In industrial laundry operations, machines are calibrated to process a specific weight of linen per cycle. Operating outside of this designed capacity—whether by overloading or underloading—can significantly compromise wash quality, equipment performance, and overall operational efficiency.
The role of automatic chemical injection
Modern laundry systems often utilise automatic chemical injection, where wash formulas are programmed to deliver precise chemical volumes at defined intervals. These quantities are calculated based on an optimal load (e.g., 100 kg). Deviations from this load size cause disproportionate chemical usage, affecting both the cleanliness of linen and the cost-effectiveness of each wash.
Effects of overloading
- Reduced wash effectiveness
Overloading limits the distribution of water, detergent and mechanical action to each item. This results in substandard wash outcomes, with stains and soils more likely to remain. - Increased machine strain
Machines attempt to compensate for the overload with intensified mechanical action, leading to excess wear and tear. This shortens the lifespan of components and increases maintenance requirements. - Higher rewash rates
Poorly cleaned linen often needs to be reprocessed, consuming additional water, energy, and chemicals—while lowering productivity and increasing operational costs. - Mechanical imbalance and damage
Unevenly distributed loads cause excessive vibration and noise, and in severe cases, can damage bearings, drums, and suspension systems.
Effects of underloading
- Wasted resources
Underloading uses the same amount of water, chemicals, energy and labour for fewer textiles, increasing the cost per kg of linen processed. - Textile damage and premature wear
Lighter loads allow for more aggressive mechanical action, which can damage fabrics and shorten linen life. - Operational inefficiencies
Multiple small loads reduce throughput, increasing the frequency of loading/unloading, raising labour demands, and leading to more frequent machine use and servicing.
Why correct load size matters
Maintaining the correct load size is essential for:
- Maximising wash quality
- Reducing resource consumption
- Protecting machine integrity
- Extending textile lifespan
- Optimising labour efficiency
Whether managing a hospital laundry or a hospitality service, adhering to machine load guidelines ensures optimal performance and long-term cost control.
By Rana Zafar.