The Greening of Reusable Textiles

1.The Greening of Reusables and How to Leverage Green in Your Marketing American Reusable Textile Association

Presented by ARTA Officers and Directors:

Steve Tinker, Gurtler Industries

Brad Bushman, Standard Textile

Mike Dineen, Pellerin Milnor

Brendan ONeill, London Hospital Linen

Ed McCauley, United Hospital Services

Howard Zins, Howard Zins & Associates

Nancy Jenkins, ARTA

Marketing always a challenge for the industry

Textile maintenance industry unknown to most

Current focus on Green provides unique opportunity we are already Green!

Customers are now more receptive toGreen message

We can market our Greenness and create greater awareness and appreciation for reusable textiles

How do we maximize the Green efficiencies of our operations and, in doing so,

How do we leverage Green in our marketing?

Outline ways to maximize the Greenness of your operationsin key areas

Provide Green messages to leverage in your marketing outreach

ChemicalsSteve Tinker

TextilesBrad Bushman

MachineryMike Dineen

Plant Operations Ed McCauley and Brendan ONeill

Facility

Government Regulations Ref Marketing Howard Zins

Analysis of total environmental impact of reusables vs. disposables.

Includes water, energy and chemical impact of laundering .

Reusable -Polyester/FC

Energy 8.0

Water 11.0

Global Warming 0.4

Acidification 1.7

Eutrophication 0.2

Disposable - Pulp/PET/FC

Energy 30.4

Water 43.0

Global Warming 0.8

Acidification 13.6

Eutrophication 0.8

Reusable Polyester/Laminate

Energy 13.2

Water 17.3

Global Warming 0.8

Acidification 5.0

Eutrophication 0.5

Disposable Pulp/PE/PES/Laminate

Energy 31.8

Water 22.8

Global Warming 0.8

Acidification 13.4

Eutrophication 0.8

Surfactants Biodegradability

Phosphates Eutrophication

Solvents Biodegradable/Renewable

Bleaches Chlorinated organics in wastewater

Water and Energy Usage How chemicals can affect

APE Surfactants

Alkyl Phenol Ethoxylates or Nonyl Phenol Ethoxylates (NPEs)

Slowly biodegradable

Some products of biodegradation have been suspected of harming aquatic life.

APE Surfactants

Europe has eliminated APEs.

Canada is phasing out APEs by 90% by 2010.

US EPA has set up a voluntary program:

SDSI: Safer Detergent Stewardship Initiative

APE Surfactants

USA: Stateand Community initiatives to ban APEs are gaining political acceptance.

USA:Sierra Club and UNITE Here (textile/laundry workers union) are promoting environmental pressure to change.

APE Surfactants

Most consumer laundry detergent manufacturers have already eliminated APEs.

Most Industrial Laundry Chemical manufacturers have non-APE detergent formulations available.

APE Surfactants

Impact of Replacing APEs:

Most replacements are 10-20% more costly.

APEs work very well on oily soils so additional detergent or additives may be required to achieve equivalent quality in the laundry with non-APEs.

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.

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

Laundry chemical manufacturers have limited phosphate and non-phosphate formulations

Organic polymers have good performance

EPA: Avoid NTA and EDTA

New Research is continuing, as green issues intensify

Renewable and biodegradable alternatives are available

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.

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

Chlorine reacts with organics in wastewater

Creates organo-carbons/chloroform

Cancer-causing agents

Oxygen Bleaches

Hydrogen peroxide

Not as effective as a sanitizer or stain remover

Requires hot (>170F) water for greatest effectiveness

Does not react with Chlorhexidene gluconate (Hibiclens)

Activated Oxygen Bleaches

Peracetic Acid

Effective at lower temperatures (120-140F)

More effective sanitizer than peroxide

Very high cost impact

Water and energy conservation and reuse requires special considerations for chemical usage.

Reuse of water can cause chemical imbalances.

Soils loads will be higher, calling for more effective rinsing.

Water reuse can cause a build-up of TDS (Total Dissolved Solids).

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

Published reports by TRSA (Textile Rental Service Association) 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 160F iflaundry chemicals suitable for low-temperature washing are used at proper concentrations .

http://www.cdc.gov/ncidod/dhqp/bp_laundry.html

Veterans 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 Laundry by Low Temperature Washing (Blaser, et al.,Journal of Infectious Diseases , Vol. 149, No. 1, Jan. 1984, 48-57).

The article concluded that there was sufficient reduction of pathogenic bacteria, even in low temperature washing (22C, 72F).

It also noted thateven with the elimination of chlorine bleach , adequate reduction in pathogens was observed when compared to traditional high temperature (71C, 160F) washing processes.

Industry initiative

partnered with EPA

Over a ten year period:

Reduced carbon footprint

15% reduction of CO 2emissions

Reduced pollutants discharged to waste stream by 43%

Textile manufacturers are building upon the historic environmental and cost per use benefits they offer in their reusable products. Areas of strategic focus include:

Manufacturing Operations

Product Design and Development

Chemical Use Thinking Out of the Box

Though many of the activities of the textile manufacturing industry may go unnoticed by the average consumer, these actions are none the less important to cost containment and overall environmental Stewardship.

Alternative Energy Use

Water Reuse

Heat Reclamation

Handling and Packaging

Alternative Energy Options:

Cogeneration(combined heat and power, CHP)

Hydroelectric

Environmental impact from conversion to hydroelectric power at healthcare blanket and towel manufacturing facility:

Union Carolina Healthcare and Hospitality Finishing Facility for flat goods sheets, pillowcases, top covers, etc. Nearly $1,000,000 was invested to upgrade wastewater treatment facility to provide the following benefits.

1,200,000 gallons of sludge converted to agricultural fertilizer

200,000 pounds annually of suspended solids removed from waste stream

490,000 pounds annually of organic pollutants removed from waste stream

Maximizing fabric utilization (cut waste)

Drawing markers to utilize as much of the fabric spread on the cutting table as possible. Cut waste percentages should be monitored and efforts should be made to ensure 95% or more of the fabric is utilized.

Recycling waste fiber

Waste fiber/fabric created by selvage trimming, cutand sew, and miscellaneous manufacturingoperations should be recycled

1,898,260 pounds of landfill waste can beavoided each year from a typical cutand sew operation.

Pallets used for yarn transport should be reusable

Pallets used for shipment of yarn cones should be returned and reused for subsequent shipments

2,371,300 pounds of landfill waste can be avoided each year by the average mill.

Yarn cones should be reusable

Yarn cones can be returned and reused by spinning operations

1,008,780 pounds of landfill waste can be avoided each year by the average mill.

Customer should specify the use of recycled corrugate.

Currently, it is estimated that over 20% of shipping corrugate used is comprised of recycled fiber

1,710,224 pounds of recycled fiber utilized each year in U.S. alone

26.91% less corrugate by weight used in the packaging of terry products vs. historic industry standard

Enhancing Durability

Energy Efficient Textiles

Room-Ready Products

Use of Recycled Fibers

Products can be made that last longer

Stronger products =Longer product life

Precise Control of Yarn Spinning

Long staple fibers, carding and amount of twist can impact the strength and durability of a finished product.

Construction

A plain weave (1:1) is generally the most durable construction as compared with double pick yarns, twill weaves or knitted products.

Selective Use of Synthetic Yarns

Terry Products can be designed to be40%-70% higher in tensile strength

Sheeting Products can be designed to be as much as 100% higher in tensile strength

Selective use of synthetic fibers that can increase product strength and decrease drying times/energy consumption.

Sheets and Towels can be made Room Ready

Cost can be avoided at the laundry if the supplier can provide a product that is ready to use right out of the box.

Products made with recycled materials are becoming better and more available

On site generation of chemicals required to finish fabrics can provide enhanced quality, reduced costs and an environmentally beneficial process. The same electrochemical process that is used to produce industrial alkalis and bleaches, is available for textile finishing and laundering operations.

Two paths to savings:

Same temperature

Process same quantity of product more quickly

Less machine run time (and/or increased capacity)

Same time

Process at lower temperatures

Reduced thermal damage to textiles

Both methods reduce energy consumption and associated energy/processing cost.

Single-use products become medical waste and are incinerated or put in landfills.

Reusable products after 75-100 cycles of use:

Items are downgraded for use in non-critical areas.

Items are donated for use in other countries.

Textile recycling: Polyester textiles are now being recycled and used to produce new polyester fibers.

When all of the use-life is completed some textiles end up in landfills.

Cannot make anyGREENdecisions ifyou do not know the facts

Examples of management systems include:

DataFusion Protocol

CHILinc

JENVIEW

PulseNet

NETLink Control Technology

MilData and MilMetrix

Washnet

Information helps you measureagainst a baseline

Stay on top of government regulations

New administration WILL result in changes

TRSAs LaundryESP (Laundry Environmental Stewardship Program)

Cost-effective, flexible program designed to raise environmental performance

Allows large and small companies to choose from a variety of initiatives.

Implementing these initiatives will result in more efficient operations

See the TRSA booth for more details.

One of the cheapest ways to getGREEN

Maintain the equipment you already have

Gaskets

Water leaks

Steam leaks

Ducting leaks

Fine tune wash, dryer formulas

Fine tune ironer temperatures and speeds

Most new equipment today uses inverters to reduce power consumption

NEMA Premium Motors will eventually become the norm

Machinery sequencers to keep machines from starting up simultaneously reduces peak demand

Saving water also saves energy (to heat water)

New technology to eliminate a rinse step

Individual machine water reuse systems

Tunnel systems to replace banks of washers

Options such as press water surge tanks to reduce water consumption of tunnel systems

Investment involves:

Reuse system

Trenches and piping

Reuse inlet valve on washers

Reprogramming wash formulas

Dryer seals to channel energythrough goods

Low BTU/lbs of water removed

Low NOx burners

Heat exchangers for use with discharged water

Shell and tube and plate

Coaxial ducting on dryers

Stack economizers on boilers

City sewer systems are moving to requiring micron-level screening of suspended soils

Wastewater collection pits can be set up for automatic cleaning

Shaker screens remove solid waste before discharge to the sewer

Drill your own water well

Solar panels

Natural light panels instead of bulbs

Alternate lights (on-off) to reduceelectricity usage

Geothermal water heating (Vogue Linen, Elko)

Reduce To use less of something

Use less water/lbs of linen

Use less btus/lbs of linen

Use less kwh/lbs of linen

Reuse To use a product several times before discarding

All laundries reuse textiles, they are Green to start with

Recycle Taking products at the end of its useful life and remanufacturing them into other products

Grind down tires to make benches

Recycle old plastic bags so that they can be remanufactured into new bags

Aluminum cans, newspapers, cotton linens

Establish a Green Team

Employee based work groups that will meet regularly to identify Green opportunities within the company

Empowers the employees to take green responsibility in the day-to-day operationsof your facility

Start measuring your utility usage per pound

Calculate fuel btus / lbs of linen

Calculate kwh / lbs of linen

Calculate gallons of water / lbs of linen

Create a report to track and monitor your progress

Start measuring your waste streams

Pounds of linens ragged out

Pounds of plastic bags discarded

Pounds of cardboard boxes discarded

Number of pallets discarded

Number of dumpster loads of trash picked up

Sell any waste stream that carries residual value to recyclers ragged out linen, plastic, cardboard, pallets, scrap metal, etc

Encourage your employees to be Green at work and at home

Recycle aluminum cans, plastic, and newspapers

Encourage car pooling

Encourage the use of mass transit

Encourage the use of programmable thermostats, window insulation, and hot water heater/pipe insulation

Mechanical room

Properly sized boilers

Heat reclaimer

Fix all air, water and steam leaks

Stack economizer

Vent condenser for boiler H 2 0 make up tank

Proper insulation of all hot H 2 0 and steam lines

Plant equipment

Water reuse systems

Inverter driven pumps and motors

Operate plant on 2 ndor 3 rdshift

Properly working steam traps on ironers

Properly maintain equipment PMs

Pressure switch controls for water volume

Facility

Energy efficient light bulbs and fixtures

Roof Use sunlight reflecting materials

Rain water cistern 1 of rain on one acre is27,154 gallons

Install sky lights

White paint on walls and ceiling to increase efficiency of lights

Auto on/off lighting instead of light switches

Office and administration

Electronic billing

Utilize conference calls versus face to face meetings

Telecommuting

Recycle paper and toner cartridges

Go paperless and when you must print use both sides

Transportation is a key element of thetextile rental industry

Significant opportunity to improve our collective environmental impact

U.S. EPA

27% of 2003 GHG Emissions came from transportation Industry in US (up from 24.8% in 1990)

EPA estimates a 48% increase in Transportation energy use and related GHG emissions between 2003 and 2025, despite improvements in engine efficiency and technology

We can do more

New engine technology in heavy duty vehicles

2007 Diesel Particulate Filters, reducing the impact of the emissions from HD vehicles

2010 EPA Emissions Requirements continue to improve the emissions from HD Vehicles

Continued pressure on the auto industry to improve MD and LD vehicle fuel economy, therefore lowering emissions

But this is not enough

Logistics technologies

GPS Tracking Systems

Logistics management

Fleet optimization

Route optimization

Driver performance

Asset performance

Delivery cost analysis

Increase ROI

Installation of GPS systems to aid in fleet management:

Route efficiency = fuel economy (reduce out of route miles)

Monitor braking efficiency

Monitor speed variances, and set speed policies

(every mph above 50 mph, reduces fuel mileage by 0.1 mph)

Promote use of cruise control

Route optimization

Reduce left Turns (3 min penalty for each left turn)

Maximize delivery Windows

Measure Driver performance

Maximize asset productivity = reduced costs

Reduce miles / kms driven = reduced emissions, and costs

Fleet optimization through:

Preventative maintenance on all vehicles to increase fuel economy, and lower operating costs 1.5%

Driver training and incentives

Pre-trip and post-trip inspections

Regular tire pressure checks

Reduction of vehicle idling

Installation of APU (Aux Power Units) to help reduce excessive idle time

Idling can cost up to 0.75 gal/hr (2.84 L/hr)

Also emits 10.23 lb of CO2/gal (2.7 kg of CO2/L )

Every minute counts

Enhanced aerodynamics improve fuel efficiency and reduce GHG

Full roof faring 5-10%

Cab extenders 1-4%

Chassis fairings 1-2%

Air cleaners 1-2%

Aerodynamic mirrors 1-2%

Points to consider:

Before making Green claims

In refuting claims by the competition

Howard Zins, Principal

Howard Zins & Associates

Many claims being made

Some factual

Some not based on good science

The Federal Trade Commission (FTC)initiates points to consider

Is there a continuing need for the Guides?

Benefits of the Guides

Evidence

Deceptive environmental marketing claims

Sustainability

Claims made should be based on facts

Advantages to the environment

Costs, including hidden costs, should be identified

Authority of a government agency

Benefits to the environment

Benefits to the health of society

Health of children

Health of the elderly

Lower healthcare costs

The utilization of factual data and studies

E.T.S.A. Impact on the Environment Report

Advantages to environment shown

Energy consumption

Global warming

Acidification (of water and soil)

Eutrophication

Post-consumer waste

Deception Up to four gallons of water to launder one surgical gown or drape

Reality Modern tunnel washing systems

Surgical gown and most drapes Under 0.5 gallons of water

Large drapes Up to one gallon of water

U.N.Bruntland Commission onSustainable Development

ASTM International Subcommittee E06.71

The reusables industry should support the FTC Green Guides

Support evidence-based conclusions

Oppose deceptive claims

Support sustainable development

Promote the health of society and a sound environment

We are green businesses offering a green product reusable textiles

We manage operations and resources to reduce our carbon footprint

Equipment, product and energy managed to maximize the 3Rs reduce waste, reuse andrecycle

Water use

0.5-0.7 gallons of water per pound of processed textile

vs. 3.0+ gallons of water with traditional washing methods

Energy usage

Under 2500 btus per pound

We partner with EPA to Reduce

Carbon Footprint

Over a 10-year period:

Increased production by 41%

Reduced water use by 28%

Saving 26 billion gallons of water

Reduced energy use by 14%

Saving 16 trillion BTU

Reduced carbon footprint

15% reduction of CO 2emissions

Reduced pollutants discharged to waste stream by 43%

We offer a green product reusable textiles which is a more environmentally friendly option to disposable products.*

*Life Cycle Assessment of Surgical Gowns, Anders Schmidt, Ph.D, dk-TEKNIK Energy & Environment, April, 2000

Reusable -Polyester/FC

Energy 8.0

Water 11.0

Global Warming 0.4

Acidification 1.7

Eutrophication 0.2

Disposable - Pulp/PET/FC

Energy 30.4

Water 43.0

Global Warming 0.8

Acidification 13.6

Eutrophication 0.8

Reusable Polyester/Laminate

Energy 13.2

Water 17.3

Global Warming 0.8

Acidification 5.0

Eutrophication 0.5

Disposable Pulp/PE/PES/Laminate

Energy 31.8

Water 22.8

Global Warming 0.8

Acidification 13.4

Eutrophication 0.8

When operations and inventory are well managed, reusable textiles are not only greener than disposable. Reusables cost less than disposables!

ReusableDisposable

Initial Cost $60.00 $4.50

Cost per Use 1.20* 4.50

Admin Costs 0.15 0.15

Laundering 0.50 -

Pack Making & Sterilization0.40 -

Waste Disposal-0.25

Total Cost Per Use $2.25 $4.90

*50 processings

Our industry is innately green

We have a once-in-a-lifetime opportunity to leverage the Green story in marketing to customers

Reusable textiles are the responsible choice,because the future is NOT disposable!

ARTA was founded 26 years ago with the mission to create greater awareness and appreciation for reusable textiles

We are offering new materials to help you market the Green message

In addition, ARTA can work with your team to create customized marketing programs.

We invite all industry associations to join together in funding a new Life Cycle Assessment Survey for 2010

ETSA survey was conducted in 2000 in Europe

Steve Tinker , Gurtler Industries

[email_address]

Brad Bushman , Standard Textile

[email_address]

Mike Dineen , Pellerin Milnor

[email_address]

Ed McCauley , United Hospital Services

[email_address]

Brendan ONeill , London Hospital Linen

[email_address]

Howard Zins ,Howard Zins & Associates

[email_address]

Nancy Jenkins , ARTA

[email_address]

Documents

The Greening of Reusable Textiles