button trap? 2 Name the three types of filters fitted to a machine. 3 What is the purpose of the filter pressure gauge? 4 What are the two different heating mediums used in a still? 5 What does the water separator do? 6 How does the extraction/drying system work? 7 What routine maintenance should be carried out on a machine? 5.20

191 Detergents Introduction The term detergent is derived from the Latin deta geri, which roughly translated means to make clean. Detergents today have come a long way since soaps were first developed, and we now have a very large range of products with increasingly specific uses. In the domestic market, for example, we now have detergents for white-work, for coloureds, for black garments and silks not to mention the wide range of specialised products used throughout the industry. As dry-cleaners, we are of course mainly interested in the detergent products we use in our business. These fall into two main groups aqueous (or wet cleaning) detergents and dry cleaning detergents. Aqueous and dry cleaning products have to perform different functions to enable them to enhance the cleansing properties of water and dry cleaning solvents. There are many products on the market here's a description of some of their properties. Wet-cleaning and washing detergents The cleaning industry began to develop the process of wet-cleaning around 1995, largely due to environmental pressures on dry cleaning. Although wet-cleaning had been in use long before J Baptiste Jolly came on the scene in the 1820s, it has not been used extensively by dry cleaners for many years. Wet-cleaning can be defined as a cleaning process using cold or tepid water with very low levels of mechanical action and specialised detergents. Most of today s washing detergents are highly complex products that are extremely effective in terms of removing and suspending soil. Both domestic and commercial detergents will, in most cases, also contain one or more of the following: stain removal agents in the form of oxidising bleaches softening agents enzymes and optical brightening agents The primary functions of washing and wet-cleaning detergents are outlined below: Washing The primary functions of washing detergents are to: reduce the surface tension of water and wet out the fabric promote the removal of soiling suspend soiling and prevent re-deposition 5.21

192 Wet-cleaning The primary functions of wet-cleaning detergents are to: reduce the surface tension of water and wet out the fabric protect moisture-sensitive textiles against the effects of mechanical action inhibit the migration and bleeding of dyestuffs promote the removal of soiling suspend soiling and prevent re-deposition Detergents have two main components an oleophilic part (oil liking) and a hydrophilic part (water liking). Most detergents ionise when dissolved in water this means that the molecules collect at the water surface where the hydrophobic tails stick out and break down surface tension, while the negatively charged hydrophilic heads remain in the water. The positively charged tails are also attracted to, and collect at any surface with which the water is in contact, and break down what is known as interfacial tension. This property enables aqueous detergents to wet out textiles quickly and efficiently. Detergents that ionise in this way are known as anionic. (See the diagram on p. 5.23) In cationic detergents the charges are reversed with the tail carrying a positive electrical charge. Cationic products are generally used as fabric softening agents. In water-based processes, the oily soils and stains do not dissolve in water alone. The hydrophobic oil liking tails of the detergent molecule are strongly attracted to the soiled textile fibres, and particularly to oily soils and stains, which readily absorb the oleophilic tails. Once soil particles or oily soiling have been surrounded by detergent molecules, the water-soluble, negatively-charged heads of the detergent form a mutually repellent layer around the soiling, because like charges repel. This effectively holds the soiling in suspension, and prevents re-deposition. (See the diagram on p. 5.23) To obtain the maximum benefit from your detergent product, it is vital that the wash process is properly structured particularly in terms of wash times. If wash stages are unduly protracted ie over 15 minutes depending on the process detergency can start to break down as the electrical charge weakens, leading to soiling being re-deposited on the load. It is also worth remembering that less is more in terms of the quantity of detergent you use. Too much can cause excessive foaming, resulting in reduced rather than effective mechanical action and soil removal! 5.22

193 Detergent molecules surrounding oil droplets in an aqueous detergent solution Anionic detergent molecule Oleophilic tail head The negative charges on the heads of the detergent molecules form a mutually repellent layer which holds the oil droplets in suspension and prevents them coalescing. It also prevents them re-depositing on the textile. Detergent removing oily substance from fibre surface The detergent is also attracted to the textile where it reduces interfacial tension between the water and the fibres and is absorbed by the soiling matter. Textile fibre Activity 2 Answer Sheets p What are the primary functions of: washing? wet-cleaning? 2 What are the main components of detergents? 3 How do you maintain maximum benefits from detergent? 5.23

194 Dry cleaning detergents Experienced dry cleaners will know that dry cleaning solvents on their own are very poor at removing soiling and stains from textiles compared to water-based processes. This is partly due to the fact that stains in particular tend to be water-based rather than oil-based. Types of dry cleaning detergents Dry cleaning detergents are synthetic products available as three major types anionic, non-ionic and cationic which may sometimes be blended together. A minority of cleaners use straight solvent with no detergent. Dry cleaning detergents also have oleophilic (oil liking) and hydrophilic (water liking) components. In the process of soil removal from textiles, the hydrophilic part of the detergent molecule seeks out moisture and moisture-soluble soil/stains. The oleophilic component helps the solvent to dissolve oily soils, facilitates the suspension and dispersion of oily soils and also particulates in the cleaning bath. Today many dry cleaning detergents that are designed for use in the machine not only act as detergents, but can often provide additional benefits such as retexturing, anti-static, softening, anti-bacteria and odour-eliminating properties. Colour classification However, even the best of today's dry cleaning detergents do not perform well when compared to detergents designed for washing. This makes good colour classification particularly important in dry cleaning. Dark garments normally carry much heavier soil loadings than light or white garments, and there can be a very high risk of re-deposition (greying) if due to pressure of work or a mistake a white or light garment is cleaned with a load of darks. A very common classification error is to clean a black garment with white trim in a dark load. This frequently leads to re-deposition and discolouration of the white component. Make no mistake if this happens, it is the cleaner's responsibility! Use of water Although water is not introduced into the machine in a controlled way, nearly all cleaners use pre-spotting detergents and spotting chemicals. These can be mixed with large quantities of water. Furthermore, the textile regain of garments when deposited for cleaning can vary considerably and under certain conditions garments may be well above their normal regain when accepted for cleaning. The capacity of the dry cleaning detergent to solubilise water can therefore be critical to the safety of moisture-sensitive garments, in particular during the dry cleaning process. It is important to recognise the difference between water that is held in solution in the solvent, and water that is in a free state or emulsified. Water that is in solution in the solvent is safe and will promote the safe removal of water solubles during cleaning. However, free and/or emulsified water in the system (giving rise to cloudy solvent) may cause serious shrinkage and/or re-deposition of soiling. Although the P symbol allows for up to two per cent of water to be added to the machine (based on the weight of the load) the cleaner needs to bear in mind that it is unlikely that every garment in the load will carry a circle P care label. Furthermore, even garments 5.24

195 that carry the label may not have been tested by a testing house against the relevant standard, and may therefore be adversely affected by any moisture addition as high as two per cent. Water-carrying detergents can generally solubilise around 10 per cent of their own volume of water in dry cleaning solvent. It will be evident bearing in mind the low detergent charges normally used in the hybrid system that for some loads the cleaner will need to be very careful about how much water is introduced into the machine by pre-spotting. Some cleaners use pre-spotting soaps diluted 1:1 with water. If these are applied liberally and randomly, excessive quantities of water can easily be introduced into the machine as a result. This can lead to shrinkage or re-deposition. A good detergent will minimise the risk of shrinkage during the cleaning process, and will promote the removal of water-based stains and soiling. Extensive trials have proved conclusively that the use of a good detergent combined with the correct process structure can load on load improve stain removal in the machine by at least 20 per cent. Activity 3 Answer sheets p What are the additional benefits from dry cleaning detergents? 2 What are the three mainstream dry cleaning processes? Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about detergents. When you have finished discuss the answers with your trainer. 1 What happens in a water-based process? 2 In which ways are dry cleaning detergents used? 5.25

196 5.26

197 Dry cleaning systems, processes and key facts Introduction There are a number of systems, processes and factors that you need to know about to be able to carry out effective dry cleaning. Dry cleaning systems Dry cleaning systems can be varied to suit the requirements of the cleaner, and many variations are possible. There are however three commonly used systems. Straight solvent systems The articles are cleaned in solvent without the addition of water or detergent, and preferably with continuous filtration. Batch system In this system the first part of the cleaning process is usually a wash over the filter. This initial stage is followed by a solvent dip, to which a soap/water mixture or an emulsion is added. Most of the water is absorbed by the textiles, but to avoid the risk of water entering the base tank or the filter, the dip is normally discharged to the still. The dip stage is often followed by a wash in filtered/distilled solvent. Hybrid system This is perhaps the most widely used cleaning system. In this system the base tank solvent is usually charged with between 2 5g/Itr of detergent. The base tank charge is maintained by detergent additions based on the volume of distilled solvent. The first stage of the process is a short dip, which should then be discharged to the still. This is followed by a second stage of continuous filtration, during which distilled solvent from the previous load and detergent are added. Systems for applying dry cleaning detergents There are several ways in which dry cleaning detergents are applied: Pre-spotting system The detergent, possibly blended with water, is applied directly to soiled or stained articles immediately prior to cleaning. Batch system The detergent concentration is not accurately controlled additions of detergent (with water when required) are typically introduced during a solvent dip stage of the cleaning process, mixing with the dip solvent and the articles being cleaned. 5.27

198 Charge system In this system there is a continuous flow of solvent containing a controlled percentage detergent (generally 1 4 per cent: 1 on a volume basis). The moisture conditions are automatically controlled by a conductivity meter that measures the solvent relative humidity. You may not have encountered this system as it not widely in use in the UK. Dry cleaning processes Normal fabrics P The normal dry cleaning process for robust garments involves cleaning in perchloroethylene for a period of at least 11 minutes, with continuous rotation of the cage. Heavily soiled garments may require up to 15 minutes or more for adequate soil removal. Additives such as detergents, water emulsions and water carriers may be added to improve dirt and stain removal. Water/soap solutions or emulsions are adjusted for the type of fibre and fabric. The outlet air temperature is restricted to a maximum of 60 C. Sensitive fabrics P Basically, the process is similar to that used for normal fabrics. However, moisture or water emulsions are not added to the solvent (or added only in very restricted amounts). Cleaning times must be reduced to a maximum of six minutes. It is usual to underload the machine and, where necessary, to protect garments with net bags. The outlet air temperature is normally restricted to a maximum of 50 C. This process is used for the following types of fabrics: knitwear (including polyester and acrylic fibres) fur fabrics crepe fabrics sensitive fabrics with a foam backing open-set, loose-spun wool fabric pure silk fabrics embossed fabrics blankets Very sensitive fabrics Characteristics of this process are the total exclusion of moisture; severe restrictions on mechanical action by using small loads and short process times and/or a stationary cage; and the omission of tumble drying. Outlet air temperatures can be reduced to around 40 C, at the operator s discretion. 5.28

199 This process is used for the following fabrics: knitted/woven angora goods novelty tweeds novelty silks chunky knits some wool Raschel fabric fluffy open-structure wool fabrics wool lace fabric sculptured velvets and furs especially weak trims delicate bead decoration Whites The greying of whites (or deposition of solubles and particulates) has always been a problem in dry cleaning. The cleaner has to understand that even the best and most effective process structure will still result in a small but measurable amount of redeposition on white loads. These small amounts of re-deposition will build up over a number of cleaning cycles, until the discolouration eventually becomes noticeable. It is therefore imperative that the dry-cleaner uses clean solvent and the correct process structure for white garments. Furthermore, even very small quantities of free water in the system can lead to an increased risk of noticeable greying. Modern dry cleaning detergents are still not capable of effectively suspending all the particulate soil released during a dry cleaning process. It is therefore critical that particulates are removed very quickly from the garments in the first three to four minutes of the cleaning cycle, when the vast majority of particulate soiling is released. This can only be achieved by starting the process with a wash over the filter. The filter wash should be followed by a rinse in distilled solvent. It is critical that for the first stage of the process, the filter is producing crystal clear solvent at a good flow rate, before the filtered solvent is introduced into the cage. The following process structure is appropriate for robust white loads: 1 Six minute filter wash, low dip using base tank solvent (solvent must be no more than a very light straw colour). 2 One-and-a-half minute drain and extract to still. 3 Minimum rinse in distilled solvent, drain and extract to base tank. 4 Dry at a maximum outlet air temperature of 60 C. The above process will need to be adjusted for sensitive white loads. Many cleaners still clean whites in a single bath of distilled solvent, without filtration. This type of process is often responsible for heavy greying on whites. 5.29

200 Key facts It is important that you know and understand the following key facts about dry cleaning: Water The presence of water in dry cleaning systems must be strictly controlled. Some textile fibres in particular wool and silk are very sensitive to moisture during dry cleaning. In the case of free water, wool and silk can suffer serious damage. At a maximum, addition of water should never exceed two per cent on the weight of the load. This particularly applies to the use of water on wool and wool mixture fabrics. Water can be introduced in a number of ways: by solvent/soap mixtures or emulsions from the garments from the spotting reagents by machine malfunctions Provided that water is present in the form of a solution in the solvent, it is generally safe. What causes damage are free water or localised wet patches on garments, due to incomplete drying out of spotting chemicals. It should also be remembered that garments may be wet when they are brought in for dry cleaning. The presence of free water is often indicated by cloudy solvent. The meaning of P and P There is sometimes confusion amongst drycleaners as to the meaning of the symbols P and P. A bar below the circle indicates that there are certain limitations that might have to be used during the process. These limitations can relate to any or a combination of the following: the addition of water the restriction of mechanical action maximum drying temperature The precise nature of the restriction is not indicated, and this is where the skill of the cleaner and additional information (such as the fibre content label) come into play. Mechanical action The length of the process influences the degree of mechanical action. It may be necessary to limit the mechanical action because the article is made from delicate fabric such as lace. In such cases the bar indicates the need for a short process (perhaps with the articles placed in a net bag). If the article has been made from soft, open-structured wool fabric, then the bar indicates restrictions both on the addition of water and reduced mechanical action. Drying temperature In the standard tests that are carried out to indicate dry-cleanability, the normal drying temperature is set to a maximum outlet air temperature of 60 C. If an article is unsuitable 5.30

201 for drying at this temperature, but is suitable for drying at a lower temperature for example 40 C then the correct after-care symbol must include the bar. This restriction on drying temperature is applicable only to heat-sensitive fibres. Quality of work The key to improved quality standards is a wholehearted commitment on the part of the staff, and good inspection systems throughout production. Garments should be thoroughly inspected at the following stages. Inspection at the counter Ideally, every garment should be inspected before the customer leaves the shop, with defects such as stains/soiling and fabric damage being brought to their attention. Examination before cleaning All parts of every garment should be inspected on a table prior to cleaning. Any necessary pre-spotting should be carried out, and any damage noted. Examination after cleaning All garments should be inspected during or after unloading the machine. Experience has shown that units adopting this policy invariably remove more stains. Final inspection A thorough, final inspection is essential if high quality is to be achieved and maintained. A detailed and systematic inspection procedure covering all parts of the garment should be adopted a cursory glance is insufficient. Staff must be made aware of what well-finished garments look like, and should understand the importance of high standards of finish at focal points. Ideally, final inspection facilities should be separate from piecing up and polyrobing. Final inspection should be done at a specially designated point with some means of rotating garments at a convenient height. Good lighting (minimum 500 lux) is essential in the final inspection area. 5.31

202 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about dry cleaning processes and systems. When you have finished discuss the answers with your trainer. 1 What is the meaning of P and P? What are the differences in the process? 2 What are the components that make up the quality of work? 3 What are the dangers of water in the dry cleaning process? How is this introduced into the machine? 4 Describe the different dry cleaning systems. 5 Describe the different ways that dry cleaning chemicals are applied? 6 How would you clean sensitive and very sensitive fabrics? 7 Describe the process of cleaning whites. 8 What is meant by mechanical action? 9 What is meant by drying temperature? 5.32

203 Application of textile finishes Introduction There are a number of types of product available. The main types are outlined below. Retexturing Retexturing is the application of finishes to the fabric to: compensate for undesirable changes in handle as a result of wear, soil removal or loss of finish in cleaning achieve a more satisfactory appearance after pressing impart special properties such as improved water or stain repellency Types of chemical used resins waxes plastic polymer for example Polyvinyl acetate fluorochemicals softening agents for example cationics Reproofing Reproofing is the application of a water-repellent agent. However, please note that the process does not impart a waterproof finish to textiles. The objective is to restore the high degree of water repellency that is the normal property of new rainwear, and which has been lost as the result of wear or cleaning. Types of chemical used wax/metallic salts silicones fluorochemicals 5.33

204 Softeners This is the application of a reagent to impart a softer handle to some fabrics. These products also help to reduce static. Types of chemical used cationic anionic These reagents are often incorporated into the retexturing compounds to improve fabric finish and drape. Methods of application impregnation (ie standing bath) substantive retexturing spray techniques Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about the application of textile finishes. When you have finished discuss the answers with your trainer. 1 What is meant by retexturing? 2 What is meant by reproofing? 3 What is the purpose of softener? 5.34

205 Activity answer sheets: Fabric soiling and staining Self-check questionnaire Question p. 5.8 Use this self-check questionnaire to make sure that you now know all that you need to know about fabric soiling and staining. When you have finished discuss the answers with your trainer. 1 What is atmospheric pollution soiling? 2 What are the different types of oils and grease soiling? 3 Describe perspiration soiling. 4 What are the five classifications of stains? 5 What have you to consider when deciding to use wet or dry process stain removal? 5.35

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207 Activity answer sheets: Dry cleaning solvents Self-check Questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about dry cleaning solvents. When you have finished discuss the answers with your trainer. 1 What would be an ideal properties list for a dry cleaning solvent? 2 What are the main solvents used in the UK? 3 What checks must be carried out to ensure solvent is used efficiently? 4 What and where would you check for solvent vapour leaks? 5.37

208 5.38

209 Activity answer sheets: The dry cleaning machine Activity 1 Question p What are the machine types used in the UK? 2 Name all the component parts of a machine. 3 What type of pump is fitted to a machine? 4 What is a regenerative filter? 5 What is the purpose of the still? 5.39

210 Activity 1 (continued) Question p What devices are fitted to a still? 7 What is a carbon recovery system? 5.40

211 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about the dry cleaning machine. When you have finished discuss the answers with your trainer. 1 What is the purpose of the button trap? 2 Name the three types of filters fitted to a machine. 3 What is the purpose of the filter pressure gauge? 4 What are the two different heating mediums used in a still? 5 What does the water separator do? 6 How does the extraction/drying system work? 5.41

212 Self-check questionnaire (continued) Question p What routine maintenance should be carried out on a machine? 5.42

213 Activity answer sheets: Detergents Activity 2 Question p What are the primary functions of: washing? wet-cleaning? 2 What are the main components of detergents? 3 How do you maintain maximum benefits from detergent? Activity 3 Question p What are the additional benefits from dry cleaning detergents? 2 What are the three mainstream dry cleaning processes? 5.43

214 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about detergents. When you have finished discuss the answers with your trainer. 1 What happens in a water-based process? 2 Describe the three mainstream dry cleaning processes? In which ways are dry cleaning detergents used? 5.44

215 Activity answer sheets: Dry cleaning: systems, processes and key facts Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about dry cleaning processes and systems. When you have finished discuss the answers with your trainer. 1 What is the meaning of P and P? What are the differences in the process? 2 What are the components that make up the quality of work? 3 What are the dangers of water in the dry cleaning process? How is this introduced into the machine? 4 Describe the different dry cleaning systems. 5.45

216 Self-check questionnaire (continued) Question p Describe the different ways that dry cleaning chemicals are applied? 6 How would you clean sensitive and very sensitive fabrics? 7 Describe the process of cleaning whites. 8 What is meant by mechanical action? 9 What is meant by drying temperature? 5.46

217 Activity answer sheets: Application of textile finishes Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about the application of textile finishes. When you have finished discuss the answers with your trainer. 1 What is meant by retexturing? 2 What is meant by reproofing? 3 What is the purpose of softener? 5.47

218 5.48

219 Notes 5.49

220 5.50

221 6 Dry Cleaning Operations Level 2 G8CC 22 Candidate Support Pack Section 6 F0JS 04 Form-finish and inspect garments using steam/air (LDC11) F0JV 04 Garment and item finishing using the ironing table after dry cleaning (LDC14) F0JT 04 Garment and item finishing using a free steam press (LDC15)

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223 Contents Introduction About these Units F0JS 04 Form-finish and inspect garments using steam/air (LDC11) Key areas of knowledge and understanding Skills and techniques F0JV 04 Garment and item finishing using the ironing table after dry cleaning (LDC14) Key areas of knowledge and understanding Skills and techniques F0JT 04 Garment and item finishing using a free steam press (LDC15) Key areas of knowledge and understanding Skills and techniques Regulations, rules and guidelines About this learning and teaching pack Health and safety and maintenance procedures Introduction Health and safety Activity 1 Setting-up and closing-down the pressing department Activity 2 Checking and maintaining presses Common mechanical faults Self-check questionnaire Types of steam, types of press and folding Introduction Efficient operation and inspection Activity 3 Types of steam and correct use Types of press: hot head presses Activity 4 Types of press: free-steam press Activity 5 Folding Self-check questionnaire iii

224 Finishing heat sensitive fabrics Introduction Heat Moisture Activity 6 Self-check questionnaire Press clothing Introduction Types of clothing Reclothing presses Correct clothing of the buck Self-check questionnaire Activity answer sheets Health and safety and maintenance procedures Types of steam, types of press and folding Finishing heat sensitive fabrics Press clothing Notes 6.39 iv

225 Introduction About these Units The following three Units are designed to help you cover all that's required for pressing and finishing garments: F0JS 04 Form-finish and inspect garments using steam/air (LDC11) F0JV 04 Garment and item finishing using the ironing table after dry cleaning (LDC14) F0JT 04 Garment and item finishing using a free steam press (LDC15) We have condensed these Units into one section here, because there is a lot of information that s common to both, and we want to avoid unnecessary duplication. Unit F0JS 04 (LDC 11) In Unit F0JS 04 (LDC11), your role will involve: forming, finishing and inspecting garments inspecting garments to control quality planning the work to form and finish garments As a competent person, you must: make sure that equipment is safe and ready to use plan the work required place garments on the former process garments in steam and air finishers inspect garments for satisfactory finishing identify any garments that are unsatisfactory or damaged unload garments place them on hangers direct garments to the correct location for dispatch make the best use of the resources available check that colleagues understand what work they must do identify any problems that may arise take appropriate action with any faults in the process 6.1

226 Key areas of knowledge and understanding This Unit will help you to develop the following key areas of knowledge and understanding: How to operate and control equipment. What services are required to make machines work. Care labels. Understanding fibres and fabrics. How faults in the process affect the condition of garments. How to record faults, and who to report them to. What hazards are associated with steam and air finishing. How to plan work, making the best use of resources available. Why it is important to identify any possible problems at the planning stage, and why these should be reported to the supervisor. Skills and techniques After working your way through this Unit, you should be able to: check that clothing and the equipment is safe and ready for use check that items are suitable for steam/air processing inspect garments for faults and foreign objects secure, straighten and clamp garments on the former inspect garments make necessary adjustments to steam/air pressure, dependent on garment/fabric requirements identify and redirect unsatisfactory garments unload and hang garments direct garments for packing and dispatch receive, check and confirm the supervisor s instructions for carrying out steam and air finishing plan how to carry out these instructions check that plans are in line with the supervisor s instructions identify any problems in finishing garments or in carrying out your supervisor s instructions and get advice from them accordingly brief colleagues on what they must do and check that they have understood the brief 6.2

227 Unit F0JV 04 (LDC 14) In Unit F0JV 04 (LDC14), your role will involve: pressing garments and items using a flat bed finishing table inspecting pressed garments and items for quality As a competent person, you must: make sure that equipment is safe and ready to use press items to the finishing specification inspect items for satisfactory pressing identify and deal with any items that are not satisfactory, according to company requirements Key areas of knowledge and understanding This Unit will help you to develop the following key areas of knowledge and understanding: Steam pressures, vacuum services and lighting requirements. Requirements for adequate air extraction. Ironing table clothing requirements. Iron temperatures adjustments and ironing/steaming techniques relative to different fabrics. How to interpret care labels. The value of vacuum in pressing. The properties of main fibres. Fabric construction. Thermal sensitive fibres and velours. Skills and techniques After working your way through this Unit, you should be able to: set-up and close-down the workstation equipment for garment pressing and finishing start-up and close-down boiler systems and air compressors use the ironing table and ancillary equipment use the iron, vacuum and blow facility use ancillary pressing aids take precautions for the protection of the fabric, garment construction, finish and trims before steaming and ironing finish items to a required standard correct distortions and restore shape to items take care of buttons, trims, accessories and zips press linings 6.3

228 avoid damage to garments care for sensitive fibres, knitwear, nap and long-pile fabrics Unit F0JT 04 (LDC 15) In Unit F0JT 04 (LDC15) your role will involve: pressing garments and items using a free steam press inspecting pressed garments and items for quality As a competent person, you must: make sure that equipment is safe and ready to use press items to the finishing specification inspect items for satisfactory pressing identify and deal with any items that are not satisfactory, according to company requirements Key areas of knowledge and understanding This Unit will help you to develop the following key areas of knowledge and understanding: Steam pressures, vacuum services and lighting requirements. Requirements for adequate air extraction. Press buck clothing requirements and ancillary tools. Use of correct lays for the garments pressed. How to interpret care labels. The value of vacuum in pressing. The use of a water spray during pressing. The properties of main fibres. Fabric and garment construction. Thermal sensitive fibres and velours. Skills and techniques After working your way through this Unit, you should be able to: set-up and close-down the workstation equipment for garment pressing and finishing start-up and close-down boiler systems and air compressors use the press and vacuum use the iron, vacuum and blow facility use of ancillary pressing aids 6.4

229 take precautions for the protection of the fabric, garment construction and finish before pressing finish items to a required standard correct distortions and restore shape to items care for buttons, trims, accessories and zips during pressing press linings avoid damage to garments care for sensitive fibres, knitwear, nap and long-pile fabrics Regulations, rules and guidelines For all three Units, you should read and get to know the following regulations, rules and guidelines: The organisation s rules, codes, guidelines and standards. Equipment operating procedures. Machine and equipment capabilities. Relevant responsibilities under the Health and Safety at Work Act and Control of Substances Hazardous to Health (COSHH). Manufacturers instructions. About this learning and teaching pack This part of the learning and teaching pack is designed to help you develop the knowledge and skills and generate the evidence required to pass all three Units. It is divided into the following sections: Health and safety and maintenance procedures Use of steam, types of press and folding Finishing sensitive fabrics Press clothing Each section contains information and follow-up activities to help you apply what you have learned. At the end of each section there is a self-check questionnaire to help you check your knowledge and understanding so far. You should discuss your answers with your trainer. 6.5

230 6.6

231 Health and safety and maintenance procedures Introduction When finishing an item of personal wear, the cleaner s main objective should be to restore the garment to a standard of finish as close as possible to that of a new garment subject to the effects of wear. For over 70 years laundries and dry-cleaners throughout the world have relied upon the Hoffman or scissor press for finishing garments. However, during the past few years there has been a move towards the use of specialised ironing tables and rotor cabinets to replace or supplement the traditional garment press and former. A high degree of skill and dexterity is needed to finish garments using the Hoffman or scissor press. This can only be acquired by detailed instruction and practice over an extended period of time. By contrast, using specialised ironing tables reduces the need for extended training considerably, because they are very easy to use. Whatever type of equipment you are working with, you will need to know the procedures for using it safely, setting it up and closing it down and for checking and maintaining it. Health and safety Due to the variety of machines in the press department and the high degree of individual handling, the risk of operator injury is quite high. The press department operative is using machines that operate at approximately C, and small burns are the most common injury. There is a risk of trapping hands between press heads, resulting in serious and painful injuries, but guard rails should be in place to prevent operator access. If any item becomes jammed or stuck the operator must be aware of the risks when they attempt to free the item, and should always remember that personal safety must come first. If the fault cannot be rectified safely, then assistance should be sought from a supervisor or engineer. Twin button controls on air operated scissor presses must operate correctly they are the front line defence against serious injury. The emergency release buttons on all machines should also be checked regularly for efficient operation. Handling dry fabric and operating presses at high temperatures could lead to fires starting if a few simple precautions are not taken: Never leave items under a hot head press for longer than is required to dry and finish them, or the result could be a scorched item or a fire. 6.7

232 Stacking pressed items on top of a rotary press body is a method often used to complete the drying process. This is a fire risk and should not be done any items left in this position for any length of time could result in damage to the article, or lead to a fire. Garment presses can present major safety hazards to finishing staff, and any health condition which might involve fainting or loss of consciousness needs to be assessed in terms of health and safety. For example, staff who have epilepsy may be at serious risk if they are allowed to operate finishing equipment. Staff must be fully aware of the dangers of steam and of the risks involved in operating faulty or badly maintained equipment. Faults such as the following may expose staff to serious risk: Guards missing on boiler sight glasses. Worn insulation on electric cables. Broken micro switches on steam irons. Faulty safety mechanism on automatic presses. It should be noted that if the safety mechanism on an automatic press is not working, the press should not be operated! The safety cut out should be tested at the start of each working day. Activity 1 Answer sheets p Small burns are the most common injury to press operatives. What immediate first aid action would you take to help ease the pain of such an injury? Setting-up and closing-down the pressing department The press department handles items that have been washed and thermally or chemically disinfected to ensure that they are hygienically clean. The press operative must ensure that their personal hygiene standards are very high and that they are not responsible for any recontamination. All work surfaces must be clean and free from dust, lint and soiling that may mark-off onto any of the items being pressed. Before starting any pressing operation, the machinery and equipment should be examined for obvious faults, including steam or air leaks, puddles and padding quality. You should also check that all guards and safety features are in place and working correctly. Refer also to Unit HS1. 6.8

233 Activity 2 Answer sheets p List ten things you would do before leaving the press department at the end of your shift to ensure health and safety and maintain production quality. Checking and maintaining presses If presses are to be capable of finishing textiles to a high standard, they must be supplied with steam at the correct pressure, the vacuum must be satisfactory, the locking pressure should be appropriate for the type of textile/garment and the bucks must be aligned correctly. In addition, the clothing must be in good condition. Steam Steam must be supplied at the correct pressure. The recommended pressure is psi ( bar) and a good average working pressure is 65 psi (4.4 bar). Good steam response (the time taken for steam to penetrate the surface of the buck) is vital in terms of production rates. On a manual press supplied with steam from a central boiler, response times of less than two seconds can easily be achieved, subject to the type of clothing and its condition. Automatic presses with their own boiler are usually much slower, with response times frequently over six seconds. If the steam pressure is allowed to fall below 55 psi, response times can climb steeply, and there is a progressive risk of condensation wetting the clothing. It is important that the steam is evenly distributed over the buck this can be checked visually. The steam should penetrate the buck smoothly and evenly from one end to the other. Uneven distribution a common fault which can seriously affect quality is usually caused by hard/consolidated clothing and/or blocked steam holes. Vacuum The importance of good vacuum cannot be over-emphasised. If the fabric is not adequately cooled and excess moisture removed before moving to the next lay, the finish will relax. A good vacuum will also assist the finisher by holding lays in position. There are three simple checks that you can carry out to assess the efficiency of your vacuum. 1 Apply steam. When it has fully penetrated the clothing, apply the vacuum, keeping the steam pedal depressed. A good vacuum will take away the steam. 2 Heat the buck with steam. After heating, shut off the steam and apply the vacuum. Run a hand quickly over the heated surface to check when cooling is complete. A good vacuum will cool the buck fully within five seconds. 3 A further check on the distribution of the vacuum can be carried out using a sheet of A4 notepaper. Apply the vacuum and draw the paper over the buck. The taper will slide easily over the surface in any area where the vacuum is poor. 6.9

234 The most common causes of poor vacuum are as follows: hard/consolidated clothing, restricting air flow vacuum passages blocked with decomposed press clothing collapsed flexible couplings between equipment and vacuum unit diameter of pipework too small long pipe runs too many right angle bends in pipework vacuum valves not opening fully inefficient vacuum units undersized vacuum units Pressure adjustment Incorrect locking pressure is probably the most common fault found on garment presses, and results in a variety of finishing faults, particularly on trousers. Adjustment of the press is always the responsibility of the finisher and at the very least it should be checked at the start of each working day. Correct locking pressure is critical in terms of trouser finishing: if it's too light, it can cause soft creases and if it's too heavy, it can cause seam, pocket lining and buck impressions. The locking pressure on both manual and automatic presses should be tested using a sheet of A4 notepaper. A handkerchief is not recommended because of the significant friction between the fabric and press clothing. The following method is recommended, and should be carried out after the press has warmed up. 1 Stand in front of the press and holding the bottom of the paper place approximately two thirds of the sheet over the bottom buck. 2 Lock the head and grip the paper firmly with both hands and pull it from between the bucks. If the locking pressure is too heavy, it will be obvious that there is a risk of tearing the paper. 3 If the locking pressure is correct, the paper will remain gripped by the press and resistance will be felt until it has been withdrawn completely from between the bucks. 4 If the locking pressure is too light, little or no resistance will be felt as the paper is withdrawn. Alignment of bucks When this check is carried out for the first time, the locking pressure should be tested at both ends of the press. This is to ensure that the bucks are correctly aligned. When the bucks are misaligned, the locking pressure may have been adjusted correctly at the narrow end of the press, but it will be too heavy or too light at the wide end. This problem often arises after presses have been dismantled and reassembled. 6.10

235 Common mechanical faults Presses can develop a number of faults, and you should know how to identify them and refer them to the appropriate person to deal with. Press locking mechanisms The failure of the locking mechanism to operate or to operate reliably is a very common fault, and the implications are seldom understood by engineers. It often leads to imprecise control of the top buck, particularly in relation to the use of vacuum. If this fault is not rectified, pressers will usually adjust their technique in an effort to accommodate it, often with considerable difficulty and loss of production. Failure of the press locking mechanism is a major equipment fault which can have a serious effect on standards of finish. Head checks/dampers The failure of these components is also a common fault and again, its significance is not appreciated by engineers. At worst, it can be the cause of a major structural failure. On manual presses, it results in the pressing technique having to be adjusted. This increases the physical effort required to operate the press, and therefore adversely affects production rates. Rapid head closure This is a fault confined to automatic presses. If the press head snaps shut, there is a risk of injury to the presser. In addition, the draught created may disturb lays, or in extreme cases blow the garment off the buck. Leaking valves Leaking valves waste energy. In addition in the case of steam valves on presses condensation from the steam and the consequent wet patches on clothing can also leave marks on garments. Leaking steam and/or vacuum valves result in a lack of precise heat control, contributing to poor standards of finish. In the hands of well trained staff, a properly clothed and well maintained press will produce higher standards of finish, with less effort and at higher production rates. 6.11

236 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all there is to know about health and safety and maintenance procedures. When you have finished, discuss your answers with your trainer. 1 List the health and safety precautions you need to take while working on the presses. 2 What are the causes of poor vacuum? 3 How do you check the pressure on a press after adjustment? 4 What are the common mechanical faults on a press? 6.12

237 Types of steam, types of press and folding Introduction The majority of the work processed through the laundry is finished in a tumble dryer, calender or tunnel finisher but some items, due to their shape, fabric or construction have to be diverted to the press department. Most of these items will be garments that will be finished on a hot head or free steam press. As items processed through the press department receive far more handling and attention than bulk processed work, it is expected that the special training and skill of the operatives will result in a high quality finish. The customer is far more likely to pick fault with a pressed item of personal clothing than over a creased sheet or pillowcase. Efficient operation and inspection Items received in the press department should have been spun in the washing machine or dried in the tumble dryers to a pre-determined level to allow finishing to take place on the selected press. Work for the Hoffman press or garment former could be totally dry, but work to be pressed on a hot head press needs to be damp to ensure quality of finish and justification of the additional labour time and effort involved in a pressed finish. Adding moisture to an article being pressed on a Hoffman press to allow crease removal will require between 3 and 15 seconds of free steam followed by twice as much vacuum time to ensure total moisture removal. Before pressing starts, examination of wash quality paying particular attention to garment collars, cuffs and underarms for residual soiling will prevent rejection after pressing. Any staining should not be pressed before attempts are made to remove it by spotting and re-washing first. Pressing at high temperature may set any residual protein based stains permanently. Generally preparing work prior to pressing by pulling sleeves through, ensuring items are not inside out and any rewash is sorted out early, will help to enhance efficiency. You may also be able to redirect some of your workload to another finishing process if it can be finished quicker and to an acceptable quality. Activity 3 Answer sheets p What is the most likely cause of protein staining on butcher s aprons that should be removed before pressing? 6.13

238 Types of steam and correct use Different types of steam are appropriate for different types of fabric, and it s important to know which is which. Bottom/ironing surface steam This is used for finished knitwear, pile fabrics and in particular heavyweight garments such as camel cloth coats. It is also used for correcting distorted areas such as pocket mouths. Top steam Top steam is used when the press head is closed. The combination of heat and pressure induces the kind of firm and stable finish that is so important on trouser legs and on the lapels and front facings of jackets. Under normal circumstances, only top steam should be used when the head is closed. It is a common error in finishing technique to use top and bottom steam together. Over-steaming should be avoided. Excess steam can drift and relax areas that have already been pressed. Vacuuming The correct use of vacuum sets the fabric and removes excess moisture. Insufficient use of vacuum (a common finishing fault), leads to relaxation and limpness. The garment should always feel cool before moving to the next lay. It is almost impossible to lay down hard and fast steaming and vacuum times owing to the wide variation in boiler plant efficiency, and the condition of individual presses. However, a good general rule is to vacuum for two or three times as long as the steam time. A token touch on the vacuum pedal is absolutely useless. Types of press: the hot head presses The hot head press has been developed from the hand iron. The work is placed on a padded table called a buck and a polished, steam heated metal head is brought down and held with some pressure to provide a pressed finish. Various designs of hot head press are seen in commercial laundries, and these include the following. The rotary press The rotary press has been used for many years. It incorporates the principle described above, but has two padded bucks, which rotate alternatively into position beneath the heated head. Air-operated rams make contact with the steam-heated metal head of the press, then lift the buck. This press allows the operator to prepare work on one buck while the other piece of work is under the head. The buck tends to be oblong and long enough to allow cotton coats and boiler suits to be processed efficiently. 6.14

239 Single head press with twin rotating bucks The pressing of a garment on this machine can involve many lays, as a coat or jacket is pressed in stages with only one thickness pressed at a time. This reduces the risk of creasing and helps to achieve the best quality pressed finish. The following diagram illustrates the time-consuming repositioning of a coat to achieve the required pressed finish. 6.15

240 Instructions for laying and pressing coats (First coat shown shaded; second coat shown black.) Lay collar and lapel of first coat. Lay yoke of first coat. Open sleeves of first coat and lay with outside uppermost for finishing. Lay front of first coat with corners of the table well into top part of sleeves. Lay second coat for pressing half the collar and lapel on the outside. Lay side of first coat with seam out near edge of table to preserve shape of coat. Lay second half of the collar and lapel of the second coat. Lay back of first coat. Reverse collar and lapel of second coat to press on underside. Lay side of first coat with seam on far edge of table to preserve shape of coat. Lay yoke on second coat. Lay front of first coat with corner of table well into top part of sleeve. Lay edge of second coat on near side of table. To gain maximum productivity, the press operative should cover as much of the buck as possible. This may involve laying two or more items up on the buck at a time. The scissor press 6.16 The principles of this press are very similar to the rotary press. However, instead of two padded bucks, it has one fixed padded buck onto which a heated hot head is lowered. This then clamps onto the work in a scissor-like action hence the term scissor press. Single buck models have largely been superseded by the rotary press. Some specialist scissor pressers still survive, however, as auxiliary presses for cuffs, lapels and collars on garments before they are finished on a shirt cabinet unit.

241 Triple bucks press In this press, three bucks are arranged in a line on a common mounting, with the collar or neckband buck in the centre. This type of press may be designed with either a closing head and rigid buck, or a rigid head with a closing buck. To prevent the operator trapping their fingers, hand or arm in the press, the machine is operated by pressing two buttons simultaneously. A guard should also be fixed around the hot head to reduce the risk of burns. Triple bucks press Three bucks arranged in line on a common mounting with the collar or neckband buck in the centre. This type of press is designed with either a closing head and rigid buck or a rigid head with closing buck. Cabinet units When cabinet units were first introduced they were a major innovation as they enabled cotton coats and shirts to be pressed to a high quality in less than half the time taken using a scissor or rotary press. The padded buck on these units was fixed vertically to the machine and was dressed a bit like a tailor s dummy. This buck then travelled along a track and the front and back of the garment were pressed by two steam-heated heads the same shape as the buck. Developments to this machine included using twin bucks on either side of a single cabinet, with hot air being blown into the garment body and sleeves to improve the finished quality. Activity 4 Answer Sheets p Hot head presses are usually operated at 150 C. List four articles that are processed through your laundry that could be finished on one of these machines. 6.17

242 Types of press: free-steam press The best known type of free-steam press is the Hoffman press. The Hoffman press The free-steam press uses live, low-pressure steam, which is blown onto and through the fabric to eradicate creases and shape the garment. These presses are used on items that have already been dried. They have a padded buck and padded head. The covering consists of perforated metal distributors that allow steam to be blown uniformly through the padding into the garment. The lower buck is fitted with a vacuum to remove the moisture and therefore help dry the garment after steaming. These presses work at lower temperatures than the hot head presses and reduce the risk of overheating and damaging heat sensitive fabrics. They are often seen in dry-cleaning plants but are also used in laundries where personal clothing made from heat sensitive fabrics needs finishing. An air operated free steam press Safety trip prevents accidental trapping of hand or arm Top buck Bottom buck Two handed controls keep fingers clear of hazard whilst pressing Foot pedals for bottom steam and vacuum Activity 5 Answer sheets p What is the main reason for using a free steam press rather than a hot head press on temperature sensitive fabrics? 6.18

243 Folding Once items have been pressed, they should be prepared for packing and despatch. This may involve putting items of clothing on coathangers, but it is more likely that they will need folding. There are many methods and styles of folding garments and flatwork, and this will be covered in your basic on-the-job training. An example of four methods of folding a shirt is given here. This helps to illustrate ways that should produce the highest quality of finish in the laundry. Hand folding methods for shirts 6.19

244 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all there is to know about types of steam, types of press and folding. When you have finished, discuss your answers with your trainer. 1 Explain how you would press a white coat on the rotary press. 2 Explain how a scissor press works. 3 What are the safety features on this type of press? 4 Why is moisture retention essential to the pressing process? 5 Why should you look at the wash quality prior to commencing pressing? 6 Explain how the following work: Rotary Press Hot Head Press Cabinet unit Hoffman press 6.20

245 Finishing heat sensitive fabrics Introduction Care in finishing must be taken with all fabrics because mishandling may cause shrinkage, extension and/or distortion. The majority of fabrics will, however, behave satisfactorily, but there are some where extra care is needed because they may be affected by heat and moisture or a combination of both. The categories below list the main fibre or fabric types and which caution is required. Heat The majority of man made fibres are thermoplastic and are therefore sensitive to heat. Dry ironing above the temperature recommended on the care label will cause glazing and possibly melting of the fabric. Scorching of natural fibres will also occur if the ironing recommendations are not followed. Polyvinyl chloride (PVC) PVC is extremely heat sensitive and will soften and shrink at very low temperatures (ie 70 C). Finishing is therefore not recommended. It should be noted that textiles containing PVC fibres should not be accepted for either cleaning or washing. Modacrylic Modacrylics are usually used in fun furs and in flame retardant curtains and bedspreads (Teklan). Shrinkage and deformation caused by heat will occur at temperatures as low as 60 C. Fun furs should not be finished at all. They should be removed from the laundry/dry-cleaning machine after an adequate cool-down procedure, and hung on a hanger to stabilise. Note the garments should be removed immediately the machine cage stops rotating. It is possible to finish modacrylic curtains by means of a vertical curtain finishing machine. Moisture Some fabrics are adversely affected by moisture. Wool Care must be taken with wool and all other animal fibres because instability can arise from hygral expansion. Hygral expansion is the reversible change in dimensions that occurs due to variable moisture regain of wool fabrics. So, for example, a garment that is steam finished without pressure will tend to expand. If it is then air blown and cooled to room temperature, it will tend to remain in the expanded state. On lightweight wool wovens this 6.21

246 may result in seam pucker and the appearance of bubbling on panels, which is not caused by interlining failure. Piece dyed goods ie solid shades are particularly prone to this, and a minimum steaming should be given. Taffeta Taffeta is a plain weave fabric which has a crisp handle and a lustrous appearance. It is usually made from silk, acetate or polyester. Sizings and finishes are often applied to taffeta during manufacture to increase the crispness and lustre. Very often these finishes are not durable and can be solubilised by water. This causes ring marks and also loss of any surface design ie moiré or water mark. Taffetas should not be steamed, but finished with a dry iron for best results. Heat and moisture Acrylic fibres become plastic in moist heat, and can be deformed and lose pleats very easily if handled in this condition. Acrylics are used in all types of garments, drapes and furnishing fabrics. Often they are made into pile fabrics which should never be steamed or ironed, because irreversible deformation of the pile will occur. Moisture regain The longer a garment can be left after cleaning, the more time it will have to regain its natural moisture content from the atmosphere before pressing. Natural moisture regained after pressing is liable to make the garment become limp and lose its set and handle. Care labels The reduced demand on the press department in most laundries over the past 20 to 30 years has been due to the development and introduction of man-made fibres. The majority of workwear garments in use today are made from polyester cotton fabric that can be finished in bulk through a tunnel finisher. Cotton workwear garments are now fairly restricted, and include specialist garments that may only be tumble dried, and some that require a quality finish such as chefs jackets, which are still pressed. In addition, items and garments made of fabrics that are sensitive to laundry detergents, heat or excessive mechanical action will usually be processed through a dry-cleaning department and will carry a do not wash or dry-clean only label. Advice on the hot plate temperature on any heat sensitive item will be shown on the care label using the hand iron symbol with dots to signify the maximum recommended finishing temperature. 6.22

247 Labelling for recommended ironing temperature IRONING Symbol Brief meaning Steam ironing may be risky. Cool iron 110 o C Medium temperature iron 150 o C Hot iron 150 o C Do not iron.steaming and steam treatments not allowed It should be remembered that an electric iron has a calibrated temperature control dial that is labelled to match the dot symbols, which should be checked against the advice on the care label before use. However, the steam heated metal head of a commercial laundry press only has a fixed temperature of approximately 150 C so extreme care should be taken in selecting items to be finished on this type of press. Activity 6 Answer sheets p List three items that will be sent to the press department for finishing and give a reason why they can t be finished in a tumbler, tunnel finisher or calender. Item eg frilly edged pillowcase Reason for pressing High quality finish required

248 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all there is to know about finishing sensitive fabrics. When you have finished, discuss your answers with your trainer. 1 Explain what fibre types cannot be pressed, and where they would be finished. 2 What are the temperature settings on an iron? And what is the temperature on a commercial laundry press? 3 How would you press PVC? 4 How would you finish Modacrylic curtains? 5 How do you finish wool products? 6.24

249 Press clothing Introduction Finishers seldom appreciate the importance of resilient press clothing and the contribution it makes to high standards of finish. It is fair to say that press clothing is seldom maintained in a satisfactory condition, with the result that many common finishing faults such as impression marks are created as a direct result of consolidation and a complete lack of resilience. The clothing on presses is there primarily to provide a smooth, resilient surface during finishing, and to accommodate the varying thicknesses of fabric in a garment s construction. A high degree of resilience is particularly important due to the pressures that are imposed when the head of the press is closed and locked. Once press clothing has begun to lose its resilience, it will become increasingly difficult for the finisher to avoid leaving seam and buck impressions on the garments. Clothing that is in good condition will mould itself around seams, pockets, buttons and zips, exerting a fairly uniform pressure over the whole lay. Correct adjustment of the press in terms of locking pressure, and the correct use of steam and vacuum are also essential if the cleaner is to take full advantage of wellclothed equipment. Types of clothing Some cleaners still use traditional clothing of the natural type. While this initially provides an ideal, resilient pressing surface, it has a limited life. Many cleaners are now moving to other forms of press clothing because of the inherent disadvantages of natural products. These include the following: KCPs are not very durable, and decompose into a fine brown powder if left on the press for too long. The decomposition products can block steam/vacuum holes in the bottom buck. The clothing consolidates comparatively quickly, affecting steam response, vacuum efficiency and steam and vacuum distribution. Synthetic alternatives are now very popular and are thought to be used by the majority of cleaners. Most do not decompose as readily as natural products, although in the case of some stitched synthetic pads resilience is not as good as that provided by a KCP. Thick felts and lightweight synthetic foam pads provide good resilience. Silicone foam is favoured by some cleaners. Although it is expensive it has good resilience, is very durable and in the long term could prove to be very cost effective. Light/medium weight foam pads are cheaper, very durable and provide good resilience. Heavyweight foam pads will last for many years but their resilience is poor and for this reason they are not recommended for general purpose pressing. Composite pads are very easily replaced and their resilience is generally good. Some types are however very thick and may adversely affect steam and vacuum times. 6.25

250 It is important that the type of clothing you choose is suitable for your press. For example, in the case of automatic presses with their own boilers, or on any press with poor vacuum or steam response, the porosity of the clothing can be critical. In view of this we recommend that you seek the advice of your supplier if you are thinking of changing. Remember, price is not the most important consideration. The methods of clothing laundry dry-cleaning presses (from the base outwards) can be summarised as follows: Bottom Buck Copper gauze. Knitted cotton padding (KCP) or synthetic alternative. Canton flannel or synthetic alternative. Outer cover. Alternatives Composite pad a single pad containing the main elements of press clothing. In some cases an outer cover will be required. Synthetic foam pad (thick). Canton flannel or synthetic alternative outer cover Wire/Nomex gauze. Canton flannel or synthetic alternative Synthetic foam pad (thin). Outer cover. Nylon press cover Canton (flannel) Knitted cotton padding (KCP) Copper gauze 6.26

251 Traditional press clothing in the correct order is as follows: Top Buck As for Bottom Buck above Alternatives Fabric Safe ray plate Wire/Gauze Canton flannel or synthetic alternative Outer cover Reclothing presses When the clothing on presses is replaced, the pressure must be released to accommodate the additional bulk/thickness of the new clothing. This is particularly important in the case of natural materials, which initially may undergo substantial reduction in thickness. You may see presser operatives who, after having clothed a press, apply top and bottom steam and stand on the centre pedal in an attempt to lock the head. This practice causes premature consolidation of the clothing, and may well reduce its useful working life considerably. Some types of clothing particularly the natural type will reduce in thickness very quickly, resulting in the need to increase the locking pressure progressively throughout the first working day. Take care when you are using springs don t leave exposed, sharp ends which will catch clothing and skin! 6.27

252 Correct clothing of the buck Sometimes, examination of presses in unit plants reveals that the springs used to hold the bottom buck cover and clothing in place are under too much tension, or that the fastening cord is too tight. This results in undulations along the buck surface, as shown below. It is important that the cover is secured firmly, so that neither the cover nor the padding can become displaced. On the other hand, undulations caused by over-tightening can be detrimental. If the surface of the buck is uneven, the garments take up the contours during top steaming. Preferential escape of steam can occur along the valleys, and can cause distortion. The diagram below shows how the crease line of a trouser leg can be deformed although, on casual inspection, the buck surface of the press did not look very uneven. The uneven surface of the buck will also affect the sharpness of the crease to some extent. For example, the parts of the garment dipping in the valleys will be subject to rather less pressure during steaming or when using a block. The vacuum effect and airflow in the regions where padding is more compressed will also tend to be lower. The combination of less pressure, followed by less effective cooling and moisture removal during vacuuming may result in softer creases at intervals along the leg. Self-check questionnaire Answer sheets p Use this self-check questionnaire to check that you know all there is to know about press clothing. When you have finished, discuss your answers with your trainer. 1 How would you re-clothe the press? 2 What materials are used? 3 What must you do after you have re-clothed the press? 6.28

253 Activity answer sheets: Health and safety and maintenance procedures Activity 1 Question p. 6.8 Small burns are the most common injury to press operatives. What immediate first aid action would you take to help ease the pain of such an injury? Activity 2 Question p. 6.9 List ten things you would do before leaving the press department at the end of your shift to ensure health and safety and maintain production quality. 6.29

254 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all there is to know about health and safety and maintenance procedures. When you have finished, discuss your answers with your trainer. 1 List the health and safety precautions you need to take while working on the presses. 2 What are the causes of poor vacuum? 3 How do you check the pressure on a press after adjustment? 4 What are the common mechanical faults on a press? 6.30

255 Activity answer sheets: Types of steam,types of press and folding Activity 3 Question p What is the most likely cause of protein staining on butcher s aprons that should be removed before pressing? Activity 4 Question p Hot head presses are usually operated at 150 C. List four articles that are processed through your laundry that could be finished on one of these machines

256 Activity 5 Question p What is the main reason for using a free steam press rather than a hot head press on temperature sensitive fabrics? 6.32

257 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all there is to know about types of steam, types of press and folding. When you have finished, discuss your answers with your trainer. 1 Explain how you would press a white coat on the rotary press. 2 Explain how a scissor press works. 3 What are the safety features on this type of press? 4 Why is moisture retention essential to the pressing process? 5 Why should you look at the wash quality prior to commencing pressing? 6.33

258 Self-check questionnaire (continued) Question p Explain how the following work: Rotary Press Hot Head Press Cabinet unit Hoffman press 6.34

259 Activity answer sheets: Finishing heat sensitive fabrics Activity 6 Question p List three items that will be sent to the press department for finishing and give a reason why they can t be finished in a tumbler, tunnel finisher or calender. Item eg frilly edged pillowcase Reason for pressing High quality finish required

260 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all there is to know about finishing sensitive fabrics. When you have finished, discuss your answers with your trainer. 1 Explain what fibre types cannot be pressed, and where they would be finished. 2 What are the temperature settings on an iron? And what is the temperature on a commercial laundry press? 3 How would you press PVC? 4 How would you finish Modacrylic curtains? 5 How do you finish wool products? 6.36

261 Activity answer sheets: Press clothing Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all there is to know about press clothing. When you have finished, discuss your answers with your trainer. 1 How would you re-clothe the press? 2 What materials are used? 3 What must you do after you have re-clothed the press? 6.37

262 6.38

263 Notes 6.39

264 6.40

265 7 Dry Cleaning Operations Level 2 G8CC 22 Candidate Support Pack Section 7 AT6W 04 Carry out the washing process (LDC4)

266 ii

267 Contents Introduction About this Unit Key areas of knowledge and understanding Skills and techniques Regulations, rules and guidelines About this learning and teaching pack Health and safety and maintenance procedures Introduction Electricity supply Compressed air supply Steam supply Activity 1 Gas Water Chemical supplies Activity 2 Control of Substances Hazardous to Health (COSHH) Activity 3 Correct settings Safety features Activity 4 Linen transport equipment Activity 5 Setting-up routines Closing-down procedure Self-check questionnaire iii

268 The ingredients for a successful wash process Introduction The main ingredients of the wash process Water Activity 6 Time Temperature Activity 7 Mechanical action Activity 8 Main components of a fully built washing product Special components of fully built detergents Activity 9 Other chemicals used in the washroom Self-check questionnaire The wash process Introduction Standard two wash process Activity 10 Other types of wash process Activity 11 Activity 12 Self-check questionnaire iv

269 Troubleshooting Introduction Yellowing and galling Greying Rust spots Creased polycotton Creased flatwork Poor soil removal Poor stain removal Chemical damage Linting Colour loss CBW blockage High detergent use Activity Activity answer sheets Health and safety and maintenance procedures The ingredients for a successful wash process The wash process Troubleshooting Notes 7.55 v

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271 Introduction About this Unit This Unit AT6W 04 Carry out the washing process (LDC4) is designed to help you cover all that s required for the washing process. Your role will involve: maintaining operating standards, equipment and supplies washing items planning the work required for washing processes controlling the washing process As a competent person, you must: make services and machinery ready for use select detergents, chemicals and programmes that are correct for classification operate machinery in accordance with supervisor s instructions load and unload machines handle items with care identify and report any machine faults remove any items that are not washed satisfactorily or have been damaged plan the work required make the best use of resources available identify any problems that may arise in carrying out the work brief colleagues and check that they understand what work they must do control the washing process select detergents, chemicals and programmes suitable for the load check that thermostats and temperature gauges have the correct settings check that work is being carried out as planned 7.1

272 Key areas of knowledge and understanding This Unit will help you to develop the following key areas of knowledge and understanding: Operational settings and the range of performance from machines. Common faults. Which detergents, chemicals and additives to use, and what they do. Care labels. Understanding fibres and fabrics. How the complete washing process works. How to carry out routine machine maintenance. Who to report faults to. How to communicate effectively. The correct load weight for the machine and the fabric. The difference between wash programmes. The temperature setting for the wash programme. The problems associated with high and low dip levels. How the wash process operates. How to select different wash programmes. How to recognise faults and malfunctions within the machine or wash process and the action to take. How to stop a malfunctioning washing machine safely. How to recognise faults or deficiencies in washed work. Skills and techniques After working your way through this Unit, you should be able to: make services and machinery ready for safe use use machines and machine controls take action when faults, inefficient machine operations or hazards are found write reports and keep records dispose of waste correctly and safely receive, check and confirm supervisor s instructions plan how to carry out instructions, making best use of resources identify problems and get advice brief colleagues and check understanding check loads for classification and process requirements identify and redirect unsuitable items select detergents, chemicals and programmes check thermostats, temperature gauges and dip levels 7.2

273 use correct additives operate machines report and record faults remove and redirect unsatisfactory items check the progress of planned work Regulations, rules and guidelines You should read and get to know the following regulations, rules and guidelines: The organisation s rules, codes, guidelines and standards. Equipment operating procedures. Machine and equipment capabilities. Relevant responsibilities under the Health and Safety at Work Act and Control of Substances Hazardous to Health (COSHH). Manufacturer s instructions. About this learning and teaching pack This part of the learning and teaching pack is designed to help you develop the knowledge and skills and generate the evidence required to pass this Unit. It is divided into the following sections: Health and safety and maintenance procedures The ingredients for a successful wash process The wash process Troubleshooting Each section contains information and follow-up activities to help you apply what you have learned. At the end of each section there is a self-check questionnaire to help you check your knowledge and understanding so far. You should discuss your answers with your trainer. 7.3

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275 Health and safety and maintenance procedures Introduction Every member of the washroom team has a major role to play in ensuring that the department is a safe and efficient working environment. To achieve this objective, the equipment used to process the washing must be maintained to a high standard, and all operators trained in machine operation and health and safety awareness. Planned preventative maintenance (PPM) should be carried out by the engineering department to ensure that manufacturers maintenance schedules are followed and safety checks are carried out. Prevention is far better than cure when dealing with production equipment, and all operatives should help the engineering department by informing them of malfunctions as soon as they happen. Electricity supply Look for evidence of potential electrical problems. Are there any obvious frayed or damaged wires or connections? Did you get a slight tingle when a machine was switched on? This tells you that the earthing is faulty and a short circuit could kill you through electrocution. Are the warning lights, beacons, etc working correctly? If you identify a fault, report it immediately to your supervisor or engineer and do not use the machine until you are sure it is safe to do so. Compressed air supply The compressed air supply may be switched on centrally, but you should be aware of any obvious air leaks. You may hear the air escaping, see a flicking air line (an air line not connected) or feel a constant flow of released compressed air. Any of these faults will affect productivity and should be reported and repaired quickly. Steam supply Steam supplied to the washroom to heat the water in the washing machines and possibly to warm the tumble dryers will be very hot. All pipes should be lagged to keep the steam dry and hot and to prevent operatives burning themselves on hot pipes. If you see damaged lagging or hear, see or feel a steam leak, then report it. Steam is supplied under pressure from the boiler house, and there will be pressure gauges on the supply line and on machines. You should be aware of the usual readings on these gauges and know what to do if they change. The steam pressure determines the steam temperature, so if the pressure falls, the temperature drops and equipment does not perform properly. 7.5

276 If the steam pressure drops throughout the laundry, most machines will not be able to operate at their optimum production rate. Finishing equipment will have to be operated more slowly to ensure that dry work, drying times will have to be extended on tumblers, and wash processes will be extended as they struggle to achieve set temperatures. When washer extractors are heating many litres of water to achieve high wash temperatures they are a major drain on the laundry steam supply. The washroom operative can help to even out the demand on the boiler by staggering the start-up times of a line of washer extractors so that they are not all trying to draw off steam at the same time. If a drop in steam pressure is due to temporary boiler failure, the washroom will often be asked to stop their washer extractors calling for steam until a working pressure has been achieved. Co-operating with this request will enable the laundry to return to full production far quicker. Activity 1 Answer sheets p Find out what the steam pressure gauge on the main supply line to the washroom should read. 2 At what high and low reading should you report a fault? Normal steam pressure Reportable low steam pressure Reportable high steam pressure Gas Gas is used in some laundries to heat tumble dryers. If you smell gas or suspect a leak, then stop operating the machinery and report your concerns to your supervisor, engineer or manager. Always put the safety of yourself and your workmates first and ask questions later. Water Water is an essential supply to the washroom. Luckily it is very rare for a mains supply to fail and leave the laundry without water. Always check the quality of the water after a burst water main has been repaired, as high sediment levels could stain or discolour your washed fabric. 7.6

277 Interruptions to water supply are usually due to pump failure or empty storage tanks and are quickly rectified. You should check for any signs of water leaks such as puddles, drips or the sound of running water before you start up any machines. A leaking water inlet valve on a washing machine can result in many litres of water draining away during shutdown periods. It can also have a detrimental effect on wash quality by increasing wash dips when production has started. Chemical supplies Chemical supplies to the washing machines should be checked before production starts, so that any low supplies can be replenished without you having to leave washing machines unattended later in your shift. You should carry out these routine checks before the start of every shift and ensure that any fault you identify is reported, following your organisation s set procedures. Many laundries now operate with liquid detergent systems that automatically dose the correct chemicals into the washing machines. Checking that dosing pumps actually run and that there is a layer of detergent bubbles during a wash should help to identify breakdowns before poor quality washing is removed from the washing machine. The use of automatically dosed chemicals has reduced the risks from having to handle chemicals for many laundry washroom staff, but for varied reasons some chemicals are still dosed manually by jug. Whether your contact with chemicals involves only changing product barrels, dosing products by jug directly into the washing machine or making up stock tanks, you should follow the safety advice on the product labels. Activity 2 Answer sheets p You are washing the last load of your shift. What would you do if you noticed that the chemical dosing pumps were not working? 7.7

278 The Control of Substances Hazardous to Health (COSHH) This legislation is now part of the Health and Safety at Work Act and puts a legal requirement on all chemical suppliers to provide safe handling data with their products. There is also a responsibility on employers to provide the necessary personal protective equipment (PPE), and on employees to use it. You will be provided with workwear garments for your protection, along with other items such as gloves, goggles, face masks and safety shoes. If you do not wear the PPE provided, you will place yourself at an increased risk of injury, and may lose your rights to compensation if you are involved in an accident at work. Activity 3 Answer sheets p What special clothing or other personal protective equipment would you expect to use during a day working in the washroom? Correct settings While carrying out your standard tasks in the washroom you should regularly check that the washing machines are operating to the correct settings. Most washing machines will have pre-set control parameters with the dip levels, process time and temperature being controlled by a process card or computer program. Other influences on wash quality like detergent, bleach, fabric conditioner or starch additions will have been set by agreement with your chemical supplier. As the operator of a washing machine don t assume that all these settings are going to be correct all the time. Control cards stick and lengthen process times, dip level sensors malfunction, thermostats break, computers lose their memory and detergent supply systems break down. You should be aware of these possibilities and constantly monitor the washing machines under your control. Most washer extractors have dip tubes that allow you to judge at a glance whether the correct low, medium, or high dip is being achieved. Having the dip tubes marked with these wash liquor levels will help you identify faults. A high dip on a wash will result in poor washing quality by reducing the detergent concentration and reducing the wash action. It will also increase wash costs by taking longer to reach the temperature and using more water. Similar problems will result from wash water flows, in a continuous batch washer, being set too high. 7.8

279 A low dip on rinses will result in poor rinsing and increased rewash due to detergent retention, yellowing of whites and skin contact reactions in the finishing department. If badly rinsed work reaches the customer, a major complaint could result from users getting sore skin (dermatitis). On a continuous batch washer similar problems could be caused by a low rinse water flow. Safety features Washing machines have many safety features to protect the washroom operative, and it is important that your training covers these. There are some elements of the machine design that may prevent you from doing something for example, not allowing you to open the door on an operating washer extractor. Other features might require you to react to a fault or emergency by, for example, pressing the large red stop button. It is important that you check that safety features are in place and that they work. Do not try to bypass any safety feature, as this can be extremely dangerous. Activity 4 Answer sheets p What are the safety features built into the washing machines in your laundry? 2 How would you check that these are working? Linen transport equipment Loading and unloading washing machines will involve using linen transport equipment. This could be linen bags or trolleys and trucks. Part of your responsibility is to check that this equipment is in good working order, and that it won t potentially harm you or damage the items you are processing. The cleanliness of the handling equipment is important bags, trucks and trolleys should be cleaned and disinfected regularly to prevent cross contamination. You should use different trucks or trolleys for soiled and clean work unless they are thoroughly cleaned and disinfected, and a liner is used. As a washroom operative you will have to lift, carry, push and pull during your shift. You should carry out these activities as safely as possible, using any equipment provided (such as drum moving trolleys) to help you with these tasks. Always following manual handling advice. 7.9

280 Activity 5 Answer sheets p What faults might you find on fabric movement equipment (such as trucks or trolleys) in the washroom? 2 What health and safety precautions should you take when handling soiled fabric items? Setting-up routines At the start of each shift, the washroom operative should ensure that there are no obvious reasons why they should not turn the washroom equipment on. Check for messages or notes from the previous shift on faults or breakdowns. Ensure that there are no warning signs of potential risks posted by the engineering department or evidence that work is in progress such as removed machine guards and abandoned tools. Bag storage systems, conveyors, washing machines and dryers will all need switching on, and you should be aware of the energy supplies each piece of equipment needs to function correctly. Closing-down procedure At the end of your shift in the washroom, you should plan to leave it so that the following shift can start-up without unnecessary delays. The floor should be swept, rubbish bins emptied and all debris from the day s production cleared away. Washer extractors should be emptied, as unwashed or partially washed fabric can be a fire risk when left in the confines of a washing machine. Soiling that can be oxidised can generate heat, ultimately leading to spontaneous combustion. Continuous batch washers should be left prepared for a thermal disinfection cycle prior to production starting on the following day. Any messages on production requirements, machine faults, etc, should be left for the next shift using the organisation s agreed communication system. If production is to stop for any length of time after your shift, all washing machines and other equipment should be left in a safe condition as laid down in your company s operational procedure. This may include switching all machines off at their control panel and isolating some supply systems. The end of a shift is a good time to check the supply of washing chemicals and to replenish stocks for the following shift. 7.10

281 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all there is to know about the health and safety and maintenance procedures involved in the wash process. When you have finished, discuss your answers with your trainer. 1 What do you do if you see smoke coming from a washer extractor motor? 2 If you deem it safe to put the fire out, what do you do first? 3 Which extinguisher do you use to put out a motor fire? 4 Which is the nearest fire exit? 5 How do you minimise manual handling injury when loading/unloading a washer extractor? 6 You get a tingle when you press the start button of the washer extractor. What does this tell you? 7 You suspect the engineer has just electrocuted himself. He is flat on the floor with a finger in the control box. What do you do? 8 You spill detergent powder into a large puddle of water over the floor. How do you make the area safe? 7.11

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283 The ingredients for a successful wash process Introduction Washing fabrics is not a simple task there are many variables involved in deciding which wash process, chemicals and type of washing machine to use. The main ingredients of the wash process A successful wash process has to combine a number of important ingredients, as shown in this diagram: Mechanical action Time Water Temperature Chemical activity Water is the one constant factor. You can t wash without it! Mechanical action, time, temperature and chemical activity are the variables that are altered to achieve the required wash result. If one of the four variables is reduced, some or all of the others will have to be increased to achieve a balanced wash process. The following pages and exercises will help you understand the influence of each variable on the wash process. 7.13

284 Water Water is something we all come into contact with every day, and therefore tend to take for granted. The laundry manager not only needs a reliable source of water he or she will also be concerned about its quality and hardness. Quality For water to be effective as a cleaning agent, it must be free from substances and bacteria that may soil or contaminate the textiles being washed. We are lucky in this country to have water that is clean and of drinking quality. However, occasionally contamination does occur. If there has been a burst water pipe or if your water is drawn from a peaty soil area, you might notice that your water is brown. This can give washed linen a yellow tint. A poor quality water supply can be treated in the laundry before being used for washing to remove contaminants and bacteria, but this can be expensive. Hardness Water hardness is caused by calcium and magnesium salts present in the water. Although these react differently, their effects on the washing process are the same and are always detrimental. Hardness can easily be removed from water by using a water softener. Hardness is measured in different units. Scientists use milligrams per litre (mg/l) although in this country degrees Clark ( C) is still commonly used. (1 C = mg/l). The level of water hardness varies greatly from area to area, and depends upon the type of rocks the water passes over and through on its way to the mains supply. In some parts of the south east of England, it can be as hard as 35 C (500mg/l) whilst in parts of Scotland it can be as low as 0. 5 C (7. 1mg/l). Hard water: destroys some of the detergent can make loads feel greasy if soap is used leads to scale build-up in washing machines leads to a hard skin forming around greasy and oily soiling, making it harder to remove makes fabrics feel hard and harsh Any water hardness has some effect on washing quality, but the greater the level of hardness, the greater the problem. 7.14

285 Activity 6 Answer sheets p Find out what your laundry s raw water hardness is. 2 What level it is softened to? Water hardness before softening Water hardness after softening Time Different parts of the wash process are given different amounts of time, depending on what you are trying to achieve. For example, it takes longer to remove soiling in the wash than it does to remove residual detergent in the rinse. The amount of time given in the wash will depend on the soiling level, but the average main wash time will be between 10 or 12 minutes. These times should start once the target temperature has been achieved. Rinsing times will usually be three minutes once a high dip has been achieved and dilution of wash chemicals can take place. Temperature The accurate measurement of temperature during the wash process is vital to allow the correct chemical reactions to take place. Some critical wash temperatures are as follows: 40 C 50 C 65 C 71 C 80 C 90 C Protein soil set above this temperature. Optimum temperature for enzyme activity. Maximum temperature for sodium hypochlorite bleach use. Minimum temperature for thermal disinfection (10 minutes UK). Minimum temperature for hydrogen peroxide use. Thermal disinfecting temperature (3 minutes UK). Minimum temperature for heavy mineral oil removal. Minimum temperature for thermal disinfection (most of Europe). 7.15

286 On a typical process for white cotton sheets, you might wash at a number of these target temperatures for different reasons: The first wash will be kept below 40 C to prevent setting protein stains. Protein is present in food, blood, sebum (skin oil), faeces etc. It will usually take a minimum of five minutes to break down this type of soiling. Thermal disinfection should be achieved on the main wash by washing for at least 10 minutes at 65 C or better still washing above 71 C for more than three minutes. The higher temperature will improve the chemical reactions between the alkali in the detergent and the soiling and, if hydrogen peroxide bleach is used, will give better stain removal. If sodium hypochlorite is used as the bleaching agent, a bleach rinse at about 50 C for five to seven minutes will result in optimum stain removal with minimum damage. Activity 7 Answer sheets p Obtain information about the following washer extractor wash processes in your laundry and complete this table. Textile Soiling 1st wash temperature 2nd wash temperature White cotton Protein White cotton Mineral Oil Mechanical action The mechanical action of a wash process depends on three main factors: design of the machine degree of loading level of water Design of the machine Washing machines come in all shapes and sizes, but all washer extractors are designed to wash linen by lifting it out of the wash water and allowing it to drop. The aim is for the wash action to imitate the lift, drop, squeeze and rub action that you would use when hand washing in a bowl. The two elements that affect the efficiency of this mechanical action are the speed at which the drum rotates and the design of the actual wash drum. 7.16

287 The speed of rotation is usually fixed. However, if the drive belts are slipping, you will probably see work wallowing in the bottom of the drum instead of being carried up to the 10 o clock position and dropped, as most open pocket machines are designed to do. The ideal wash action will also be lost if the rotation is too fast, and work is just carried around the outside of the cage. The gentle action setting seen on many washing machines keeps the rotation speed the same, but increases the dwell time between rotations. The design of the washing machines drums will usually be one of the following: Open Pocket Y Pocket D Pocket The open pocket machine is the most common. It is usually fitted with three or more beaters to help lift and carry the work to nearly the top of the machine. The subsequent drop and squeezing action of the work gives this type of machine the highest level of action. The Y pocket drum is only usually found on larger washer extractors where it helps to keep different classifications separate, and aids loading and unloading. Due to the limited space inside the drum, lifters are not usually fitted. The wash action is much reduced in this type of machine, but is adequate for light to medium soiling classifications. The D pocket machine is the least popular, and is usually found on side-loading machines. Beaters are usually fitted but the wash action is very restricted. Degree of loading Washing machines are usually referred to by their maximum loading capacity (for example, the 90kg machine). This figure is usually calculated using cotton sheeting as the standard classification. If the load is above this designated weight (overloading) the restricted movement and drop of the linen will reduce mechanical action. Overloading will result in poor wash quality. If the load is below this designated weight (underloading) the work may be carried too high in the cage and either dropped late or not dropped at all. This reduces the mechanical action. 7.17

288 You may be trained to load your washing machines to a set weight, but you must take into account how bulky an item is and how this will affect the mechanical action of the wash. For example, you would never manage to squeeze 90kg of lightweight polyester filled duvets into a washing machine with a maximum loading capacity of 90kg. Level of water This is usually referred to as the dip, and is a very important factor in controlling the mechanical action and wash quality. The dip is referred to in two ways either the standing dip or the running dip. Standard dip Running dip The running dip is usually lower than the standing dip, as water is lifted by the cage rotation. Because of the cushioning effect of water and the tendency for textiles to float, a high dip reduces the level of mechanical action. This is why it is important to ensure that the wash stages of a process have a low dip and maximum mechanical action to help break down the soiling embedded in the fibres. 7.18

289 Activity 8 Answer sheets p Detail the types and number of washing machines you have in your laundry. Machine type CBW Open Pocket W/ex Y Pocket W/ex D Pocket W/ex Number 2 Select a washer extractor in your washroom and find out what weight of load would be selected for the following classification. Name of machine Drum design Open pocket Y pocket D pocket Maximum loading capacity Item Polycotton sheets Duvets Cotton towels Polycotton workwear Loading weight 7.19

290 Main components of a fully built washing product The chemical processes that help to remove soiling are complex, and are constantly being researched and developed. A brief history of the development of modern laundry chemicals from the original soap to the fully built detergents of today will hopefully help you to understand the terminology. Before the 1960s almost all laundries used a mixture of soap and alkali. The soap was a product derived from the action of alkali and natural oils or fats such as olive oil and palm oil (vegetable) or tallow (animal). Very little soap is now used in laundries, but the term soap is still used to describe washing detergents. The new chemicals used in the washroom are soapless detergents made by complex reactions based on a range of petrochemicals. Various types of detergents are made. Each has different properties, which can be effectively used to remove different types of soiling. Detergents alone have limited properties and, if used on their own, would give poor results. Because of this, fully built products were developed in the late 1960s. These contain a wide range of different chemicals that achieve a good wash result either on their own or in combination. The ingredients of these fully built detergents do vary depending on the type of soiling or fabric they are intended to be used on, but most products share the same basic ingredients although the ratios may vary. Here are the main ingredients of fully built detergents. Soapless detergents These are probably the most chemically complex ingredients, and their role is to lower the surface tension between the water and the fibres to allow the water to quickly and thoroughly wet-out the fabric. A secondary action is to actually remove soiling from the surface of the fabric. Each molecule of detergent is made up of two parts a head and a long straight tail. The head is hydrophilic it is attracted to water and the tail is oleophilic it is attracted to oil. The diagram below shows a droplet of oil on a fibre submerged in water. 7.20

291 When detergent is added, the molecules try to put their heads in water and their tails in oil. The only place they can achieve this is on the droplet of oil connected to the fibre. As the surface of the oil becomes covered with detergent molecules, the molecules begin to attach themselves to the point where the oil and fibre are joined, and therefore weaken this joint. Eventually the connection between the oil and fibre is broken and the oil is lifted off into the water. It was mentioned in the section on hard water that water hardness affects this process. Firstly, it will destroy some of the detergent and secondly, it will coat the oil with a hard shell almost immediately and make it more difficult for the detergent molecules to attach themselves. 7.21

292 Alkalis Alkalis form the greatest proportion of a bag of built detergent product. Several alkalis are available, but the most common are sodium metasilicate and sodium carbonate. Both will be present (in different ratios) in most fully built detergents, depending on the classification the product is aimed at. The main functions of an alkali are to: prevent the detergent molecules from breaking down (because their heads have separated from their tails). This is less likely to happen if the wash solution is highly alkaline create alkaline conditions that make some fibres (particularly cotton) swell making soil removal easier react with the oils and fats in the soiling to make crude soaps, which the detergent finds easier to remove provide some soil suspension of removed soiling Carboxy methyl cellulose (CMC) CMC is a soil suspending agent. It attracts released soiling and holds it in suspension, thereby stopping it from being deposited back again on the washed fibres. Polyphosphates Polyphosphates are added to the washing detergents you use at home to effectively soften the wash water. But in industrial detergents, their role is to surround the calcium and magnesium in the soiling so that it doesn t affect the efficiency of the detergent activity. Polyphosphates are not added to industrial detergents in sufficient quantities to overcome the problems caused by hard water. Optical brightening agents (OBA) These chemicals are added in very small quantities. They coat the surface of the fabric, absorb invisible ultraviolet light and reflect it back from the fabric as visible white light. This makes the textiles appear bright and fresh in daylight. Special components of fully built detergents Soapless detergents, alkalis, soil suspending agents, polyphosphates and OBA are the main ingredients of fully built detergents. However, some contain special additives to improve the product s performance on certain soiling or fabrics. Soap Soap is still added to some fully built detergents to add a slightly soft feel to fabrics, and provide lubrication inside the washing machine. 7.22

293 Enzymes Enzymes are very complex organic molecules found in the human stomach. They digest certain types of protein and fatty soiling. A wash containing enzymes should be maintained below 50 C for at least 10 minutes, so the enzymes can break down their particular soiling target. Bleaching agents These are sometimes added to built detergent products in the form of sodium perborate. Sodium perborate is only active between 60 C and 80 C, although activators can be added to allow it to become active at lower temperatures. Bleaches built into detergent products do not have the same flexibility as those that are applied with separate chemicals. Bleaches Bleaches are used in the laundry to remove visible stains and unwanted dyes from fabric. They fall into two basic categories oxidising bleaches and reducing bleaches. The two most commonly used laundry bleaches are sodium hypochlorite (NaOCL) and hydrogen peroxide (H 2 O 2 ) both are oxidising bleaches but operate in different ways and require different conditions. Oxidising bleach: sodium hypochlorite (NaOCL) This is still the most common type of bleach in use in this country and is commonly called chlorine bleach because of its smell. It is a very crude, basic chemical that like all bleaches does not have a detergent s ability to remove soiling and hold it in suspension before carrying it away. As noted earlier, its optimum temperature for use is about 50 C. Below this, its action is slow and above this, the action can be very rapid and can cause chemical damage to fabrics. Bleaching with sodium hypochlorite is usually carried out in the first rinse, with a dose of approximately 6 8 m/s per kg of dry weight work. On automatic feed systems, hypochlorite bleach should always be added below the water line and be flushed in by water. 7.23

294 It is an extremely effective disinfectant at very low concentrations (approximately parts per million). Sodium hypochlorite bleach should not be used when washing some flame retardant treated fabrics, as it can destroy this treatment. It will also neutralise the benefits of enzymes and perborate/peroxide bleaches if used in the same bath. If large brown stains start to appear on hospital work after it has been washed in a process that includes sodium hypochlorite, this is probably the result of a chemical reaction between the hospital disinfectant chlorhexadine and the bleach. The resulting stain cannot be removed. The answer is prevention rather than cure use only sodium perborate or hydrogen peroxide bleach on hospital work where this type of staining might be present. Oxidising bleach: hydrogen peroxide (H 2 O 2 ) Hydrogen peroxide is usually sold at a strength of 35 per cent to the commercial laundry market. It is inactive below 60 C and becomes fully active only at temperatures above 80 C. Unlike sodium hypochlorite, hydrogen peroxide has no bacterial effect. It is considerably more expensive than sodium hypochlorite and although only 2 3mls/kg of dry weight work is used, it is still more expensive to use. The benefits of hydrogen peroxide are that lower volumes need to be stored and it can be used on pastel or coloured work without stripping the colour. Chemical damage to textiles from using hydrogen peroxide is far less likely than with sodium hypochlorite. Sodium perborate is a similar chemical compound to hydrogen peroxide, but it is used at high temperature at a dosage rate of 400g to 100kg of dry weight work in solid powder form. From a health and safety viewpoint both sodium hypochlorite and hydrogen peroxide are corrosive, and extreme care should be taken when handling either of them. The two products should never be mixed, as this will result in chlorine gas. Reducing bleach: sodium hydrosulphite (Na 2 S ) This is the most common reducing bleach. Reducing bleaches are rarely used in laundries except for specific dye removal, and even then not as part of a wash process. 7.24

295 Activity 9 Answer sheets p Activity 9 1 List the names of the fully built detergents used in your laundry and state what hazard warning symbol for example, corrosive or toxic they have on the bag or drum. Product name Hazard warning 2 What are the five main ingredients of a fully built detergent? 3 What bleach do you use in your laundry and at what temperature is the bleach process carried out? Other chemicals used in the washroom A number of other chemicals are used in the washroom. They are described below. Sour As most washing detergents are chemically alkaline, they can be neutralised by the addition of an acid. A laundry sour is a mildly acidic chemical that is added to the final rinse of a process to prevent white work turning yellow. This is called galling, and is due to the effect of heat on residual alkali during finishing. Sours should not be used as a substitute for good rinsing. They are designed to neutralise excess alkaline from the raw water. Acetic acid is a commonly used sour. Antichlor An antichlor is added to a process to neutralise any retained chlorine bleach. If cotton items are tumble dried or calendered with chlorine bleach residues on the fibres, they can be chemically damaged. Sodium thiosulphate and sodium bisulphite are commonly used as antichlors. 7.25

296 Fabric conditioner Fabric conditioners coat the fibres with a cationic detergent to provide a soft feel and give body to cottons. They also reduce static electricity on polyester. They are added to the final rinse of a process. Starch Starch is used to give body and stiffness to fabrics and can help to reduce soil and stain penetration. It is typically used on table linen and most successfully applied in a special starch rinse at the end of the wash process. Natural starches made from wheat, corn, rice or potato typically require a low dip, minimum 38 C (ideally 50 C) rinse of about 10 minutes duration prior to the final extract. There are also some synthetic and blended starches available that have been specially developed for man-made fibres. Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all there is to know about the ingredients for a successful wash process. When you have finished, discuss your answers with your trainer. 1 At the start of each shift, what would you look for? 2 What would happen to the washer extractors if the steam pressure drops? 3 What are the main causes of the water pressure dropping? 4 What are the consequences of the dip levels not being at the correct levels for washing? 5 What action should you take at the end of your shift in the laundry? 6 What are the main elements of a wash process? 7 What are the problems caused by hard water? 8 Can you name the seven critical wash temperatures? 9 What is the correct temperature for a pre-wash? 10 What are the three main factors that govern the mechanical action of a wash process? 11 What are the dangers of over or underloading the machine? 12 You are given classified loads that contain eight loads of sheets, six loads of towels and one load of pillowcases. How would you plan your washer extractor loads to be washed? 7.26

297 The wash process Introduction You now know all about the ingredients you need for a successful wash process, so the next section will show you how they are all put together to form the wash process. Standard two wash process The following process is a typical washer extractor process for medium soiled white cotton work. It is a two wash process. Operation Time Dip mins Temp Additions C Wash (1) 8 Med 35 Detergent Drain 1 Wash (2) 12 Low 80 Detergent Drain 1 Rinse (1) 7 Med 45 Hypochlorite Drain/spin 1 Rinse (2) 3 High Cold Drain/spin 1 Rinse (3) 3 High Cold Drain/extract 10 Wash 1 As most soiled linen contains some protein soiling, a first wash has been programmed to provide eight minutes at below 40 C to allow for the complete breakdown of protein soiling. A medium dip has been selected to ensure thorough wetting out, reasonable mechanical action and enough water to carry any heavy soiling. The amount of detergent added will depend on the level of soiling, but approximately two thirds of the total detergent addition should be made at the start of the first wash. Drain The machine is drained to dump the removed soiling. No interspin is used because this would remove too much detergent and force the soiled water through the fabric. As a result, this would act as a filter and become recontaminated. 7.27

298 Wash 2 This wash is where the firmly attached soiling is removed, so it is important that the mechanical action, temperature and chemical activity are all at their maximum, and enough time is given to allow them to work. The wash dip should be low to ensure a high mechanical action. You should ensure that the dip is still low after the high temperature has been reached, because if there is a poor steam supply and it takes quite a long time to achieve 80 C, the steam might have condensed back to water in the machine and raised the dip. The remaining one third of detergent should be added to the detergent carried over from the first wash, to give a high level of chemical activity. A temperature of 80 C will give good chemical activity and ensure thermal disinfection. It is essential that this temperature is maintained throughout the set wash time of 12 minutes. Drain The machine is drained again to remove the suspended soiling. Rinse 1 The object now is to remove all the remaining wash chemicals and any remaining staining. Once the medium dip has been achieved, sodium hypochlorite should be added at a rate of approximately 8 10 mls per kg of dry weight of work. The medium dip will allow the bleach to be evenly distributed throughout the wash load. (A lower dip might cause a patchy result, and a higher dip might over-dilute the bleach.) To ensure good bleaching activity without excessive chemical damage, a temperature of C should be maintained for seven minutes. Drain/spin The machine is again drained, but this time an interspin is also used to increase the removal of chemicals. Rinses 2 3 These rinses will completely remove the remaining chemicals, including the sodium hypochlorite. Rinsing is merely a process of dilution, and therefore a high dip is required. No temperature is used. Three minutes at high dip should be sufficient time for total mixing. Drains and interspins between rinses will increase chemical removal, and reduce water consumption. Final extract The length of the final extract depends on the classification, the type of washer extractor and the finishing process the load is destined for. 7.28

299 . Activity 10 Answer sheets p If you were to use hydrogen peroxide bleach instead of sodium hypochlorite on this process where would you add it and how much would you use per kg of dry weight work? Other types of wash process The two wash process is only one type of process. There are many variations that could be made to it, depending on the requirements of classification, fabric type and soiling level. Here s an example. A wash process for engineers coloured polycotton workwear would not normally include any bleach addition at all, and would have other significant differences from the cotton sheet process. Soiling on engineers workwear is likely to be mineral oil based, and this tends to form a firm bond with the polycotton fabric. To help the detergent to break this band the first wash temperature may be set above 80 C. This will soften the oil and grease and increase the chemical activity of the alkali in the fully built detergent. A special cool-down stage has to be added to the process as polyester fibres tend to suffer from thermal shock creasing if the reduction in temperature from the high wash temperature to the cool rinse is too rapid. This stage will ensure that the temperature falls from about 80 C to below 52 C no quicker than 4 C per minute. This should reduce the level of thermal creasing. However, be warned more pressure creases can be imposed if the polyester cotton process includes a long final extract stage. As polyester cotton is not as absorbent as cotton, it will only require a very short spin. 7.29

300 Activity 11 Answer sheets p Using the information you have been given in this Unit, see if you can complete the following process for medium protein soiled white polycotton workwear. You might want to complete this process as a group exercise. Operation Time Dip C Temp Additions C Mins Wash (1) Drain Wash (2) 80 Cooldown 10 Med Bleach rinse Drain Rinse Drain Rinse Extract

301 Activity 12 Activity 12 Answer sheets p How do you start a loaded washer extractor on your standard used sheet programme? 2 How do you programme your machine to achieve a standard towel wash? 3 Follow a standard cycle on one of your washer extractors and note the times, temperatures and chemicals at each stage. Step Wash (1) Wash (2) Drain Rinse (1) Drain Interspin Rinse (2) Drain Interspin Rinse (3) Drain Final Extract Total programme time Step time Water temperature Chemicals 7.31

302 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all there is to know about the wash process. When you have finished, discuss your answers with your trainer. 1 Explain what the following wash processes are and what they do? Wash 1 Wash 2 2 What are the functions of the rinses in the process? 3 What length of time should you allow for a final extract? 4 Name another wash process? 7.32

303 Troubleshooting Introduction Despite working your way through this Unit of your SVQ training, things are still going to go wrong. This troubleshooting guide to common laundry problems will hopefully help you to find solutions quickly, and increase the productivity of the washroom. Here are a number of common problems. We ve suggested some possible causes and further areas for investigation. If you re not sure about any of these, or want further information, talk to your trainer. Yellowing and galling Retained alkali in white work check detergent and sour addition. Iron in the water supply rust in pipes/water tank. High alkalinity of raw water has the water supply changed? Contaminated steam supply check for brown/yellow water. Is the detergent stock solution too strong? Has too much chlorine bleach been used? Does the work smell? Dye transfer what was washed before this load? Are rinse dips high? Is CBW rinse flow correct? Was the washing machine overloaded? Was the extraction long enough? Poor starching procedure? Greying Is the water hard? Check the water softener. Is there a soiling redeposition problem? Check detergent additions. What was processed before this load? Possible dye transfer. Has the work been contaminated by mineral oil soiling? Is there scale in the washing machine? Are all the dips and water flows correct? Is the wash temperature correct? Was there under or overloading of the washing machine? Rust Spots Iron in the water rusty pipes and storage tanks. Iron in the steam rusty pipes/poor lagging. Wet steam in the tunnel finisher. Rusty iron items in the washing machine. Customer contamination blood, medicines etc Carry out a recovery wash with oxalic acid. 7.33

304 Creased polycotton Poor cooldown target reduction at 4 C per minute. Over-extraction pressure creases. Extraction when work is warm pressure creases. Check wash and rinse dips. Machine overloaded should be max 80 per cent of capacity. Problem with tunnel finisher. Washing machine stopped during hot stage. Wrong process used. Creased flatwork Extraction too long or too short. Alkali retention causing creasing on calender check rinses. Poor starching. Poor soil removal Not enough detergent check dosage. Wash dips too high poor mechanical action. Washing machine underloaded or overloaded. Detergent stock solution understrength. Wash flows on CBW too high. Poor stain removal Strength of sodium hypochlorite low. Not enough bleach added per kg of linen. Strength of hydrogen peroxide low. Bleach bath dip too high. Temperature of peroxide/perborate bath too low. Too much soiling in bleach bath. Chemical damage Too much sodium hypochlorite used above 10m1s/kg. Bleach bath dip too low. Temperature of sodium-hypochlorite bleach rinse too high. Rinse water flows too low in CBW. Bleach splashed on dry linen before washing. Customer linen abuse. 7.34

305 Linting Over bleaching chemical damage. Wash dips too low. Use of contaminated re-used water. Polycotton and cotton fabrics washed together. Fabric at fault short textile fibres. Rough surfaces in machinery. Colour loss Sodium hypochlorite used on coloured fabrics. Poor sequencing on CBW colours follow whites. High temperature wash. CBW blockage Dips too low or too high. Overloading. Hard water. Scale in washing machine. High detergent use Stock solution strength too high. Overdosing automatic or manual. Washing more linen. Theft. 7.35

306 Activity 13 Answer sheets p Can you think of any other problems and possible solutions? 7.36

307 Activity answer sheets: Health and safety and maintenance procedures Activity 1 Question p Find out what the steam pressure gauge on the main supply line to the washroom should read. 2 At what high and low reading should you report a fault? Normal steam pressure Reportable low steam pressure Reportable high steam pressure Activity 2 Question p. 7.7 You are washing the last load of your shift. What would you do if you noticed that the chemical dosing pumps were not working? 7.37

308 Activity 3 Question p. 7.8 What special clothing or other personal protective equipment would you expect to use during a day working in the washroom? Activity 4 Question p What are the safety features built into the washing machines in your laundry? 2 How would you check that these are working? 7.38

309 Activity 5 Question p What faults might you find on fabric movement equipment (such as trucks or trolleys) in the washroom? 2 What health and safety precautions should you take when handling soiled fabric items? 7.39

310 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all there is to know about the health and safety and maintenance procedures involved in the wash process. When you have finished, discuss your answers with your trainer. 1 What do you do if you see smoke coming from a washer extractor motor? 2 If you deem it safe to put the fire out, what do you do first? 3 Which extinguisher do you use to put out a motor fire? 4 Which is the nearest fire exit? 5 How do you minimise manual handling injury when loading/unloading a washer extractor? 6 You get a tingle when you press the start button of the washer extractor. What does this tell you? 7.40

311 Self-check questionnaire (continued) Question p You suspect the engineer has just electrocuted himself. He is flat on the floor with a finger in the control box. What do you do? 8 You spill detergent powder into a large puddle of water over the floor. How do you make the area safe? 7.41

312 7.42

313 Activity answer sheets: The ingredients for a successful wash process Activity 6 Question p Find out what your laundry s raw water hardness is. 2 What level it is softened to? Water hardness before softening Water hardness after softening Activity 7 Question p Obtain information about the following washer extractor wash processes in your laundry and complete this table. Textile Soiling 1st wash temperature 2nd wash temperature White cotton Protein White cotton Mineral Oil 7.43

314 Activity 8 Question p Detail the types and number of washing machines you have in your laundry. Machine type CBW Open Pocket W/ex Y Pocket W/ex D Pocket W/ex Number 2 Select a washer extractor in your washroom and find out what weight of load would be selected for the following classification. Name of machine Drum design Open pocket Y pocket D pocket Maximum loading capacity Item Polycotton sheets Duvets Cotton towels Polycotton workwear Loading weight 7.44

315 Activity 9 Question p List the names of the fully built detergents used in your laundry and state what hazard warning symbol for example, corrosive or toxic they have on the bag or drum. Product name Hazard warning 2 What are the five main ingredients of a fully built detergent? 3 What bleach do you use in your laundry and at what temperature is the bleach process carried out? 7.45

316 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all there is to know about the ingredients for a successful wash process. When you have finished, discuss your answers with your trainer. 1 At the start of each shift, what would you look for? 2 What would happen to the washer extractors if the steam pressure drops? 3 What are the main causes of the water pressure dropping? 4 What are the consequences of the dip levels not being at the correct levels for washing? 5 What action should you take at the end of your shift in the laundry? 6 What are the main elements of a wash process? 7.46

317 Self-check questionnaire (continued) Question p What are the problems caused by hard water? 8 Can you name the seven critical wash temperatures? What is the correct temperature for a pre-wash? 10 What are the three main factors that govern the mechanical action of a wash process?

318 Self-check questionnaire (continued) Question p What are the dangers of over or underloading the machine? 12 You are given classified loads that contain eight loads of sheets, six loads of towels and one load of pillowcases. How would you plan your washer extractor loads to be washed? 7.48

319 Activity answer sheets: The wash process Activity 10 Question p If you were to use hydrogen peroxide bleach instead of sodium hypochlorite on this process where would you add it and how much would you use per kg of dry weight work? Activity 11 Question p Using the information you have been given in this Unit, see if you can complete the following process for medium protein soiled white polycotton workwear. You might want to complete this process as a group exercise. Operation Time Dip C Temp Additions C Mins Wash (1) Drain Wash (2) 80 Cooldown 10 Med Bleach rinse Drain Rinse Drain Rinse Extract

320 Activity 12 Question p How do you start a loaded washer extractor on your standard used sheet programme? 2 How do you programme your machine to achieve a standard towel wash? 3 Follow a standard cycle on one of your washer extractors and note the times, temperatures and chemicals at each stage. Step Wash (1) Wash (2) Drain Rinse (1) Drain Interspin Rinse (2) Drain Interspin Rinse (3) Drain Final Extract Total programme time Step time Water temperature Chemicals 7.50

321 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all there is to know about the wash process. When you have finished, discuss your answers with your trainer. 1 Explain what the following wash processes are and what they do? Wash 1 Wash 2 2 What are the functions of the rinses in the process? 3 What length of time should you allow for a final extract? 4 Name another wash process? 7.51

322 7.52

323 Activity answer sheets: Troubleshooting Activity 13 Question p Can you think of any other problems and possible solutions? 7.53

324 7.54

325 Notes 7.55

326 7.56

327 8 Dry Cleaning Operations Level 2 G8CC 22 Candidate Support Pack Section 8 F0K7 04 Tumble-dry items (LDC7)

328 ii

329 Contents Introduction About this Unit Key areas of knowledge and understanding Skills and techniques Regulations, rules and guidelines About this learning and teaching pack Tumble-dry items Introduction Health and safety Activity 1 Dryer design Activity 2 Tumble-dryer operational routines Activity 3 Tumble-dryer efficiency Activity 4 Choice of drying process Activity 5 Tumble-drying different fabrics Activity 6 Care labels for drying fabric Activity 7 Self-check questionnaire Activity answer sheets Tumble-dry items 8.19 Notes 8.25 iii

330 iv

331 Introduction About this Unit This Unit F0K7 04 Tumble-dry items (LDC7) is designed to help you to prepare equipment and tumble-dry items. Your role will involve: preparing machinery and items for tumble-drying tumble-drying items organising the work required for tumble-drying controlling the tumble-drying process As a competent person, you must: make machinery and equipment ready to use carry out routine maintenance plan the work remove any items not suitable for tumble-drying select the correct programme and operate machines load and unload items deal with items that are not satisfactorily dried or are damaged make the best of the resources available identify any problems that may arise check that colleagues understand what work they must do identify and deal with any items that are unsatisfactory check that work is carried out as planned Key areas of knowledge and understanding The Unit will help you develop the following key areas of knowledge and understanding: Routine maintenance procedures. The services that are required to make machines work. Programmes and how to select them. Care labels for drying. Understanding fibres and fabrics. How to deal with different fabrics. How to prevent spontaneous combustion. Which hazards are associated with the tumble-drying process. How the tumble-drying process works. Why it is important to identify any possible problems at the planning stage, and why these should be reported. 8.1

332 Skills and techniques After working your way through the Unit, you should be able to: get machinery and equipment ready for use carry out routine maintenance check that loads are ready for tumble-drying select the programme and operate the machine load and unload items identify and deal with unsatisfactory items identify and deal with faults and hazards pass items to the next process receive, check and confirm the supervisor s instructions for carrying out tumble-drying plan how to carry out instructions check that plans are in line with the supervisor s instruction identify problems in tumble-drying work or in carrying out the supervisor s instructions brief colleagues on what they must do and check that they have understood their brief Regulations, rules and guidelines You should read and get to know the following regulations, rules and guidelines: The organisation s rules, codes, guidelines and standards. Equipment operating procedures. Machine and equipment capabilities. Relevant responsibilities under the Health and Safety at Work Act and Control of Substances Hazardous to Health (COSHH). Manufacturer s instructions 8.2

333 About this learning and teaching pack This part of the learning and teaching pack is designed to help you develop the knowledge and skills and generate the evidence required to pass this Unit. It has one section: Tumble-dry items This section contains information and follow-up activities to help you apply what you have learned. At the end of this section there is a self-check questionnaire to help you check your knowledge and understanding so far. You should check your answers with your trainer. 8.3

334 8.4

335 Tumble-dry items Introduction The principle of tumble-drying is quite simple. Fabric items are placed in a perforated drum within the tumbler and warm air is then drawn into the drum and circulated through the fabric. The hot airflow evaporates water from the work in the drum and, as the air increases in humidity, it is sucked out of the dryer and discharged to the atmosphere through filters. These filters retain lint, dust and other debris. Health and safety The tumble-dryer is fitted with a door interlock to prevent the opening of dryer doors while the case is rotating, which could lead to arm and shoulder injuries. Tumble-dryers are machines designed to remove moisture from fabric. This removal can be total for fully dried work or partial for conditioned work, which will then be finished and fully dried on another machine. The high temperatures reached in tumble-dryers and the availability of fabrics that may burn could lead to fires starting if precautions are not taken. Hot, dry fabric should not be left in tumble-dryers or barrows, or the build up of heat in the centre of the load could result in spontaneous combustion and then fire. Particular care should be taken with fabrics such as engineers overalls and oven cloths that could have been soiled with oil, grease or other combustible substances, because these might not have been washed out. They are a greater fire risk. The cool-down stage of the drying process should be used to reduce the risk of fires starting. Unloading the tumble-dryer by hand should be a safe operation as internal metal surfaces and metal zips and press-studs will not be too hot to handle. Cleanliness is important in the drying department to prevent the build of lint in or around the tumble-dryers. All the hot metal surfaces on the outside of the dryer such as steam pipes and air trunking should be insulated to prevent operative contact and burns. Regular, planned preventative maintenance should be carried out to support the tumbledryer operator s health and safety, and any faults reported should be repaired as soon as possible. 8.5

336 Activity 1 Answer sheets p How do you check that the door interlock on your tumble-dryer is operating correctly? Find out from your HS1 Unit (Health and Safety) about spontaneous combustion, then answer the question below. 2 What are the two main steps a laundry can take to minimise the risk of spontaneous combustion? Dryer design All tumblers work on the same basic principles, whatever their design. The most common type of tumbler is the batch tumbler. This is matched to the operating capacity of the laundry s washing machines. These tumblers can be stand alone machines that are loaded and unloaded manually, or loaded automatically by conveyor from a linked washing machine. Pass through tumblers are usually used to condition work for a follow-up finishing process by breaking up the cheese from a CBW press. Continuous tumblers are similar to continuous batch washers in appearance, but have a hollow cylindrical drum with beaters that are positioned to direct the work through the machine. These dryers are the least common type seen in commercial laundries. They are used for dust mats. Tumble-dryers can be heated by steam, gas, fluid heat or electricity. Whatever the power source used, there will be little external difference in the construction of the dryer, although the internal air and heat flows may vary. The following diagrams illustrate two batch tumblers with different power sources and airflows. 8.6

337 A standard steam heated tumbler Heater Heater battery battery Air Air exhaust exhaust 8.7

338 A bottom heated gas-fired tumbler The choice of tumbler design will usually depend on the type of washing machines used and how critical the link is between the productions of each machine. The types of fabric being processed and the finish required will also have a major influence on the temperature, humidity and loading rate required. The tumbler will have a number of controls and instruments to help the operator control the critical factors that influence drying efficiency. A timer will be available to enable the laundry to establish and set drying times for specific classifications. A cool-down system may well be linked to the timer switch so that the dryer switches automatically to cold air injection for the final stage of the drying process. This cools the work in the dryer prior to discharge to reduce the risk of spontaneous combustion and fire in fully dried loads. Drying or conditioning polyester-cotton garments should be followed by a cool-down stage to prevent hot garments being compressed in the dryer or the truck into which they are discharged this results in set pressure creases. Thermometers registering the inlet and outlet air temperature will allow recommended drying temperatures to be accurately achieved and the tumbler to be operated within controlled parameters. 8.8

339 Switches, dials or levers will be available to allow the temperature in the dryer to be increased or decreased by the operator. This can be done by physically altering the airflow from hot to cold air, or by reducing the heat source for example, by modulating the gas supply. The drum rotation speed or action can also be altered depending on the contents of the dryer, usually by means of a switch linked to the drive motor. Activity 2 Answer sheets p Give two reasons why a cool-down stage may be necessary at the end of the drying cycle in a tumble-dryer. 2 If the inlet and outlet temperature on a tumble-dryer both registered 120 C the fabric would be fully dried. What would you do to this load before unloading the machine and how would this reduce a health and safety risk? Tumble-dryer operational routines If a tumble-drying department is to operate efficiently, it has to follow a set of work instructions and procedures. These procedures will vary depending on the type of tumbledryer operation your plant operates. Prior to starting the dryers at the beginning of your shift, all easily accessible filters should be cleaned and all equipment checked for damage and cleanliness. The first load dried should be observed and checks made on door seals, the inlet air temperature (which should register at approximately 120 C) and the drum rotation. If the drum rotation does not appear normal and the load is not moving around the cage correctly the dryer should be reported, as it probably has a slipping or broken drive belt. Once the standard drying time is complete, check the load and assess the performance of the drying cycle. If there are any significant variations on the standard result achieved, investigate obvious causes such as defective door seals, blocked lint screens or an open cool-down flap and rectify the fault or report it to your supervisor or engineer. Closing down the tumble-drying department at the end of a shift should include making sure that any fully dried work that doesn t have to be processed immediately has a full cool-down period before discharge to borrows. All tumblers should be emptied and lint screens cleaned. Any washed article waiting to be dried should be covered down to prevent contamination from dust, and uneven drying out overnight. The department should be swept or vacuumed, and all waste disposed of sensibly. All machinery should be switched off, following your company s set procedures. 8.9

340 If you are leaving any machinery or equipment in a damaged or faulty condition, ensure that this has been reported to your supervisor or engineer. Fix signs or notices to the equipment to warn other employees of the situation. It is a good policy to have all dried and undried loads labelled with the customer s name, so that identification is clear and immediate for anyone assessing the work in the department. Any messages or instructions left for the following shift should be clear and left where they will not be missed. Activity 3 Answer sheets p The following faults could reduce the performance of a tumble-dryer. Tick the causes of the faults that you could check yourself. The tumbler is overloaded. The tumbler is underloaded. The dryer door is not shut properly. There is a missing seal. The cool-down flap was left open during a drying process. The dryer drum is not rotating correctly. There is a hole in the dryer casing. The drum perforations are blocked by melted plastic. The drive belts are broken. The timer is operating too fast. The inlet temperature is too low. The outlet temperature is not increasing. Tumble-dryer efficiency The efficiency of a tumble-dryer is dependent on the available airflow. Dryers can be designed to use the air in the environment around the machine, draw fresh air from outside the building or recycle the hot air already in the machine. Many dryer installations draw their air supply from the environment where they are situated, and then pass this air through the heat source for the tumbler before it reaches the fabric in the machine. On steam heated tumblers the air is drawn through a steam battery that acts like a radiator and warms the air. To prevent contaminating the battery and the work in the tumbler, this air passes through filters to remove dust, lint and debris. The benefit of using air from around the machine is that it will be quite warm and therefore takes less heating, 8.10

341 but it inevitably contains a lot of material that needs filtering out. Air drawn from outside the building will be a lot less contaminated, but will also be a lot colder and use more energy to heat. The air supply that seems to make the most economic sense is the recirculation of the exhaust air from the tumble-dryer, which is filtered into a fresh air supply. This air will be quite heavily contaminated with water vapour and lint, which will need to be removed before it can be reused. However, the energy required to operate a tumbler dryer by this method will be reduced by up to 26 per cent. Tumble-drying can use up to a third of the total steam consumption of a laundry, so heat recovery systems can save a lot of money. You should also remember that it is far more cost effective to remove water from fabric by extraction at the washing stage than by tumble-drying. You should never be tempted to compensate for poor extraction by extended drying times. Filters must be cleaned regularly to maintain good airflows through a tumble-dryer. The operator will usually be responsible for regular cleaning of the air outlet filter screen. Maintenance or specialist cleaning personnel will be responsible for other filters and ducting. Fans are used to draw the heated air through the load in the tumble-dryer, and it is very important that these fans are operated at the correct speed and rotate in the right direction to provide the necessary airflow. Airflows can be reduced if the perforations in the dryer cage become blocked. The most common cause of blockages is plastic bags melting in the dryer. The efficiency of the dryer will be reduced if the tumble-dryer is not sealed properly. This can be caused by badly fitting filters or door seals, or even by damage to the outer casing of the machine, which allows air to leak in. Correct loading of the tumble-dryer is critical to air flows and effective evaporation of moisture. The moisture retention after washing, the fabric type and the size of the items to be dried should all be taken into account when maximum loading weights are determined for different classifications. Cotton items can generally be loaded to the machine s capacity, but polyester cotton should be loaded to approximately 65 per cent of the tumbler s capacity to prevent pressure creases forming during the drying cycle. Very bulky items like duvets may have to be dried at only 35 per cent of the maximum capacity. 8.11

342 Tumble-dryer Loading % Capacity Cottons Polycottons Duvets You should remember that underloading can create as many problems as overloading. An underloaded dryer will not work efficiently or cost effectively. The work will not tumble correctly and often will not dry evenly, while using as much energy as a fully loaded dryer. Activity 4 Answer sheets p Tick the factors that you think are necessary to successfully dry a load of polyester cotton workwear coats. Correct time set for the drying operation Set machine for cold air inlet only Set machine for an automatic cool down operation Load machine to capacity Clean the air outlet filter screen Load machine to 65 per cent capacity 8.12

343 Choice of drying process The choice of drying process will depend on the fabric type and the final finish required on the items being processed. Fully dried works are usually those items that require no further finishing prior to folding and packing. Conditioned works are items that only need a proportion of the moisture content removed before they are completely dried and finished on another machine. Many laundries over-dry conditioned work in the tumble-dryers, as they haven t taken the full drying capacity of the finishing equipment into account. In other words, they unnecessarily remove moisture by the relatively expensive use of tumble driers. It costs three times as much to remove dampness from a cotton sheet in a tumbler than it would on a calendar, and 25 per cent more to remove moisture from a polyester cotton coat in a tumbler compared to a tunnel finisher. 8.13

344 Activity 5 Answer sheets p Write a list of six items that would be fully dried in a tumble-dryer. 2 Give six examples of items that are only conditioned in the tumble-dryers and state which machine they are finished on. Conditioned item Equipment finished on Tumble-drying different fabrics Although there are many different types of fabrics available, most large commercial laundries restrict the number of fabrics they accept to make processing simpler. Cotton, polyester and polyester cotton fabrics are the most common fabrics, because they are the easiest to process and finish. 100 per cent cotton items like towels and bath mats are fully dried in a tumble-dryer to produce the required finish, but some cotton items will require a more controlled drying process. Bed linen and table linen will only need conditioning in the tumble-dryer before a calender completes the drying and finishing process. One major problem with tumble-drying cotton is shrinkage. This is particularly noticeable on garments and fitted items. Polyester and polyester-cotton can be fully dried or conditioned in a tumble-dryer, but a cool-down stage will be required to prevent pressure creases. The other problem with these man-made fabrics is the generation of static electricity caused by the dry fibres rubbing against each other. You can reduce this by using a fabric conditioner/softener in the final rinse of the wash process, or by leaving some moisture in the fabrics if this is acceptable to the final finish required. 8.14

345 If you are given an item made from linen, wool, mixed fibres, acrylic or other fibres or from material not usually dried in your department, you should find the care label attached to the item and read the advice given about drying. Activity 6 Answer sheets p If you tumbled a woollen jumper on a high heat setting it would shrink, lose its pleasant feel and might scorch. Tick the likely results of drying white cotton and polyester garments together on a high heat setting. The polyester garment would get over-dried. The polyester garment would crease. The cotton garment would never dry. The polyester garment would go yellow. The cotton garment would catch fire. Care labels for drying fabric The effects of using the wrong drying technique can result in permanent damage to the articles being dried. If there is any doubt in your mind about the suitability of tumbledrying or the method of removing moisture from an article, then seek advice from your supervisor or manager. DRYING Symbol Brief meaning Tumble dry at low heat setting Tumble dry at high heat setting Do not tumble dry Hang to dry Dry flat Drip dry 8.15

346 Activity 7 Answer sheets p Investigate the tumble-drying operation at your laundry and fill in the following chart for one tumble-dryer. Tumble-dryer selected:... Capacity... kg/lb Article Max. loading weight kg/lb Drying time Cool down time Cotton towels Polyester cotton workwear coats Cotton sheets 8.16

347 Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about tumble-drying items. When you have finished discuss the answers with your trainer. 1 What are the different types of dryers, and what are the main features of each? 2 What are the different types of controls usually fitted to dryers? 3 What is the dryer dependent on for efficiency? 4 What is the purpose of the steam battery on a steam-heated dryer? 5 What is more energy efficient proper extraction in a washer extractor or an extended drying time? 6 Who is responsible for cleaning filters, and how often should they be cleaned? 7 What is the purpose of the fans? 8 What are the main problems of poor airflow? 9 Why is it important to load the dryer correctly? 10 Why is it important to remove hot items from the dryer and why is there a cool-down period? 11 What are the requirements for tumble-drying different types of items and fabrics? 12 What are the hazards associated with the tumble-drying process? 8.17

348 8.18

349 Activity answer sheets: Tumble-dry items Activity 1 Question p How do you check that the door interlock on your tumble-dryer is operating correctly? Find out from your HS1 Unit (Health and Safety) about spontaneous combustion, then answer the question below. 2 What are the two main steps a laundry can take to minimise the risk of spontaneous combustion? Activity 2 Question p Give two reasons why a cool-down stage may be necessary at the end of the drying cycle in a tumble-dryer. 2 If the inlet and outlet temperature on a tumble-dryer both registered 120 C the fabric would be fully dried. What would you do to this load before unloading the machine and how would this reduce a health and safety risk? 8.19

350 Activity 3 Question p The following faults could reduce the performance of a tumble-dryer. Tick the causes of the faults that you could check yourself. The tumbler is overloaded. The tumbler is underloaded. The dryer door is not shut properly. There is a missing seal. The cool-down flap was left open during a drying process. The dryer drum is not rotating correctly. There is a hole in the dryer casing. The drum perforations are blocked by melted plastic. The drive belts are broken. The timer is operating too fast. The inlet temperature is too low. The outlet temperature is not increasing. Activity 4 Answer Sheets p Tick the factors that you think are necessary to successfully dry a load of polyester cotton workwear coats. Correct time set for the drying operation Set machine for cold air inlet only Set machine for an automatic cool down operation Load machine to capacity Clean the air outlet filter screen Load machine to 65 per cent capacity 8.20

351 Activity 5 Question p Write a list of six items that would be fully dried in a tumble-dryer Give six examples of items that are only conditioned in the tumble-dryers and state which machine they are finished on. Conditioned item Equipment finished on

352 Activity 6 Question p If you tumbled a woollen jumper on a high heat setting it would shrink, lose its pleasant feel and might scorch. Tick the likely results of drying white cotton and polyester garments together on a high heat setting. The polyester garment would get over-dried. The polyester garment would crease. The cotton garment would never dry. The polyester garment would go yellow. The cotton garment would catch fire. Activity 7 Question p Investigate the tumble-drying operation at your laundry and fill in the following chart for one tumble-dryer. Tumble-dryer selected:... Capacity... kg/lb Article Max. loading weight kg/lb Drying time Cool down time Cotton towels Polyester cotton workwear coats Cotton sheets 8.22

353 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about tumble-drying items. When you have finished discuss the answers with your trainer. 1 What are the different types of dryers, and what are the main features of each? 2 What are the different types of controls usually fitted to dryers? 3 What is the dryer dependent on for efficiency? 4 What is the purpose of the steam battery on a steam-heated dryer? 5 What is more energy efficient proper extraction in a washer extractor or an extended drying time? 6 Who is responsible for cleaning filters, and how often should they be cleaned? 8.23

354 Self-check questionnaire (continued) Question p What is the purpose of the fans? 8 What are the main problems of poor airflow? 9 Why is it important to load the dryer correctly? 10 Why is it important to remove hot items from the dryer and why is there a cool-down period? 11 What are the requirements for tumble-drying different types of items and fabrics? 12 What are the hazards associated with the tumble-drying process? 8.24

355 Notes 8.25

356 8.26

357 9 Dry Cleaning Operations Level 2 G8CC 22 Candidate Support Pack Section 9 F0JW 04 Inspect and prepare laundered and cleaned items for dispatch (LDC17)

358 ii

359 Contents Introduction About this Unit Key areas of knowledge and understanding Skills and techniques Regulations, rules and guidelines About this learning and teaching pack Retail packing and dispatch Introduction Health and safety Identification Quality control Racking Activity 1 Packaging Activity 2 Dispatch Communication Activity 3 Self-check questionnaire Bulk packing and dispatch Introduction Health and safety Documentation Quality control Activity 4 Packing Activity 5 Self-check questionnaire Activity Answer Sheets Retail packing and dispatch Bulk packing and dispatch Notes iii

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361 Introduction About this Unit This Unit F0JW 04 Inspect and prepare laundered and cleaned items for dispatch (LDC17) is designed to help you fold items and make up orders for dispatch. Your role will involve: folding items and inspecting them for quality making up orders and dispatching items As a competent person, you must: inspect items remove and redirect any that are substandard fold items pass them to packing and dispatch make up and label orders store them in the correct location transfer them to the dispatch point maintain the finish and condition of the items Key areas of knowledge and understanding This Unit will help you to develop the following key areas of knowledge and understanding: How to identify and handle items. How to identify customer specifications and requirements. How to fold items using manual methods, automatic or semi-automatic machinery. The importance of accurate labelling. Care labels. Understanding fibres and fabrics. Acceptable quality levels. The characteristics of different fabrics in relation to creasing and preservation of finish. Which materials to use when making up and labelling orders. 9.1

362 Skills and techniques After working your way through the Unit, you should be able to: check that machinery and equipment is safe and ready inspect and fold items and remove and redirect any that are substandard pass items on for packing and dispatch make up orders to specification make up and label parcels store items prior to dispatch check against documentation and transfer to dispatch Regulations, rules and guidelines You should read and get to know the following regulations, rules and guidelines: The organisation s rules, codes, guidelines and standards Equipment operating procedures Machine and equipment capabilities Relevant responsibilities under the Health and Safety at Work Act and Control of Substances Hazardous to Health (COSHH) Manufacturer s instructions About this learning and teaching pack This part of the learning and teaching pack is designed to help you develop the knowledge and skills and generate the evidence required to pass this Unit. It is divided into the following sections: Retail packing and dispatch Bulk packing and dispatch Each section contains information and follow-up activities to help you apply what you have learned. At the end of each section there is a self-check questionnaire to help you check your knowledge and understanding so far. You should discuss your answers with your trainer. 9.2

363 Retail packing and dispatch Introduction Retail packing and dispatch is a term used in some laundries to describe the process of checking and packing washed articles that are to be returned to an individual. These articles have usually been identified by a temporary laundry mark (eg Polymark ) and they receive the extra level of attention required to produce a high-quality, finished product that justifies a premium charge to the customer. Health and safety Packaging and despatch department will not usually use a lot of machinery to carry out their tasks. A packaging machine may be used and all safety and operational features should be in place to help prevent accidents. The movement of finished goods will probably present the greatest risk in this department. The lifting and carrying of fabric items should be carried out using recommended lifting techniques that reduce the risk of muscular injury. The amount carried should never exceed your safe lifting weight. Each individual must learn to recognise the limits of their strength and lifting capacity, so as to avoid those situations in which they may be at risk of overexertion. Pushing and pulling trolleys and trucks should not place any undue strain on the body. If the weight is too great for ease of movement or if wheels are not operating correctly, there is a responsibility on each individual to look for a solution to the problem. Identification As items arrive in the packing department they should be matched by their temporary identification number on the marking system before being checked and then stored together on the numbered racking system. Quality control As each item arriving in the packing department has to be identified and racked, the packer has a responsibility to carry out quality control checks. Articles should not be racked if they are still damp they should be returned to the finishing department for remedial action. A general assessment should be made of the overall quality of finish, fold and cleanliness of each item. Items that feel harsh and rough may have been over dried, not rinsed properly or finished on the wrong machine. Folded articles should have a consistent size and shape to enable them to be stacked neatly and to impress the customer. Cleanliness can be judged by the overall appearance of the article. Does it appear bright and smell clean and fresh? The inside of the collars on shirts and coats can be examined and any indication of staining should be investigated. 9.3

364 The customer s objective of sending soiled articles to the laundry is to receive them back in a clean and presentable state that approaches their appearance when new. The customer will usually accept a slight delay caused by rewashing to achieve this objective, but receiving shoddy work will result in complaint and lost custom. Maintaining the finish given to articles by the calender, press and folding department is part of the packer s role. Fabrics have different characteristics, which should be borne in mind when stacking or moving articles. For example, polyesters tend to crease easily and nylons do not maintain folds or stack well due to the slippery nature of the fabric. Racking Once articles have been identified and checked, they should be transferred from the transport barrow or trolley onto an identified racking system as soon as possible. The racking system will be numbered to correspond to the temporary identification marks put on each article that has been processed. Workstation preparation should include making sure that the racking system is hygienically clean. You should dust down and wipe over all surfaces that will come into contact with the washed articles with a damp cloth. You should then dry all shelves before any work is placed on them. During this preparation checks should be made for any sharp edges or protrusions that might damage the clean fabric, and remedial action carried out or instigated. Any litter or debris should be removed from the packing area, as it is a potential contaminant. You should dispose of it in accordance with company policy. All staff involved in packing clean linen should be aware of their responsibilities to maintain a high standard of person hygiene. Any recontamination of the washed articles will undermine all the work done by their colleagues in other departments and may put the reputation of the laundry and the health of the customer at risk. The quantity on the rack should be checked against the documentation and once all items have been accounted for, packing can commence. The collection of articles that numerically appear to tally with the documentation should be removed from the racking system and each item s identification tag checked against the tag on the documentation. When every item has been checked off, the temporary identification tags can be removed and the articles packaged for return to the customer. Activity 1 Answer sheets p What action would you take if one shirt from a customer s order of ten shirts was sent for packing with a badly soiled collar? 2 If a customer s order was complete except for a missing handkerchief, what action would you take? 9.4

365 Packaging Laundries use many different types of packaging to protect their clean laundry work while it is returned to the customer. Fabric bags, plastic hampers, boxes, plastic bags and wrapping in polythene or paper are all quite common methods of packaging. Disposable packaging is the most common particularly types that can be cut to size. There are machines that allow clean laundry work to be shrink-wrapped in polythene when folded, or poly-robed if despatched on coat hangers. Laundries that provide a shirt-washing service sometimes use special packaging. Each shirt is individually packaged and, in some cases, cardboard stiffeners can even be used to maintain the finish on the collars. Duvet washing is a growth market and special large plastic carrier bags are available to provide custom-made packaging. Activity 2 Answer sheets p List five types of packaging used to distribute washed goods to your customers. Dispatch The packer is responsible for transferring clean packaged laundry to a storage area prior to delivery to or collection by the customer. This storage system should be designed to accommodate the packaged laundry without risk of damage to either the packaging or the finished goods. All packages should be stored in a neat manner and in the correct location so that they can be distributed to customers efficiently. Communication The packer will have to have good communication skills because while they are completing a customer s order they might, for example, have to speak to all the other departments in the laundry to locate missing items. The quality checks that are a necessary part of the job may well involve returning items for refinishing or rewashing, and the cooperation of other departments must be sought with tact and an appreciation of their workload. Some customers complaints or queries about their washing may have to be handled directly by the packing room staff. Concern over a piece of personal property can lead to the customer becoming quite emotional, and the laundry s representative must show a level of sympathy and give assurance that everything possible will be done to sort out the problem. 9.5

366 As with all other departments in the laundry, communication between you and your workmates must include communicating problems and information that will enable the laundry service to operate efficiently from shift to shift. Messages left at the end of a shift should be clear and concise, and should help to maintain an effective packing and despatch service. Activity 3 Answer sheets p List six tasks that you could carry out at the end of your shift that would help the person taking over to do their job safely and efficiently. Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all there is to know about retail packing and dispatch. When you have finished discuss your answers with your trainer. 1 What does the term retail packing and despatch mean? 2 What does the workstation preparation involve? 3 How should articles be received at this area? 4 What standards of hygiene would you expect in this area? 5 Explain the quality control standards expected in this department. 6 What are the various methods of packing finished items? 7 What health and safety implications are there in this department? 8 What communication skills are required in this department? 9.6

367 Bulk packing and dispatch Introduction Bulk packing involves bringing together many similar articles to a central delivery point for dispatch as one consignment. This can involve washed workwear sent to factories and other organisations, bed linen and table linen for hotels, restaurants or hospitals and dryfold items sent to any customer in large quantities. Health and safety Transporting items between the packing department and the dispatch area may involve the use of conveyor belts or overhead coat hanger conveyors. This equipment should be maintained according to the manufacturers recommendations, and all guards kept in place. No breakdown repair should be attempted unless the conveyor has been isolated and measures taken to prevent accidental start-up. Manual handling of heavy loads can lead to serious muscular injury if precautions are not taken. Always use the equipment provided to help move heavy objects. If something is too heavy, seek assistance or reduce the weight. Linen bags should only be filled to an acceptable weight limit they should not be filled to capacity, irrespective of weight. Trolleys should be checked before use for sharp protrusions or jammed wheels and any faults should be rectified before they are used. The weight of articles stacked in trolleys must not exceed the recommendations for safe movement. If you want to fill the trolley without exceeding safe weight limits or toppling the laundry, you might have to mix ironed flat work with lighter dry-off classifications. Protective clothing should be available to all staff to protect them from their working environment and to prevent contamination of the clean linen from packers' personal clothing. Any floor spillages should be cleaned up as soon as you see them. Documentation The counting of bulk packed and delivered items is still carried out manually in some laundries but many modern plants have introduced electronic counting systems. The use of bar codes, transponders and scanning equipment has improved the speed and accuracy of this task, which has an obvious link to the laundry s income. The information provided by using bar codes or transponders provides the laundry with additional information on the number of times each item is washed, which helps to control stock levels and ensure stock rotation. Quality control Quality inspection is difficult because of the large number of items passing through a bulk packing room particularly if these items are folded. 9.7

368 Packing room staff must rely on the finishing department to withdraw items that are stained, damaged, or of poor overall quality. But the packer has a responsibility to be aware of the general colour, feel, smell and moisture retention of items passing through the department and must identify and withdraw items below the required standard. Poor handling in the packing department can damage the quality of the finished goods. Folded items should be handled with care to retain a good finish and tight fold. The appearance of items when a bag is opened or trolley uncovered by the customer will give an instant impression of the laundry s standards, so neatness in the packing department is very important. Workwear garments stored and dispatched on hangers can have their finish and appearance ruined by crushing too many garments on a rail. This pressure creasing is particularly noticeable on polyester cotton items. As with all clean linen handling, high personal hygiene standards should be maintained to prevent recontamination. The packing and dispatch areas within the laundry are usually towards the outside of the building, and you can prevent contamination of clean linen with air borne dust, lint and debris by restricting the opening of doors and windows. If windows have to be opened for ventilation, they should be covered with gauze screens to restrict access. A good cleaning routine is very important to maintain high standards of hygiene. The end of each shift should see the whole area cleared of dust, debris and litter preferably by vacuum cleaner as brushing will result in greatly increased airborne contamination. If the same trolleys or bags are used for clean and soiled articles, they must be chemically or thermally disinfected between trips to prevent cross-contamination with bacteria. Activity 4 Answer sheets p List five preventative measures that can be taken to prevent washed and finished work getting contaminated with dust and lint in the packing department. 2 What methods could be used for communicating information between shifts in the packing department? 9.8

369 Packing Laundries are increasingly being developed with production lines for specific classifications of washing. In this way mechanisation of the different stages of processing can increase productivity and reduce costs. Often these different production lines will provide supply-finished goods to the bulk packing and dispatch area. The role of the packing department will vary according to the type of articles being processed, and the organisational procedures that are in place to satisfy the requirements of the laundry s customers. Workwear plants that dispatch garments on hangers will have large storage areas where garments are directed automatically from the tunnel finisher. Hygiene conscious customers such as food factories may insist on all garments being poly-robed prior to dispatch and this will form part of the flow line for the work. Workwear on hangers for engineering or low risk accounts will generally be stored and delivered unpackaged, but the loading facility for getting the clean workwear from the storage area to the delivery vehicle will be planned and constructed to reduce any risk of contamination. Folded workwear will usually be racked or packed directly into nylon bags. This packing should be carried out using special bag trolleys that hold the bag open at a good loading height or on tables. Trying to pack a hamper bag on the floor puts unnecessary strain on the packers joints and muscles and is likely to result in contamination of the clean articles being packed. Some large accounts may have workwear delivered in covered trolleys. This method enables racking and packing to be carried out in one operation. Flatwork processed on calenders can be bulk packed directly from the folder into delivery cages. To assist the packing department with counting this linen, it is often stacked in layers. The delivery cages should be fitted with a liner to protect the fabric from contamination. For smaller accounts or to cater for a customer s preference, nylon hamper bags can be used for packing. These bags are not waterproof and attention should be given to where they are packed and stored to prevent contamination of the clean articles inside. Where laundries operate a clean-for-soiled exchange service from a transport vehicle, packing often involves using shrink-wrap polythene bundles of a set number of items. Dry fold items such as towels, bath mats, blankets, duvets, etc are usually accommodated in the same packing method used for flatwork. 9.9

370 Activity 5 Answer sheets p List five possible sources of contamination of clean but uncovered workwear stored on coat hangers. 2 Give three reasons why sheets should not be packed into a hamper bag on the floor. Self-check questionnaire Answer sheets p Use this self-check questionnaire to make sure that you now know all that you need to know about bulk packing and dispatch. When you have finished, discuss your answers with your trainer. 1 What weight limit should the contents of a linen bag hold? 2 Why should trolleys be checked prior to you using them? 3 What PPE equipment should be used in this area? 4 What method is used in your laundry to ensure that the correct items get to the correct customer? 5 In what ways might an item be substandard, so that you would be unable to return it to the customer? 6 What cleaning routines are in place for your laundry? 7 How do you ensure that the quality of the finished items remains constant until delivered? 9.10

371 Activity answer sheets: Retail packing and dispatch Activity 1 Question p What action would you take if one shirt from a customer s order of ten shirts was sent for packing with a badly soiled collar? 2 If a customer s order was complete except for a missing handkerchief, what action would you take? Activity 2 Question p. 9.5 List five types of packaging used to distribute washed goods to your customers

372 Activity 3 Question p. 9.6 List six tasks that you could carry out at the end of your shift that would help the person taking over to do their job safely and efficiently

373 Self-check questionnaire Question p. 9.6 Use this self-check questionnaire to make sure that you now know all there is to know about retail packing and dispatch. When you have finished discuss your answers with your trainer. 1 What does the term retail packing and despatch mean? 2 What does the workstation preparation involve? 3 How should articles be received at this area? 4 What standards of hygiene would you expect in this area? 5 Explain the quality control standards expected in this department. 9.13

374 Self-check questionnaire (continued) Question p What are the various methods of packing finished items? 7 What health and safety implications are there in this department? 8 What communication skills are required in this department? 9.14

375 Activity answer sheets: Bulk packing and dispatch Activity 4 Question p List five preventative measures that can be taken to prevent washed and finished work getting contaminated with dust and lint in the packing department What methods could be used for communicating information between shifts in the packing department? 9.15

376 Activity 5 Question p List five possible sources of contamination of clean but uncovered workwear stored on coat hangers Give three reasons why sheets should not be packed into a hamper bag on the floor

377 Self-check questionnaire Question p Use this self-check questionnaire to make sure that you now know all that you need to know about bulk packing and dispatch. When you have finished, discuss your answers with your trainer. 1 What weight limit should the contents of a linen bag hold? 2 Why should trolleys be checked prior to you using them? 3 What PPE equipment should be used in this area? 4 What method is used in your laundry to ensure that the correct items get to the correct customer? 5 In what ways might an item be substandard, so that you would be unable to return it to the customer? 9.17

378 Self-check questionnaire (continued) Question p What cleaning routines are in place for your laundry? 7 How do you ensure that the quality of the finished items remains constant until delivered? 9.18

379 Notes 9.19

380 9.20