Premium Commercial Cleaning Systems Deliver Innovation and Efficiency while Reducing Environmental Impact

Karin Tetlow

Delivering a project that meets today’s growing requirements for sustainability is one of the top demands facing design professionals. With green building growing at double digit rates and owners in both the public and private sectors increasingly querying firms as to their proficiency regarding matters of environmental responsibility, a knowledge and understanding of what truly constitutes green is critically important.

The green market has clearly matured since the U.S. Green Building Council certified its first LEED® building in 2000. Fears that fly-by-night manufacturers whose products would not live up to long-term scrutiny would undermine the entire green movement have not materialized. Nor is green thought of as a fad anymore. Rather, investment in green products has delivered welcome returns as more manufacturers incorporate sustainability in their planning strategies. But telling questions remain: How do design professionals distinguish a truly green product in today’s market where virtually every product has some aspect of green in its description? How do design professionals argue for the additional expense of a high-end, high performing and truly green sustainable product in a market that increasingly focuses on the bottom line?

These questions are particularly relevant for those specifying commercial cleaning systems, where long-term benefits of higher-end models must be evaluated and compared with the immediate benefits of lower initial price points. Green should not be thought of as products in isolation but instead, as a “system” in which all the pieces need to work together. It is essential, therefore, that design professionals not only examine products, but also understand the manufacturer’s “system,” and how all the pieces work together to deliver both cost benefits and sustainability. In other words, the manufacturer’s policies, manufacturing techniques and commitment to environmental—and product—responsibility are an integral part of being truly green. When examining the benefits of a truly green and more expensive sustainable system, therefore, design professionals would be wise to look at both the product and the manufacturer. “One way to identify efficient high quality products that are environmentally responsible is to examine the manufacturer and see if it has a clear sustainability program in place,” says Miele applications sales manager Marvin Royal.

A typical high-end production facility for laboratory glass washer cleaning systems employs cutting edge technology. Image courtesy of Miele Professional

One 113–year-old German-based high-end cleaning systems manufacturer which has made a commitment to sustainability is an example of what constitutes across-the-board sustainability where all the pieces are intended to work together. With a declared goal to develop efficient and durable products whose production, consumption and disposal have as little impact as possible on the environment, the company employs leading efficient manufacturing techniques and uses recyclable materials. It invests two to four years in product development and over five percent of total turnover in R&D (the U.S. spends 2.7 percent of its GDP on R&D).

The company uses Computer Aided Virtual Environment (CAVE) for product development and has developed new processes—one of which ensures fingers leave no prints behind. Finished products are each subjected to long-term tests (10,000 hours for all machines). Sustainability begins by the company certifying its own and suppliers’ management systems according to international sustainability and social standards. Every two years it publishes a sustainability report that includes facts and figures on production facilities and the life cycle elements of each type of cleaning system—from power, water and chemical consumption to recyclability of product materials, CO₂ emissions and waste.

Among the premium products recently introduced are the world’s first dishwasher whose water consumption is just 0.28 cu ft of water per cycle, a laundry washer that reduced water consumption by 20 percent, a wet (as opposed to “dry”) cleaning system that uses no toxic chemicals and a heat pump tumble dryer that consumes half the power of conventional dryers. Paying attention to smaller energy savings, stand-by power consumption is reduced to less than one watt on the entire product line, with many products consuming 0.02 watts when the main power switch is turned off.

Design professionals could be assured that products delivered by the manufacturer in this example reduce environmental footprint and are rugged and reliable. But how do such products meet client requirements and what are the specifics of long term cost savings? An examination of sustainability features of premium cleaning systems followed by specific needs of different markets helps answer those questions.

Commercial Cleaning Systems
While virtually every project has need of cleaning equipment products, many commercial building types have special performance needs that can include sanitization and disinfecting as well as superior cleaning. Laboratory, medical, dental and veterinary facilities, restaurants, recreational centers, day-spas and beauty salons, hospitality and assisted living facilities all have special performance requirements that go far beyond those of the familiar domestic appliance.

Sustainability factors

High-end sustainable products are engineered for energy efficiency and having the smallest possible environmental impact. Factors that contribute to sustainability include:

Factory rated machine life. Cleaning systems manufacturers typically provide information on the factory rated machine life of products in terms of operating hours, which vary according to their application. A machine life of 15,000 operating hours, for example, would translate into a long life of at least 10 years if the washer had heavy usage of six hours on each of the 260 working days a year. If the machine were a commercial dishwasher used six times a day for six days a week, its life would be far longer.

Machine construction. A critical factor in evaluating product life is the materials used for different washer components. The washer chamber of a high quality machine is typically constructed from either Type 304 or Type 316L stainless steel (Type 316L has greater resistance to corrosion); sidewalls and ceiling are made from Type 304; while the floor and door are constructed from Type 316. Laser welded seams outside the washer chamber are preferred over spot-welding where corrosion could occur.

Pump life. Machine pump life is extended if cleaning systems are fitted with multiple sump filters that prevent debris from recirculating. Filters upstream of the circulation pumps protect and extend pump life. For some applications pumps are fitted with a gentle start mechanism, which will also contribute to maximum pump longevity.

Recyclability. Recyclability of materials is one of the most significant features of a green product. Since stainless steel is North America’s number one recycled material and is 100% recyclable, cleaning systems equipment fabricated from stainless steel have a high recyclable rate. One manufacturer with a 90-plus percent recyclable rate on every product clearly marks all plastic components to facilitate recycling.

Minimizing water and chemical cleaning agent usage. Cleaning systems designed for sustainability are engineered to use less chemicals and less water, which means less chemical effluent entering the groundwater. Using less cleaning agents to get items clean can be accomplished by using powerful circulation pumps, high water temperature and low water levels. A typical high-end manufacturer will use flow meters and pressure switches—rather than timing circuits—on all incoming washer lines in order to save water by allowing precise filling.

A built-in water softener too, will enable detergents to work more efficiently and provide better cleaning if the water is hard. It is gentler on the washer and eliminates scaling. Manufacturers can adjust the performance of water softeners according to the hardness of the water, and can deactivate them if the incoming water is already soft.

Energy efficiency and operating cost savings. A direct result of using less water and consequently less heating time to heat that water, is a lower consumption of electricity. Insulation of units further reduces the amount of electricity used. This lowers costs and puts less load on building HVAC systems. Depending on the application, water savings for premium machines can amount to over 30 percent when compared with other products using the same wash program. Lower usage of chemicals and detergents also lowers operating costs.

Sanitization. With increasing incidence of flu epidemics and antibiotic-resistant bacteria, plus an expanding regulatory climate, cleaning systems that address sanitization are increasingly valued. One solution is having separate pumps for circulation and drainage, which reduces cross-contamination. Other solutions, depending on the application, include extremely high water temperature rinse cycles.

A premium undercounter laboratory glassware washer features a test port for facilities requiring machine validation. Image courtesy of Miele Professional

Laboratory Glassware Washers
As research becomes more and more precise, perfectly clean glassware is mandatory if repeatable results are to be obtained. Labs from water treatment plants doing trace metal analysis to university tissue culture labs, require machine validation that confirms compliance with standards of cleanliness. In response, manufacturers offer a range of lab glassware washers for the education, pharmaceutical, public health, forensic, water quality, specialty labs and industrial parts cleaning markets.

A manufacturer with over 45 years of lab glassware cleaning expertise offers a number of typical high-end products. These range from a basic undercounter model for high schools and colleges to increasingly sophisticated large capacity models with touch-control machine interface. Reliability is addressed by balancing wash time, water temperatures, water circulation, and specific detergents.

Design professionals should be aware of the special efficiency and sanitization performance features that are particularly applicable to lab glassware cleaning systems. These can include:

Machine validation. Precise sensors and leading componentry plus fault indicators and a test port are generally required for machine validation. Some manufacturers offer complete validation services including extensive IQ/OQ (Installation Qualification (IQ) documents that the correct instrument was received and installed properly; Operational Qualification (OQ) tests that the instrument meets specifications in the user environment).

Glassware protection. Delicate glassware, metal components and electronics are better protected if high-volume water pumps operate at low pressure.

Heated deionized (DI) final rinse. A high temperature DI final rinse is the best way of completely eliminating residue.

High water temperatures. Sensors that monitor wash temperatures for incoming and circulating water ensure consistent temperatures for higher temperature water sanitization.

HEPA filtered forced air drying. Specification of HEPA filtered forced air-drying can help meet sanitization requirements.

Reducing human error. To reduce human error, some larger models are fitted with a maintenance-free conductivity monitor and a spray arm monitoring system.

Ability to operate the machine while wearing gloves. Manual dial or touch screen controls allows operator to use the machine when wearing gloves.

Machine noise level. Some undercounter models allow conversation in the lab without distraction. Larger models operate at levels,, which are slightly less than those of casual conversation.

Overflow protection. A waterproof system, will protect a lab from overflow water by shutting off the incoming water supply and alerting the user.

Accurate detergent dispensing. An automated liquid dispenser provides high levels of accuracy and eliminates potential user error in the dosing process. The reservoir means less refilling between detergent container changes.

Steam condenser. Inclusion of a steam condenser eliminates the need for an external machine. This avoids potentially hazardous steam from venting into the lab during operation.

An example of a dental thermal disinfector that exceeds OSHA standards for microbial contamination reduction. Image courtesy of Miele Professional

Instrument Washer/Disinfector
Most non-surgical medical and dental practices appreciate a systematic approach to washing, rinsing, drying and disinfecting instruments that is efficient, saves time and meets or exceeds OSHA standards for microbial contamination. One manufacturer with 40 years of experience producing/manufacturing washer disinfectors in the dental field, offers a premium stainless steel, large capacity washer-disinfector with short program durations for processing instruments. It achieves thermal disinfection during the final rinse by the water temperature reaching and holding at 200°F for 10 minutes. The Dental Advisor Biomaterials Research Center in Ann Arbor, MI, measured its efficacy and found that it was effective in cleaning cassette and instrument surfaces after a single cycle. After using the washer-disinfector for eight months, nine dental consultants gave it a 91 percent approval rating. Other practitioners reported that it enhanced doctor productivity by 20 to 50 percent and allowed more chair time with patients. Efficiency features available in premium models include:

Saving time. A single cycle effective cleaning of instruments permits more chair time with patients.

Thermal disinfecting. Can reduce microbial contamination by 99.99 percent., High level thermal disinfection is achieved during the final rinse cycle when the temperature rises to and holds at a high temperature for a specified number of minutes.

Ample disinfecting machine capacity. Two or multi-level chamber can accommodate cassettes and a variety of hinged instruments.

Reduces sharps incidents. Minimizing instrument handling lowers the possibility of sharps incidents.

Premium commercial laundry systems have the capacity to program machines for different washing and drying needs. Image courtesy of Miele Professional

Commercial Laundry Systems
There is nothing quite like the fresh aroma and warm, lavish touch of freshly laundered bath towels or bed linens. Yet many a heritage hotel guest, familiar with the results of using the basement washer/dryer back home, has wondered how that sense of luxury is achieved. The answer is a premium professional commercial laundry system that offers day-in day-out speed, capacity and specialized programs that can handle dirty uniforms from industrial plants or vet hospitals to six-hundred-thread sheets at fine hotels and luxury yachts—all without damage to fabrics.

Among the many requirements of commercial washing systems are reliability, high throughput, ruggedness and efficiency. Another requirement is flexibility so that a single programmable machine can clean sheets and horse blankets—albeit separately. A high-performance laundry system achieves these requirements through various water volume and temperature management controls mentioned above.

New drum design

Another approach is a re-design of the laundry drum. One manufacturer has developed a convex-pattern honeycomb drum for laundry washers and dryers that enhances cleaning and reduces fabric wear. The size of the drum’s water exit holes is smaller and a network of water channels create a skim water layer that cushions clothes while the drum rotates. The honeycomb design allows virtually no penetration of fabric through the drum. (In traditional washing drums, the fabric penetrates the water exit holes, which leads to pilling and shortened lifespan.) An independent study, conducted by WfK Applied Laundry Research Institute in Krefeld, Germany, showed that garments washed in the honeycomb drum were cleaner and lasted up to four times longer than garments washed in a traditional drum.

Other performance features of commercial laundry systems may include:

Soft mount. Utilization of soft mount technology where drums are suspended rather than stationary as found in most traditional commercial machines, extends the life of the machine. Soft mounted machines can easily be installed compared with hard mount machines, which require bolting to a reinforced concrete pad. Soft mounting also dramatically reduces vibration and allows manufacturers to achieve higher spin G forces

Program controller. A significant feature of laundry systems that can accomplish various demands is a thoroughly tested controller that can program the machine for different needs such as 600+ Thread Count Sheets or Down Comforters & Pillows. Some models have a customizable, updatable smart card controller, which could contain multiple programs designed for different laundry needs.

Reduced moisture extraction time. This can be accomplished by high G-force moisture extraction.

Moisture sensors. Residual moisture sensors in dryers govern the amount of retained moisture depending on the program selected; when ironing linens, for example, sensors can stop the drying process at 25 percent moisture to reduce wrinkles, ease finishing and increase work flow.

Overheating safeguards. Moisture sensor technology detects dryer overheating. Most commercial dryers depend on an external fire suppression system.

Protection of fabrics. Effective drum design can quadruple life of fabrics.

Imbalance sensor. A two-stage imbalance sensor can manage optimum laundry distribution during spinning.

Soft mounted, quiet with low vibration cleaning systems for equine facilities handle all sizes of horse equipment. Image courtesy of Miele Professional

Convex-pattern honeycomb drum enhances cleaning and reduces wear on fabrics. Image courtesy of Miele Professional

Farms, pet and vet medical centers

In some applications a laundry system must deliver more than clean. In veterinary medical centers, dairy farms and pet resort/boarding establishments, a washing system needs to deliver clean laundry that is also free of bacteria, so as to avoid cross-contamination. Professional equine medical and training establishments have particularly demanding laundry requirements because a horse has varied equipment such as blankets and saddle pads, which get heavily soiled. If these are not bacteria-free after washing, infections and cross contaminations could occur. Equally problematic is the scale of the items needing washing. Residential-sized washing machines are too small for horse blankets. Laundromat-size machines are not suited to properly clean and care for blankets and saddle pads, and laundromats often expressly prohibit the use of their machines for so rugged a task.

Typical premium commercial cleaning equipment is constructed by hand and individually tested before delivery. Image courtesy of Miele Professional

Premium laundry system controller contains programs designed for an array of laundry items. Smart cards are updatable and can be customized. Image courtesy of Miele Professional

Example of high performance, small footprint, stackable commercial cleaning system has four temperature cleaning programs. Image courtesy of Miele Professional

Small footprint commercial washer and dryer

Also available on the market is a high-end small footprint commercial cleaning system suitable for a day spa, car wash, gym, restaurant, medical office, hair salon or bed and breakfast. This product has a drain pump that eliminates the need for a floor drain and is sized so that washer and dryer can stack or fit side-by-side under a counter. Short and quiet drying times are achieved through a high G force moisture extractor.

Heat pump tumble dryer

A European manufacturer recently introduced the first commercial heat pump tumble dryer to this country, which promises to reduce utility costs by 46 percent over conventional high-end tumble dryers.

Increasingly used in Europe where studies have shown energy usage to be at least half of that used for conventional dryers, heat pump dryers are new to the U.S. Encouraging their use, the Environmental Protection Agency predicts that advanced heat pump dryers could reduce CO₂emissions by 32-34 percent when compared with standard electric models. The heat pump dryer uses a honeycomb drum, and a refrigerant that is condensed by a compressor and led in a closed circuit through a heat exchange unit where heat exchange with the circulating drying air takes place. Because this transfer of energy is rapid and very efficient, energy consumption and running costs are significantly lower. Fluff filters in the door and door opening as well as fine filters trap lint and detergent residues. A fine filter in front of the heat exchanger adds protection. In addition to the efficiency features of other laundry systems, the heat pump has the additional performance benefits:

Protects fabrics. Heat pump dryers reduce drying temperatures, which protects fabrics.

Reduced utility costs. Savings are expected to be nearly half those of conventional high-end tumble dryers.

Reduced CO₂ emissions. Heat pump dryer reduces CO₂ emissions by using less electricity.

Rotary Irons

Essential for providing a professional finish to laundered items such as bed linens, tablecloths and napkins, rotary irons are specified according to dimensions and throughputs (lbs per hr) required. One manufacturer’s largest iron will easily process a king sized sheet in one pass with a single fold. Typical specifications include:

Adjustable temperature and speed controls. This allows irons to be used for any fabric.

Model size. Models range in roller length for handling different throughput rates.

Wet Cleaning

Twenty years ago two German companies, a cleaning systems manufacturer and a detergent manufacturer, developed a wet cleaning washer/dryer system with honeycomb drums that uses water and a safe biodegradable detergent process to clean clothes which are normally dry-cleaned. Environmentally safe it is a welcome replacement for the familiar odiferous dry cleaning system that uses “perc,” or perchloroethylene. Banned in California since 2007— the EPA finally gave its approval of the ban in 2011—perc has been documented as a “probable human carcinogen” that leaches into ground water. Some states, including New Jersey, have awarded grants to dry cleaners who switched to wet systems.

The biggest immediate benefit of wet cleaning is that it is the most effective way to remove water based stains and odors, rendering clothes not only truly clean, but fresh smelling. But more significant, the process does not expose workers or customers to toxic chemicals or contaminate ground water. Practically all garments can be cleaned in a wet cleaning washing/dryer system. Typical wet cleaning machines have the same efficiency features listed above for high-end commercial laundry systems.

Commercial Detergents

In addition to offering washers, dryers and rotary irons, manufacturers provide commercial detergents in order to optimize the entire cleaning process and, if their machines are built for sustainability, to ensure that the detergent, softener and related products are also environmentally safe. One typical high-end manufacturer offers several such products. These range from powders containing enzymes for effectively cleaning heavily soiled clothing and textiles, liquids for cleaning both light and dark colored cotton, synthetics and blends, detergent specifically formulated to protect wool and silk fibers to a waterproofing agent that waterproofs overalls and rain gear. A fabric softener reduces static and wrinkles and can be used for everything from jeans to cotton towels. One product is a liquid rice starch finish for bed linens and table linens.

If a facility uses 20 disposable mops per week, it can save approximately $3,000 in two years if a gentler laundry system is used. Image courtesy of Miele Professional

Mop Cleaners

The ability to reuse microfiber or cotton mops in the daily cleaning routine translates into thousands of dollars per year for a cleaning company in both supplies and labor costs. Microfiber mops are specifically designed for reuse with most premium brands manufactured to withstand 500 detergent laundering cycles and just 200 cycles if bleach is used. The challenge is how to gently launder mops to make them last longer. One manufacturer introduced several innovations to do just that. Its mop cleaner won accolades from a retirement home housekeeping team. After using it for six months, mop cleaning labor and costs were reduced by two-thirds. (See chart for estimated total cost savings.)

An automatic conditioning occurs during the wash cycle that infuses mops and cloths with detergent or disinfectant so they are ready to use right out of the drum. Spinning mops before washing them releases 50 percent of the soil before the actual cleaning process begins. This reduces labor time spent on carrying buckets and wringing mops, which translates into savings of $22,400 in three years. A dispensing module allows dispenser pumps to deliver the requisite amount of detergent, which can reduce detergent consumption by about one-third. By eliminating additional rinse cycles, gallons of water are saved.

Premium energy saving commercial dishwasher uses six gallons of water per cycle. Image courtesy of Miele Professional

Commercial Dishwashers
Achieving dishwasher sanitization without the use of caustic chemicals is a challenge. Most commercial dishwashers are tank systems, which recirculate dirty water until the final rinse. One high-end model, the only NSF/ANSI 3 approved/Americans with Disabilities Act (ADA) compliant freshwater commercial dishwasher, uses fresh water intake for each new fill with no need for caustic chemical or fear of cross-contamination. NSF International is accredited by the American National Standards Institute to develop voluntary standards for public health and safety. NFA/ANSI 3 covers commercial warewashing (the cleaning and sanitizing of equipment and utensils). Performance features of premium models may include:

Cycle times. Fast cycle times that include a high temperature sanitizing final rinse will save staff time.

Water consumption. An efficient machine using precise metered water intake will consume less gallons per cycle than a typical dishwasher.

Sanitization. A commercial dishwasher can achieve sanitization by setting the final rinse at high temperatures.

Polishes silverware. A commercial-scale dish and cutlery washer replaces the tiresome task of polishing silverware.

Service and support
In addition to identifying performance, cost savings and sustainability features, conscientious design professionals look at installation and service support. “Older established manufacturers with direct services are more likely to be available for long term support,” says Royal. “When purchasing higher quality products with longer life cycles, it’s important to consider service support further into the future.”

Moreover, a manufacturer offering a number of highly efficient equipment options is a useful resource for design professionals. Whether helping calculate savings or estimating product life cycle costs, a manufacturer with hands-on experience of assessing the environmental impacts of its operations could offer invaluable input for both specifiers and their clients—particularly if the client is requiring green construction. Some manufacturers have a personal use program where licensed professionals are invited to enjoy products for their personal use.

Conclusion
Identifying truly green premium commercial cleaning systems requires more than reading a list of sustainability characteristics. It requires attention to the manufacturer’s commitment to environmental responsibility and how that is expressed in producing reliable, long life systems that improve productivity and have as little environmental impact as possible. It also requires understanding the performance features of many different cleaning systems. High-end longer life cleaning systems require less water to heat, use less power, require less chemicals and discharge less chemically tainted effluent. More efficient systems are also easier to manage and save labor. Commercial cleaning systems that offer these immediate cost savings and longer-term environmental benefits should help meet today’s requirements for sustainable design.

Miele Professional is the commercial products division of Miele, Inc. The professional division leads the way in the development of innovative technology and meets the highest demands in washing, dishwashing, cleaning and disinfection in commercial applications. www.miele-pro.com