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Laundry Science
1.
Laundry Science September
28, 2011 Louisville, KY © 2011, Gurtler Industries, Inc.
2.
Steven J. Tinker •
Gurtler Industries, Inc., Vice President, Research & Development – 35+ years in industry with Ecolab & Gurtler – Technical Service – Product development – Marketing • American Reusable Textile Association Association, President – Mission: To create a greater appreciation for and acceptance of reusable textiles. • Healthcare Laundry Accreditation Council Council, Vice-Chair, Advisory Committee – Founding member of Board, 2005 © 2011, Gurtler Industries, Inc.
3.
Part I -
Laundry Chemistry Basics The Science of Cleaning © 2011, Gurtler Industries, Inc.
4.
Laundry Chemistry Basics Chemistry affects
all aspects of the laundering process… © 2011, Gurtler Industries, Inc.
5.
pH • pH: Scale
of values from 0 to 14 that measures the relative acidity or alkalinity of a solution. – pH 7.0 is neutral – Alkaline solutions are > pH 7.0 – Acid solutions are < pH 7.0 © 2011, Gurtler Industries, Inc.
6.
Acid/Base • Alkalies: Chemicals
that release hydroxide ions : in solution: (- OH) – Sodium hydroxide, metasilicate sod. carbonate metasilicate, • Acids: Chemicals that release hydrogen ions in solution: (H+) – Hydrochloric acid, sulfuric acid, phosphoric acid In Water: NaOH Na+ + -OH HCl H+ + -Cl © 2011, Gurtler Industries, Inc.
7.
Water Water is 99+%
of what we wash with, therefore the quality of your water is critical for the best results. © 2011, Gurtler Industries, Inc.
8.
Water • Water Hardness:
Calcium and magnesium carbonate, dissolved in water – Grains per Gallon (gpg): measurement of the degree of ): hardness, 1 gpg = 17.1 mg/l CaCO3 – Part Per Million (PPM): One milligram CaCO3 per liter of water, 1 gpg = 17ppm © 2011, Gurtler Industries, Inc.
9.
Water Hardness -
CaCO3 Medium Very Soft Hard Hard Hard 0 to <75 75 to <150 150 to <300 300 mg/l and mg/l mg/l mg/l greater 1 to 4 gpg 4 to 9 gpg 9 to 17.5 gpg > 17.5 gpg © 2011, Gurtler Industries, Inc.
10.
Water Chemistry • Total
Dissolved Solids, TDS – Measurement of all the solids (salts, hardness, etc.) in the water – Important in laundry, as this is also the solids that would be left behind in fabric after it is dried © 2011, Gurtler Industries, Inc.
11.
Water Chemistry • Chlorine:
Added to water supply for sanitation – Usually added at 0.5 to 2.5 ppm – Higher levels can cause corrosion or damage water softener resins © 2011, Gurtler Industries, Inc.
12.
Water Chemistry • Iron
Major impurity that can cause problems in laundry – Levels of 0.2ppm or more are a concern – Causes yellowing of fabric – Interferes with bleaching © 2011, Gurtler Industries, Inc.
13.
Water Chemistry • Alkalinity:
Active and inactive – Inactive (below pH 8.3) is also called bicarbonate alkalinity – High levels of inactive alkalinity can cause rinsing difficulties © 2011, Gurtler Industries, Inc.
14.
Water Chemistry • Other
issues: – Acidity – Color – Suspended matter – Organic growth – Carbon dioxide and oxygen © 2011, Gurtler Industries, Inc.
15.
Laundry Chemistry –
The Wash Process • Soil Sorting • Four Factors of Cleaning • Wash Process …and more © 2011, Gurtler Industries, Inc.
16.
Sorting • Match the
process to the special requirements of the classification • Maximize soil removal while minimizing textile degradation • Cost effective use of chemistry, energy, time, water and equipment © 2011, Gurtler Industries, Inc.
17.
Sorting • Soil Levels
– Very light, light, medium, heavy, extra heavy – Special soil classifications: blood, grease, ink • Colors – Colorfastness, bleaching, dye transfer • Fabric types – Cotton vs. polyester © 2011, Gurtler Industries, Inc.
18.
Loading Guidelines • Weighing
– Clean, dry weight vs. soiled weight • Machine types – Open pocket vs. split pocket – Tunnels vs. washer-extractors extractors • Fabrics © 2011, Gurtler Industries, Inc.
19.
Basic Washing Process Methods
of cleaning: – Diluting – Emulsifying – Wetting – Deflocculating – Neutralizing – Oxidizing – Dissolving – Reducing – Saponifying – Antiredeposition © 2011, Gurtler Industries, Inc.
20.
© 2011, Gurtler
Industries, Inc. Standard Laundry Process Mechanical Chemical Action Action Temperature Time © 2011, Gurtler Industries, Inc.
21.
© 2011, Gurtler
Industries, Inc. Low Temperature Process Mechanical Action Chemical Action Time Temperature
22.
Wash Process –
Flush • Flushing – removes gross, soluble soils – Blood soils - Keep under 110º F – Also can increase the temperature of the fabric for more efficiency in the next step – Can use a small amount of alkali or surfactant to “wet” the fabric and condition the soils © 2011, Gurtler Industries, Inc.
23.
Flush Chemistry • Alkali
& Detergent (see Break Chemistry) • Water & Soil Conditioners: Phosphates, organic polymers – Chelates water hardness & iron – Suspends soils – Aids in solubilizing soils – State Phosphorus regulations – Non-corrosive SHMP EDTA-Metal complex © 2011, Gurtler Industries, Inc.
24.
Wash Process: Break •
Break Cycle – First step with alkali and surfactant – Can be separate steps – With decrease in cotton, alkali is less important – Surfactants more effective on polyester © 2011, Gurtler Industries, Inc.
25.
Break Chemistry • Alkalies:
Usually based on Sodium Hydroxide or : “Caustic” – “Break” up soils – Saponify fats – Neutralize acid soils – Hazardous: Corrosive to skin and to some metals © 2011, Gurtler Industries, Inc.
26.
Suds Chemistry • Detergents
or Surfactants: Nonionic – Low foaming – Emulsifies oils – Wets fabrics – Neutral, non-corrosive © 2011, Gurtler Industries, Inc.
27.
Wash Process • Suds
and Carryover – Suds operation can be combined with the Break operation for light soils • Depending on the soil level, there can be multiple Suds steps • Additional alkali and surfactant – Carryover: Additional step that utilizes residual chemistry from Break for continued soil removal action © 2011, Gurtler Industries, Inc.
28.
Laundry Chemistry: Chelants Water
& Soil Conditioners: Phosphates, organic polymers Sequester water hardness & iron Suspends soils Aids in solubilizing soils SHMP EDTA-Metal complex © 2011, Gurtler Industries, Inc.
29.
Wash Process: Bleaching •
Bleach Step – Soils should be removed from the textiles and the water should be clear – Bleach is required to decolorize residual stains – Temperature, pH, time and concentrations are key factors © 2011, Gurtler Industries, Inc.
30.
Laundry Chemistry: Bleaches Bleaches
decolorize stains Oxidation Chlorine Bleach Hydrogen Peroxide (Oxygen Bleach) Reduction Oxalic Acid Sodium Hydrosulfite © 2011, Gurtler Industries, Inc.
31.
Bleach Chemistry • Bleaches:
Chlorine & Oxygen – Oxidize stains (decolorize) – Chlorine hazards: • Incompatible with acids (sours) • Very corrosive to metals, skin – Peroxide hazards: • Incompatible with alkalies • Corrosive to metals, skin © 2011, Gurtler Industries, Inc.
32.
Bleach Chemistry Bleaching: Chlorine
vs. Oxygen – Pros & Cons • Chlorine – Pros: – Excellent stain remover – Highly efficient at 140°F F – Lower costs • Chlorine – Cons: – Can cause damage to cotton if misused – Creates permanent Hibiclens stain © 2011, Gurtler Industries, Inc.
33.
Bleach Chemistry Bleaching: Chlorine
vs. Oxygen – Pros & Cons • Peroxide – Pros: – Safer on colors and fabrics – Does not affect Hibiclens (chlorhexidene gluconate) negatively • Peroxide – Cons: – Not as effective stain remover – Requires higher temperatures: 170 170-180°F – Higher costs – Requires DHS security assessment © 2011, Gurtler Industries, Inc.
34.
Enzyme Technology Alternative to
bleaches • Proteases: Protein soil removal – Blood, BM – Food-based stains • High and low temperature varieties – 100 - 130°F – 130 - 160°F • Effective at moderate alkalinity, pH 10.5 © 2011, Gurtler Industries, Inc.
35.
Enzyme Technology Alternative to
bleaches • Amylases – Starches – Food-based stains • High and low temperature varieties – 100-130°F – 130-160°F • Effective at higher pHs © 2011, Gurtler Industries, Inc.
36.
Wash Process -
Rinse • Rinsing – Remove residual chemicals and soils – Reduce temperatures to 100ºF in 15º steps to minimize wrinkles – Three rinses are typical, some classifications require more – Intermediate extracts can be helpful • Reduce water usage - increase wear © 2011, Gurtler Industries, Inc.
37.
Wash Process –Antichlor •
Antichlors: Reducing agents : – Step prior to final rinse – Neutralize residual chlorine – Incompatible with acids – Usually not corrosive or hazardous © 2011, Gurtler Industries, Inc.
38.
Wash Process: Sour •
Sour: o Final rinse, adjusts pH to 6.0 6.0-6.5 o Usually HFS, Phosphoric or Citric acids o Corrosivity can be an issue o Neutralize residual alkali from break step o Neutralize inactive alkalinity from water © 2011, Gurtler Industries, Inc.
39.
Finish Chemistry • Finishes:
Softeners or starches – Softeners improve “hand” of fabric and reduce static in dryer – Starches increase body of fabric • Natural versus synthetic – Anti-Bacterial Treatments Bacterial – Water Repellent Treatments – Soil-Release Finishes © 2011, Gurtler Industries, Inc.
40.
Wash Process -
Extract • Extraction – Removes excess moisture – Extraction is more efficient than dryers or ironers in moisture removal – Recommend final rinse at 100ºF minimum for better efficiency © 2011, Gurtler Industries, Inc.
41.
Specialty Chemistries • Specialty
additives – Solvent-detergents – Enzyme detergents – Brighteners – Iron removal treatments – Dust control additives © 2011, Gurtler Industries, Inc.
42.
Basic Washroom Tests •
Water hardness titration • Alkalinity titration • Chlorine or Oxygen tests – Active levels in wash process – Concentrated bleach activity • pH Indicator for final rinse • Residual chlorine • Iron – In textiles – In water © 2011, Gurtler Industries, Inc.
43.
Sample Titration Report
© 2011, Gurtler Industries, Inc.
44.
Part II –
Green Technology Environmental Issues & Water and Energy Conservation © 2011, Gurtler Industries, Inc.
45.
Chemical Environmental Issues •
Surfactants – Biodegradability • Phosphates – Eutrophication • Solvents – Biodegradable/Renewable • Bleaches – Chlorinated organics in wastewater • Water and Energy Usage – How chemicals can affect © 2011, Gurtler Industries, Inc.
46.
Environmental Concerns • Surfactants:
– The active cleaning agent in most detergent formulations, – Surfactants change the chemical and physical relationship between water and the surface to be cleaned. – Surfactants loosen and suspend soil and enhance the wetting property of water. – Environmentally improved surfactants biodegrade to less toxic and less persistent chemicals. © 2011, Gurtler Industries, Inc.
47.
Environmental Concerns • Biodegradation:
– Linear alcohol ethoxylates (LAEs) biodegrade to linear alcohols and carboxylic acids, compounds typically with lower environmental concerns. – Alkylphenol ethoxylates (APEs), in contrast, might biodegrade under anaerobic conditions to alkylphenols which persist in the environment and are considered toxic to aquatic organisms. – Also, LAEs are soluble in cooler water and so might aid in the development of low temperature, energy energy-saving detergents. © 2011, Gurtler Industries, Inc.
48.
Green Product Technology EPA
Initiative: APE (NPE) vs. LAE Surfactant Technology – LAE surfactants that are considered more eco eco-friendly due to their improved biodegradability. – Many laundry chemical suppliers have a full line of detergents available that utilize surfactant technology that meets the requirements of the US EPA’s Safer Detergent Stewardship Initiative (SDSI). © 2011, Gurtler Industries, Inc.
49.
Biodegradable Surfactants SDSI -
Safer Detergent Stewardship Initiative • Elimination of detergents that are not completely biodegradable. • Detergent formulators have alternative formulas available now. • Industry conversion has begun, and will progress over the next few years. © 2011, Gurtler Industries, Inc.
50.
Green Product Technology
NPE vs. LAE Surfactant Technology • Europe has eliminated APEs. • Canada fully converted to the new surfactants at the end of 2010. • TRSA has committed to EPA to work to a full conversion to LAE technology within their membership by 2014 © 2011, Gurtler Industries, Inc.
51.
Phosphates Phosphates cause premature eutrophication of lakes…
© 2011, Gurtler Industries, Inc.
52.
Phosphates • Phosphates in
laundry products: – Sequester water hardness ions, preventing them form interfering with detergent action – Suspend soils – Enhance detergent efficacy • Since the early 1970s “P” has been regulated – States developed limits and bans – No national standard © 2011, Gurtler Industries, Inc.
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Phosphates • Laundry chemical
manufacturers have limited phosphate and non-phosphate formulations phosphate – Organic polymers have good performance – EPA: Avoid NTA and EDTA • New Research is continuing, as “green” issues intensify – Renewable and biodegradable alternatives are available © 2011, Gurtler Industries, Inc.
54.
Solvents Hydrocarbon solvents do not biodegrade,
plus can pollute air… © 2011, Gurtler Industries, Inc.
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Solvents • Traditional solvents
include: – Odorless mineral spirits – aliphatic hydrocarbons – Cyclical hydrocarbons – more aggressive, more odiferous – D-Limonene – extracted from oranges – “Butyl Cellosolve” solvent ” • All have negative environmental or health issues. © 2011, Gurtler Industries, Inc.
56.
Solvents • Safer solvents
currently available – DPM: More environmentally friendly, according to EPA • New research on “renewable” solvents – Derived from plant sources, not petroleum – Soy and corn-based – Biodegradability is a plus © 2011, Gurtler Industries, Inc.
57.
Chlorine Bleach • Chlorine
reacts with organics in wastewater – Creates organo- carbons/chloroform Cancer-causing agents © 2011, Gurtler Industries, Inc.
58.
Chlorine Substitutes • Oxygen
Bleaches – Hydrogen peroxide – Not as effective as a sanitizer or stain remover – Requires hot (>170°F) water for F) greatest effectiveness – Does not react with Chlorhexidene gluconate (Hibiclens) © 2011, Gurtler Industries, Inc.
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Chlorine Substitutes • “Activated”
Oxygen Bleaches – Peracetic Acid – Effective at lower temperatures (120-140°F) – More effective sanitizer than peroxide – Very high cost impact © 2011, Gurtler Industries, Inc.
60.
Chlorine Substitutes • Enzyme
Technology– – Proteases & Amylases – Effective at lower temperatures (120-140°F) – Excellent at odor removal © 2011, Gurtler Industries, Inc.
61.
Green Fabric Softener
Technology • New Softener Technology – Biodegradable softeners – Renewable feedstock sources: • Plant-based chemistry vs. based petroleum or animal sources © 2011, Gurtler Industries, Inc.
62.
Green Product Technology What
should you look for? • Biodegradable surfactants • Natural solvents • Renewable raw material sources • No or low phosphate formulas • Super-concentration for reduced packaging concentration • Low temperature performance © 2011, Gurtler Industries, Inc.
63.
Water and Energy
Conservation • New technologies designed for water reuse and heat transfer have been introduced to the laundry industry. • Aggressive development efforts in new water and energy conservation efforts continue. • Retrofitting older equipment may be an option. © 2011, Gurtler Industries, Inc.
64.
Water and Energy
Considerations • Water Reuse – Chemical Considerations – Neutral and low alkaline detergents – Improved soil suspension agents and additives – Higher levels of water conditioners • Reuse of water allows for reuse of chemicals. – Rebalance chemical usage © 2011, Gurtler Industries, Inc.
65.
Part III –
Textiles © 2011, Gurtler Industries, Inc.
66.
Textiles
© 2011, Gurtler Industries, Inc.
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Textiles Cotton
Polyester © 2011, Gurtler Industries, Inc.
68.
Textiles
Cotton Fiber Microfiber Polyester Fiber © 2011, Gurtler Industries, Inc.
69.
Laundering Polyester/Microfiber • Polyester
Properties – Softer, “cotton” feel – Absorbent – Soil release properties/finish © 2011, Gurtler Industries, Inc.
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Laundering Polyester/Microfiber Traditional high
alkaline and high temperature washing methods are not the most efficient or effective. • Low alkaline, high surfactant technology is most effective. • Medium temperatures (140-160ºF) 160ºF) are best © 2011, Gurtler Industries, Inc.
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Laundering Polyester/Microfiber
Oily Soils are the most difficult to remove • Detergents should be balanced to low HLB value; more oleophilic in nature. • Phosphate builders aid in oil emulsification and removal © 2011, Gurtler Industries, Inc.
72.
Laundering Polyester/Microfiber
Damage to Polyester - Alkaline Hydrolysis © 2011, Gurtler Industries, Inc.
73.
Laundering Polyester Damage to
Polyester • Alkaline Hydrolysis – Caused by extra high alkalinity combined with high temperatures – Fibers will scale and fracture – Lint may be a problem © 2011, Gurtler Industries, Inc.
74.
Laundering Polyester Alkaline Hydrolysis
Undamaged Fiber © 2011, Gurtler Industries, Inc.
75.
Laundering Polyester Undamaged Fiber
Damaged Fibers © 2011, Gurtler Industries, Inc.
76.
Laundering Polyester Heat Damage •
Polyester will melt at 250ºC or 482ºF © 2011, Gurtler Industries, Inc.
77.
Laundering Polyester Heat Damaged
Fibers © 2011, Gurtler Industries, Inc.
78.
Part IV –
Hygienically Clean Textiles © 2011, Gurtler Industries, Inc.
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Pathogens: “Superbug” Awareness •
Increased awareness of resilient pathogens – MRSA: Methicillin Resistant Staphylococcus Aureus • Very difficult to control when a patient is infected. – C-Diff: Clostridium Difficile • Spore form survives on surfaces and is very difficult to deactivate. MRSA Hepatitis B C. Diff © 2011, Gurtler Industries, Inc. © 2011, Gurtler Industries, Inc.
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Hygienically Clean Textiles Definition
– • The textile has been treated such that "bioburden" has been adequately removed so that the item can be used without fear of being a source of contamination in a healthcare use. – And that the item can be treated with normal methods (steam sterilization) as needed to sterilize the textile. • AAMI (Association for the Advancement of Medical Instrumentation) defines the term "hygienically clean" as "free of pathogens in sufficient numbers to cause human illness.” © 2011, Gurtler Industries, Inc.
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The Laundering Process The
wash process utilizes several techniques to assure that the bioburden is reduced or eliminated. These techniques include: • Dilution: Several water changes during the cleaning process physically remove and flush away bio bio-organisms. Mechanical action is also a factor to consider as bioburden is loosened from the fabric by proper mechanical action action. • Heat: Washing at elevated temperatures (>140ºF) deactivates much of the common bio-organisms. organisms. © 2011, Gurtler Industries, Inc.
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The Laundering Process •
pH: High pH (>10.5) will "attack" or deactivate bio bio- organisms. In addition, large swings in pH, from neutral (7.0 - 8.0) in first flushes to alkaline (10.5 - 11.5) during the main wash cycles to acid (5.5 - 6.5) will adversely affect bio bio- organisms. © 2011, Gurtler Industries, Inc.
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The Laundering Process •
Oxidation: Chlorine bleach or oxygen bleaches contribute to the bio-organism deactivation – organism – Chlorine bleaches are well known to have excellent anti anti-bacterial and anti-viral efficacy. – Oxygen bleach is considered to be somewhat less aggressive on bacteria and viruses, however, when combined with the other cleaning factors in a laundry formula, oxygen bleach is considered effective in deactivating residual microbes. – Peracetic acid is an “activated” oxygen bleach that also has excellent anti-microbial and anti-viral activity. viral © 2011, Gurtler Industries, Inc.
84.
The Laundering Process •
Drying: Drying or ironing at temperatures that exceed 180ºF on the fabric surface deactivate any potential remaining organisms. • Chemical Sanitizers or Bacteriostats: Some laundries as an extra precaution will use EPA registered products that will act as sanitizers in the final step of the laundry process. © 2011, Gurtler Industries, Inc.
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The Laundering Process •
Published reports by ALM (Association for Linen Management), TRSA (Textile Rental Service Association), CDC (Centers for Disease Control and Prevention) and AAMI indicate: A well designed wash formula that appropriately uses the above techniques will provide "hygienically clean" textiles. © 2011, Gurtler Industries, Inc.
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Low Temperature Washing •
Published reports by TRSA and AAMI indicate that a well designed wash formula will provide "hygienically clean" textiles, even at lower wash temperatures. • CDC: “Studies have shown that a satisfactory reduction of microbial contamination can be achieved at water temperatures lower than 160 if laundry chemicals suitable 160°F for low-temperature washing are used at proper temperature concentrations.” http://www.cdc.gov/ncidod/dhqp/bp_laundry.html © 2011, Gurtler Industries, Inc.
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Low Temperature Washing •
Veteran’s Administration sponsored a research study that investigated the effect of low temperature and chemical oxidation on the “hygienically clean” aspects of the laundering process used in their laundry facilities. • This study is entitled “Killing of Fabric Associated Bacteria in Hospital Fabric- Laundry by Low Temperature Washing” ( (Blaser, et al., Journal of Infectious Diseases, Vol. 149, No. 1, Jan. 1984, 48 , 48-57). • The article concluded that there was sufficient reduction of pathogenic bacteria, even in low temperature washing (22ºC, 72ºF). • It also noted that even with the elimination of chlorine bleach adequate bleach, reduction in pathogens was observed when compared to traditional high temperature (71ºC, 160ºF) washing processes. © 2011, Gurtler Industries, Inc.
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Questions?
© 2011, Gurtler Industries, Inc.
89.
Contact information Steve
Tinker Office: 708 708-331-2550 Cell: 708 708-870-7743 sjtinker@gurtler.com © 2011, Gurtler Industries, Inc.