· web viewtick the correct statements. washing above 40 c washing above 65 c for 10 minutes....

Laundry OperationsSVQ Level 2GC8N 22

Tutor Support Pack

Publishing informationSecond edition

Published date: June 2012

Publication code: DB5765

First Published 2007

Published by the Scottish Qualifications AuthorityThe Optima Building, 58 Robertson Street, Glasgow G2 8DQ Lowden, 24 Wester Shawfair, Dalkeith, Midlothian EH22 1FD

www.sqa.org.uk

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 Editorial 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 2012

http://www.sqa.org.uk/

iii

GC8N 22 — Laundry Operations Level 2

ContentsSection 1: Introduction

Section 2: Health, safety and security at work in the laundry and dry cleaning industry (HS2)IntroductionSuggested answers: FireSuggested answers: Accidents and emergencies Suggested answers: Other hazards in the laundry plant Suggested answers: Electricity and machine safety Suggested answers: Control of Substances Hazardous to

Health (COSHH)Suggested answers: Security Suggested answers: End of Unit Activity

2.12.52.9

2.112.17

2.212.232.25

Section 3: Classify items and make up loads for cleaning (LDC3)IntroductionSuggested answers: Sorting domestic, personal and

specialist laundrySuggested answers: Sorting contract laundry Suggested answers: Classification

3.1

3.53.133.17

Section 4: Inspect and dispatch laundered and cleaned items (LDC17)IntroductionSuggested answers: Retail packing and dispatch Suggested answers: Bulk packing and dispatch

4.14.54.9

Section 5: Carry out the washing process (LDC4)Clean items safely by continuous tunnel washing processes (LDC5)Process cabinet roller towels in one stage (LDC6)IntroductionSuggested answers: Health and safety and maintenance

proceduresSuggested answers: The ingredients for a successful

wash processSuggested answers: The wash processSuggested answers: The continuous tunnel washer Suggested answers: Troubleshooting

5.1

5.11

5.155.215.255.38

Section 6: Tumble-dry items (LDC7)

IntroductionSuggested answers: Tumble-dry items

6.16.5

Section 7: Press and finish garments following laundry (LDC8)Form-finish and inspect garments using steam and/or air (LDC11)IntroductionSuggested answers: Health and safety and maintenance

proceduresSuggested answers: Types of steam, types of press and

foldingSuggested answers: Finishing heat sensitive fabrics Suggested answers: Press clothing

7.1

7.7

7.117.157.17

Section 8: Process flat work through calenders (LDC9)

IntroductionSuggested answers: Process flat work through calenders

8.18.5

iv GC8N 22 — Laundry Operations Level 2

vGC8N 22 — Laundry Operations Level 2

Section 9: Dry-finish and inspect garments using a tunnel finisher (LDC10)IntroductionSuggested answers: Dry-finish and inspect garments

using a tunnel finisher

9.1

9.5

Section 10: Maintain effective working relationships at work (LDC25)IntroductionSuggested answers: Maintaining effective working

relationshipsSuggested answers: Communicating effectively with

others at work

10.110.7

10.15

vi GC8N 22 — Laundry Operations Level 2

1

Laundry Operations Level

2GC8N 22

Tutor Support Pack Section 1 Introduction

GC8N 22 — Laundry Operations Level

1.1


IntroductionAbout this packWelcome to this tutor support pack. It has been designed to help you help candidates to meet the requirements of the SVQ in Laundry Operations at level 2. The Units candidates will cover are as follows:

Mandatory Units• Health, safety and security at work in the laundry and dry cleaning industry (HS2)• Maintain effective working relationships

Option Group 1 — choose ONE Unit from the following• Carry out the washing process (LDC4)• Clean items safely by continuous tunnel washing processes (LDC5)• Process cabinet roller towels in one stage (LDC6)

Option Group 2 — choose ONE Unit from the following• Tumble-dry items (LDC7)• Press and finish garments following laundry (LDC8)• Process flat work through calenders (LDC9)• Dry-finish and inspect garments using a tunnel finisher (LDC10)• Form-finish and inspect garments using steam and/or air (LDC11)• Use a safe system of work for unblocking continuous tunnel washers (LDC 23). See Candidate Support Pack for NPA Safe Operation of Continuous Batch Washers — printed copies are available through SQA's Customer Support Centre (phone 0845 279 1000 or e-mail [email protected]). There is a charge for this pack.

Option Group 3 — choose ONE Unit from the following• Classify items and make up loads for cleaning (LDC3)• Inspect and dispatch laundered and cleaned items (LDC17)

Once candidates have completed these Units and worked through this support pack, they should know all there is to know about the laundry process!

How the pack is organisedThe learning and teaching materials in this pack are organised around the Units themselves.

These materials will help candidates to develop the specific knowledge and skills that they require for each Unit. They will also help candidates to generate the evidence they need to pass each Unit.

1.2


Each section of the pack contains the information candidates need to know about a particular topic, while the activities give them the opportunity to apply what they have learned. There is also a self-check questionnaire at the end of each section, which will test how much they have remembered and understood. You should discuss the results with them — this will highlight their strengths and weaknesses, and will be a good basis for their self-evaluation.

AssessmentAs the candidates’ trainer or tutor, you should use the various activities and self-check questionnaires to assess them as they work their way through this support pack. You should also tell them what the Evidence Requirements are for each particular Unit.

Finally, remind candidates that they will be formally assessed by an assessor once they have completed each Unit.

Assessment methodologyThe SVQ in Laundry Operations at level 2 is in the remit of Skillset, and this section outlines the required assessment methodology.

The guidance and criteria covering the SVQs require Skillset to produce an Assessment Strategy. Both the awarding bodies and the centres must follow this. It is designed to give greater clarity and guidance to the assessment of SVQs, to ensure their quality and promote confidence in those who gain them.

Details of the Assessment Strategy are outlined at the approval stage. All centres will have to sign up to the Assessment Strategy before they can enter candidates for the qualification. The Approvals Section of the awarding body monitors this, and the centre’s approval status is not updated until it is signed off and returned.

This guidance note for assessment methodology gives you and the centre information on the main points of the Assessment Strategy, and how it will affect your centre.

1 Evidence and assessmentThe document SVQ Assessor Guidelines — SVQ in Laundry Operations (available from www.sqa.org.uk) gives details of the types and amount of evidence required, and the conditions under which it should be obtained.

Assessment can involve a range of different or combined assessment methods. Some of the most commonly used methods are observation, product evaluation and questioning. Other forms of assessment may include personal statements and witness testimonies.The SVQ Assessor Guidelines document gives advice on the best form of assessment to choose for the different Evidence Requirements of the SVQs, and also how to make sure that the evidence is valid, authentic and practicable.

Details of how to record the evidence — with examples of completed paperwork — are also provided.

1.3


2 SimulationCentres and trainers or tutors should be aware of the requirements of the National Occupational Standards with respect to simulation.

The Assessment Strategy gives details of specific Units within the SVQs where simulationis not permitted. This document is available from SQA.

Prior approval must be sought from an External Verifier (EV) for any proposed simulated activities. The approval submission should indicate in general terms how the centre intends to meet these requirements.

Contact with the EV should be made through SQA, Glasgow.

3 Expertise of assessors and internal verifiers (IV)Centres should adhere to the requirements detailed in the Assessment Strategy. Details of the qualifications, competence and experience of assessors and internal verifiers should be submitted to Appointee Management at SQA, Glasgow, prior to the approval process. These details will be confirmed during EV visits. It is the centre’s responsibility to inform Appointee Management at SQA, Glasgow, of any changes in the details.

If there is any doubt about the detail of the requirements, SQA will contact the SSC for clarification.

4 External quality control of assessmentEach active centre is subject to a minimum of one external verification visit by SQA in each calendar year.

The Unit F0JK 04 Health, safety and security at work in the laundry and dry cleaning industry (HS2) — which is mandatory in both the level 2 qualifications — will be sampled at all EV visits.

The sample of work for external verification should, ideally, comprise the work of a number of candidates. The EV will select the candidates and notify the centre in advance. The number of candidates should be large enough to ensure assessment reliability. If, however, the EV identifies any problems, the sample can be increased. For centres with a few candidates, the entire group of candidates’ work will be scrutinised.

Additional sampling by the EV is recommended where a vested interest exists in the outcome of assessment. Low candidate numbers, however, might not allow for additional candidate sampling, and in this case the EV will ensure that portfolios include satisfactory witness testimonies or other evidence from outwith the direct line management of the candidate.

1.4


Workplace skillsAs a result of working through all the Units in Laundry Operations, candidates 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, they will develop more specific skills. These are outlined in the introduction to the relevant section.

ResourcesBefore they begin working on this SVQ, candidates should be given a copy of the following documents from you or from their employer:

• 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 and your candidates enjoy using this pack, and that it will help you help them to pass the SVQ in Laundry Operations. Good luck!

2


2GC8N 22

Tutor Pack

Section 2

FN43 04Health, safety and security at work

in the laundry and dry cleaning industry (HS2)

ii GC8N 22 — Laundry Operations Level 2

iii


ContentsIntroductionAbout this UnitKey areas of knowledge and understanding Skills and techniquesRegulations, rules and guidelinesAdditional requirements for man-made fibres About this learning and teaching pack Evidence Requirements

2.12.12.22.22.32.32.4

Suggested answers: FireActivity 1Activity 2Activity 3Activity 4Activity 5Self-check questionnaire

2.52.52.62.62.72.7

Suggested answers: Accidents and emergenciesActivity 6Self-check questionnaire

2.92.9

Suggested answers: Other hazards in the laundry plantActivity 7Activity 8Activity 9Activity 10Activity 11Activity 12Activity 13Self-check questionnaire

2.112.112.112.122.122.132.142.14

Suggested answers: Electricity and machine safetyActivity 14Activity 15Activity 16Self-check questionnaire

2.172.172.182.18

Suggested answers: Control of Substances Hazardous to Health (COSHH)Activity 17Activity 18Activity 19Self-check questionnaire

2.212.212.212.22

Suggested answers: SecuritySelf-check questionnaire

2.23

Suggested answers: End of Unit activityMajor incident 2.25

2.1


IntroductionAbout this UnitThis Unit — Health, safety and security at work in the laundry and dry cleaning industry (HS2) — is designed to help candidates develop responsibility for their own health, safety and security in the workplace, and to monitor the workplace for hazards. Their 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, the candidate 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 understandingThe Unit will help candidates 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.• What hazardous substances are used in the workplace, and methods making safe or

reducing 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 maintain security to cover personnel, public and premises.• Correctly use the various types of PPE in your premises.• Comply with procedures in the event of one of the following types of emergencies:

— Fire— Contamination (eg from leaks, spillages, gas emissions)— Accident and injuries to persons— Explosions (eg gas)

2.2


Skills and techniquesAfter working their way through the Unit, candidates 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 — they should correct them if

possible, and report them• note service malfunctions and chemical leaks

Regulations, rules and guidelinesCandidates 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.• HSG (95) Health Service Guidelines.• HACCAP (Hazard Analysis and Critical Control Points).

Workplace skillsCandidates should be able to:

• Communicate effectively with colleagues and customers.• Comply with written instructions.• Complete forms, reports and other documentation.• Keep accurate records.

2.3


Additional requirements for man-made fibresCandidates 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 emission)• accident and injury to persons• explosion

About this learning and teaching packThis part of the learning and teaching pack is designed to help candidates 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 candidates apply what they have learned. At the end of each section there is a self-check questionnaire to help them check their knowledge and understanding so far. You should discuss their answers with them.

And finally, there is an end of Unit activity that puts all their knowledge to the test! You should discuss this activity with candidates before they undertake it.

2.4


Evidence RequirementsIn this Unit, the candidate will require to carry out the collection and delivery of items from the customer with knowledge of the following:

• Show where alarms, emergency exits, escape routes, emergency equipment and assembly points are located.

• Know what alarms sound like, and evacuation procedures.• Know which hazardous substances are used in the workplace, and methods of

making safe or reducing their danger in the event of an accident.• Show how to handle and store hazardous substances.• Know what the most likely accidents and emergencies in the workplace are and how

to deal with them.• Know how to shut down the plant in the event of an emergency.• Know how to monitor the workplace for hazards and risk assessments of the

workplace.

These tasks will be observed by recording the candidate’s practical and knowledge evidence of the Unit. Simulation will be allowed in certain parts of this Unit. The minimum requirement is observing the candidate over the whole Unit. Please note that the answers to the questions are only suggestions, and should not be taken as gospel! Different cleaning centres will have their own procedures and ways of working, and these should also be taken into account.

Finally, you should inform candidates that they will be formally assessed by an assessor once they have completed this Unit.

2.5


Suggested answers: Fire

Activity 1

Add two more guidelines to this list to prevent fires starting in your laundry

1 Local answer.

2 Local answer.

Activity 2

1 What does your fire alarm sound like? Is it a buzzer, bell, klaxon, etc? Is it continuous or intermittent?Local answer.

2 What should you do if it goes off?Leave the laundry in an orderly manner.

3 What should you do with the equipment or machine you are working with?Close down any machinery.

4 Which exit should you use?The nearest to your workstation.

5 What route should you take to the exit?The shortest but safest route.

6 Should you carry out any tasks on the way to the exit?No tasks should be carried out.

7 What should you do when you get outside?Wait for the supervisor or person in charge to take a roll call.

2.6


Activity 3

1 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.

Local answers.

Activity 4

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?Local answer.

2 Are gangways to the fire exits marked on the floor?Local answer.

3 Are gangways kept clear?Local answer.

4 Are all fire exits kept clear on both sides?Local answer.

5 Is all fire fighting equipment well maintained?Local answer.

6 Are all fire exits clearly marked?Local answer.

2.7


Activity 5

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.

Local answers.

Self-check questionnaireUse 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?Local answer.

2 Where are the fire call points?Local answer.

3 If you discovered a fire what would you do first?Shout ‘FIRE!’ and activate the fire alarm.

4 Who would you tell? What would you tell them?Your supervisor. The location and severity of the fire.

5 What should you do with any machinery?Turn off machinery, if it is possible and safe to do so.

6 What would you do with any doors and windows and why?Close all doors and windows to starve the fire of oxygen.

7 Where is the fire evacuation point for the laundry?Local answer.

8 Why is a roll call taken?To ensure that all members of staff are accounted for.

9 When would you re-enter the building?After being told it is safe to do so by the fire authorities.

2.8


Self-check questionnaire (continued)10 What is spontaneous combustion? How and why does it start?

It is the generation of extreme heat by a chemical reaction. It can be caused by trapped heat in a load of drying.

11 What is good practice to avoid spontaneous combustion?Spread the load from the dryer on a table, and do not leave it in the trolley.

12 What types of work should you be particularly careful with?Items contaminated with kitchen oils, either in a trolley or washing machine.

13 How many types of fire extinguishers are there in your laundry? What types of fire are they used on?Local answer.

2.9


Suggested answers: Accidents and emergencies

Activity 6

1 Who is your trained first aider?Local answer.

2 Where is your first aid box kept?Local answer.

Self-check questionnaireUse this self-check questionnaire to make sure that you now know all that you need to know about accidents and emergencies.


1 Where are the first aid boxes?Local answer.

2 Who checks the boxes?Local answer.

3 Who is the nominated first aider in your laundry?Local answer.

4 What would you do if you had an accident?Tell your supervisor and the person responsible for first aid, and enter it in the accident book.

5 What are the most likely accidents in the laundry?Burns from steam or handling hot items from the dryer or presses.

6 How would you treat them?Run burn under cold water or place a cold compress on burn and seek help from the first aider.

7 What items would you find in the first aid box?Plaster, bandages, sterile water, safety pins, scissors.

2.10 GC8N 22 — Laundry Operations Level 2

Self-check questionnaire (continued)8 Find out where your company’s ‘health and safety policy’ is

displayed, read it and show your trainer. Give three examples each of• Your employer’s duty to you• Your duty to the organisation and colleagues

Local answer.9 How should you check for sharp objects?

Always pat don’t poke.10 What is your responsibility with PPE?

(a) Always wear the appropriate protective clothing at all times you are on duty or undertaking a specific function that requires protective workwear.

(b) If the workwear is ‘single-use’ and disposable, when you have finished with it — it is disposed of safely and correctly.

(c) If the item is re-useable, for example, staff uniform, it is laundered or cleaned at the correct intervals according to the company policy and is kept in a good state of repair.

(d) Keep all PPE correctly stored — and know where it is when needed. For example, special goggles may be required when handling chemicals, but you may not handle chemicals all day and may only need to use them once or twice a day for short periods. It is essential that you know where the goggles are stored and they are stored in a safe place and are kept clean and free of contamination and soiling — and replaced if they are broken.

11 What should you do when moving barrows?• ALWAYS PUSH the container — NEVER PULL IT.• Never overload it so you cannot see where you are going;

and• Always be aware of those around you — especially in front

of the container so you do not bump into them or the equipment and damage the container and the machinery.

2.11GC8N 22 — Laundry Operations Level 2

Suggested answers: Other hazards in the laundry plant

Activity 7

1Identify and name a machine in your laundry or dry cleaning plant where you could come into contact with live steam.Local answer.

2Can you think of two other effects on productivity of reduced steam pressure?• It takes longer to complete work.• It causes a build-up of work in other areas.

Activity 8

Think of what could happen as a result of a water leak.1What risks do pools of water on the laundry floor pose to laundry staff?

Employees can slip and injure themselves.2What are the dangers of hot water dripping from an overhead pipe?

Employees could be scalded.3How can linen be damaged as a result of being allowed to become

damp in storage?It can result in mildew, and will then need a rewash.

Activity 9

1What would you do if you identified a water, steam or air leak on the piece of equipment you were working on?Inform the supervisor, and close down the machine if it’s safe to do so.

2If 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?Mop it up and dry off the area. If this is not possible, cone off the area with the correct signage.


Activity 10

1 How should you deal with litter in the laundry?This should be swept up and disposed of.

2 What should you do to avoid an infestation of rodents in the laundry? Ensure that no food is allowed in the laundry, and that all linen is kept off the floor.

3 What should you do if you smell gas?Any smell of gas should be reported immediately.

4 What should you do in the event of a spillage?When a spillage occurs always ensure that the affected area is cordoned-off to prevent others from accidentally walking through the spillage. Seek assistance to contain the spillage and always follow the appropriate procedures for cleaning up the spillage.

5 What types of chemicals are used in the wash process?These can include very strong alkalis, acids and bleaching agents.

6 What safety procedures should you use when dealing with chemicals?This includes knowing what to do in the event of an accidental spillage as well as wearing the correct personal protective equipment and handling/movement/storage procedures.

Activity 11

Which of the following methods will reduce cross-contamination from soiled laundry? Tick the correct statements.Washing above 40 °CWashing above 65 °C for 10 minutes. ✓Sweeping floors regularly. ✓Chemical disinfection of work surfaces. ✓Encouraging frequent hand washing. ✓


Activity 12

1 Try to find out at least three ways used in your plant to reduce cross contamination.Local answer.

2 What risks are there from contact with soiled linen?You can come into contact with viruses such as Hepatitis B and HIV.

3 What could be the result of sharp blades, syringes or swarf left in a soiled boiler suit pocket sent to the laundry?You can be injured when checking for these items.

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?They could catch fire during the drying process.

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 labelledBag colour-coded ✓A hot water-soluble bag ✓Container labelled with details of contamination Only packaged in cardboard boxesNet bags used that can go directly into the wash


Activity 13

What protective clothing is available for you to use? Please tick the appropriate boxes.Smock coat GogglesBoilersuit Face maskApron Jacket/trousersRubber gloves Safety shoes

Cotton gloves

Other?Local answers.

Self-check questionnaireUse this self-check questionnaire to make sure that you now know all that you need to know about hazards in the laundry plant.


1 What does a RED alginate bag contain?Linen contaminated with, for example, blood.

2 How is the linen from a red bag handled and why?The bag is placed unopened into the washing machine. This ensures that the employee is less likely to catch any infection.

3 What would you do if you found a needle or something similar?Tell your supervisor, and place the item in an appropriate container.

4 What personal protective equipment (PPE) should the sorter wear?Gloves, apron, mask and appropriate footwear.

5 What are the risks from coming into contact with soiled linen?You can come into contact with viruses such as Hepatitis B and HIV.

6 What do you think might happen if blades, syringes, etc are sent to the laundry? You can be injured when checking for these items — so wear the appropriate PPE.


Self-check questionnaire (continued)7 What do you think might happen if matches or lighters are

sent to the laundry?They could catch fire during the drying process.

8 Where do dust and lint come from? What are the potential risks from dust and lint in the laundry? Name six risks.Risk 1 — 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.Risk 2 — dust, debris, human skin scales, hairs and so on are brought into the laundry with the soiled linen.Risk 3 — the variable airflows in a laundry (caused by heat, the movement of goods and the opening and closing of doors) cause turbulence, and this moves all the dust and lint around in the air. A 50kg dryer sucks 3,500 cubic feet of air per minute in through the tumbling work, and out to the atmosphere.Risk 4 — when the plant closes at night, or for longer periods, airborne dust and lint settle on surfaces throughout the laundry.Risk 5 — 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.Risk 6 — the quality of 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.Risk 7 — the quality of washed and finished fabrics can be spoiled because of recontamination by dust.Risk 8 — equipment should be cleaned frequently. This prevents the dust and lint build-up that can potentially reduce efficiency and cause malfunction and danger to the operative.Risk 9 — the build-up of dust and lint overhead and on machinery is a serious fire risk.

9 When was the lint and dust last cleared from all the machinery at your workstation?Local answer.


Suggested answers: Electricity and machine safety

Activity 14

Choose a machine that you use regularly and identify which of the following safety devices are available for your protection.

machine: ……………………………………………… safety guards flashing lightinsulated pipes cut-off deviceemergency stop button/audible alarmwarning signs electrical fuses

Local answers.

Activity 15

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.


Activity 16

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.Local answer.

Self-check questionnaireUse this self-check questionnaire to make sure that you now know all that you need to know about electricity and machine safety.


1 Where are the emergency stop buttons for your laundry located?Local answer.

2 Can you describe the various audible alarms that sound in the laundry?Local answer.

3 Are there any warning signs in the laundry? Can you identify them?Local answer.

4 If you came across defective electrical equipment what would you do? Switch off the machine, and report the fault to the supervisor and engineer.

5 There are 10 points that can protect you from electrocution — can you list at least eight?• Note the electrical hazard symbol on all access covers to

electrical components.• Company policy is that all wiring is to national regulations,

and is carried out by a competent electrician.• There is one isolator per machine to enable you to make

the machine safe while you rescue your colleague.• All cabling is either armoured in the conduit or overhead

cable tray so that you are unlikely to damage it accidentally.

• The isolator box cannot be opened — even by the electrician — if the lever is in the ‘ON’ position.

• Guards are placed all over live electrical components.


Self-check questionnaire (continued)• Guards are held in place by screws, not handles, and all these

should be tightly in place.• All electrics should be well away from drips or potential water

splash.• All machinery should be properly earthed so that there is no

‘tingle’ when the start button is operated.• There should be regular checks to ensure that there is no

smoke or smell coming from the motors, frayed insulation or bare wires.

2.20


2.21


Suggested answers: Control of Substances Hazardous to Health (COSHH)

Activity 17

1 Identify two products that you use in your laundry that have a hazard- warning 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.Local answers.

Activity 18

Go and find the Safe Handling Data Sheet for one of the chemicals you handle. Now answer the following questions:

1Are there any restrictions on this chemical coming into contact with other chemicals?

2Is there any information that should be given to the Fire Service if this chemical is in the vicinity of a fire?

3What should you do if this product is swallowed by a workmate?Local answers.

Activity 19

1 How should chemicals be stored safely?Chemicals should be stored separately, as some chemicals react against each other.

2 You have to change a container of bleach, how should this be carried out? Any special PPE must be worn, and care should be taken to avoid any spillage.

3 What information would you find on a safety data sheet?What is in the chemical, what to do in the event of an accident, whether the chemical is an irritant, and so on.


Self-check questionnaireUse 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.


1 What do the letters COSHH stand for?Control of Substances Hazardous to Health.

2 How many plastic chemical kegs can you stack one on top of another?None!

3 Where is the COSHH information kept in your laundry?Local answer — in the COSHH folder.

4 Identify two products that are used in the laundry that have a hazard- warning symbol on the label. What is the symbol and what does it mean? Local answer.

5 Using a hazard data sheet for one of these products, list key points for storage, and so on.Local answer — from data sheets.

6 List the potential COSHH hazards in the laundry.Local answer — from risk assessments.

7 Now carry out a full risk assessment in the laundry — using the form provided by your trainer — for cleaning a tumble dryer lint screen. Local answer.

8 How do you deal with the following waste materials:• polythene bags• string• waste fabricAll local answers.

9 Your colleague receives a bleach splash to his eye. What do you do? Treat it as per the instructions on the container label, or on the hazard data sheet.

10 To whom would you report hazards in the laundry?The supervisor.


Suggested answers: Security

Self-check questionnaireUse this self-check questionnaire to make sure that you now know all that you need to know about the security section.


1 How would you maintain the security of employees’ personal belongings? Keep them in a locked staff room with, for example, a secure coded lock.

2 How do you protect employees from risk of attack?Keep accessible areas of the laundry to a minimum.

3 How can you prevent theft of laundry equipment — for example, a computer?An inventory of goods should be kept and checked after each shift.

4 How would you deal with an unauthorised person entering the laundry during working hours?Ask for their ID and the purpose of their visit.

5 How can a laundry protect commercial information such as customer lists or this training manual?This should be kept in one area — for example, the office or training room.


Suggested answers: End of Unit activityMajor 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.

Info

rm

emer

genc

y se

rvic

es

Info

rm s

uper

viso

r

Info

rm e

ngin

eer

Info

rm

wor

kmat

es

Soun

d fir

e al

arm

Stop

mac

hine

Evac

uate

bui

ldin

g

Rep

air

faul

t

Fire 6 4 3 1 2 5

Steam leak 1 2

Electrical fault 2 3 1

Machine malfunction

2 3 1

Chemical leak 4 2 1 3

Gas leak 5 2 4 1 3Weather damage 3 2 1

3


2GC8N 22

Tutor Support Pack Section 3

FN47 04Classify items and make up loads for

cleaning (LDC3)

ContentsIntroductionAbout this UnitKey areas of knowledge and understanding Skills and techniquesRegulations, rules and guidelines About this learning and teaching pack Evidence Requirements

Suggested answers: Sorting domestic, personal and specialist laundryActivity 1Activity 2Activity 3Activity 4Activity 5Activity 6Activity 7Activity 8Activity 9Self-check questionnaire

3.13.13.23.23.23.3

3.53.53.73.73.83.83.93.9

3.103.10

Suggested answers: Sorting contract laundryActivity 10Activity 11Activity 12Activity 13Activity 14Self-check questionnaire

3.133.133.133.143.143.14

Suggested answers: ClassificationActivity 15Activity 16Activity 17Activity 18Activity 19Activity 20Activity 21

Self-check questionnaire

3.173.173.17

3.183.183.193.193.20

GC8N 22 — Laundry Operations Level 2 iii

3.vGC8N 22 — Laundry Operations Level 2

IntroductionAbout this UnitThis Unit — Classify items and make up loads for cleaning (LDC3) — is designed to help candidates prepare items and make up loads for cleaning. Their 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, the candidate must:• prepare items for classification• prioritise work• classify items and make up loads

Key areas of knowledge and understandingThis Unit will help candidates 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.• Making up correct weight loads for the weight capacity of machines.• Why different types of items need different weight loads.• How to prioritise loads.• Care labels.• Understanding fibres and fabrics.• Constructions of items.• The importance of identifying delicate/sensitive items.• Awareness of work priorities/sequencing.• Delaying with discrepancies in documentation.• How to deal with lost property as per the organisation’s guidelines.

3.2


Skills and techniquesAfter working their way through the Unit, candidates 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• comply with written instructions, company policies and procedures

Regulations, rules and guidelinesCandidates 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• HSC (95) 18 (Health Service Guidance)• HACCP (Hazard Analysis and Critical Control Points)• BS EN 14065 where appropriate (British Standards)

Workplace skillsYou should be able to:

• communicate effectively with colleagues and customers• comply with written instructions• complete forms, reports and other documentation• keep accurate records

About this learning and teaching packThis part of the learning and teaching pack is designed to help candidates 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

3.3


Each section contains information and follow-up activities to help candidates apply what they have learned. At the end of each section there is a self-check questionnaire to help candidates check their knowledge and understanding so far. You should discuss their answers with them.

Evidence RequirementsIn this Unit, the candidate will require to prepare items and make up loads for cleaning using the following:• Show how to sort the items by staining and soiling degrees, ie — light, medium and

heavy.• Show how to sort by material/fabric type taking care not to mix the fabrics for the

wash process, and taking note of the care label instructions.• Show all loads that have to be weighed so that the machines are loaded as per the

manufacturers’ instructions and the material types being washed.• Know what to do if an excessively soiled load of items come into the laundry.• Know how to check that all the equipment is in good repair.

These tasks will be observed by recording the candidate’s practical and knowledge evidence of the Unit.

The only machine involved in this Unit is the weigh machine for loads.

The minimum requirements are:• CTW over a period of an hour, as the same type of item is being classified.• using washer extractor over two deliveries of soiled items.

Please note that the answers to the questions are only suggestions, and should not be taken as gospel! Different cleaning centres will have their own procedures and ways of working, and these should also be taken into account.


3.4


3.5


Suggested answers: Sorting domestic, personal and specialist laundry

Activity 1

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?

Local answers

Activity 2

1 You see smoke coming from a pile of dirty laundry. What should you do first?

• Put it out with a hose. 4 (depending on fire)• Tell your supervisor/manager. 1• Put it out with an extinguisher. 3 (depending on fire)• Evacuate and sound the fire alarm. 2

2 Where is the nearest fire alarm to your workstation in sorting?

Local answer3 Where is the nearest fire extinguisher for a linen fire?

Local answer

3.6


Activity 2 (continued)

4 How do you use this particular extinguisher correctly?

Local training and per instructions on the extinguisher.5 What would you do to open windows and why?

Close the windows to starve the fire of oxygen.What would you do if you were the last to evacuate the room and if so why?

The last person to leave the laundry should close the door. This is to starve the fire of oxygen.

6 How do you secure customers’ property so that it does not get mixed up and lost?

You should observe the candidate dealing with a customer and mark accordingly.

7 You cut your finger on a blade whilst checking pockets. What do you do?

Tell your supervisor, seek first aid and dispose of the blade appropriately.

8 What precautions do you take to avoid infection when sorting work?

Wear the appropriate personal protective equipment.

Activity 3

recycled %

sent for landfill %

incinerated %

3.7


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

Local answersTotal

Activity 4

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 ………………………………………..........

Local answers

3.8


Activity 5

The Polymarksolvent that is used automatically by the Polymarkmarking 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:

Local answers if appropriate to your laundry, then from data sheet.

Activity 6

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?

Scissors, item list, PPE, barrows/trolleys2 What do you do with linen in red bags?

They should be kept in a sealed, secure area and unopened and handled as little as possible until they can be put directly into the washing machine. This will help to prevent candidates picking up viruses or infections.

Activity 7

3.9


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 °C10 minutes

71 °C3 minutes

40 °C hypo bleach

40 °Cdetergent disinfectant

wool jumper × ×white cotton × ×sheetcotton flameretardant ×curtains

Activity 8

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.

Local answers


Activity 9

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?

Wash at 60 °C with a reduced mechanical action, and use NO bleach in the process.

Self-check questionnaireUse this self-check questionnaire to make sure that you now know all that you need to know about sorting domestic, personal and specialist laundry.


1 What type of clothing should be worn in the sorting area?Mask, gloves, apron and overalls.

2 Give three examples of why soiling is hazardous to health?

You can pick up viruses, bacteria and infections from soiling.3 Describe how you would lift difficult loads in linen handling.

You would first assess the weight of the load. If one person can lift it, you should crouch at the load and straight lift. If it requires a two-person lift, you should both stand straight- legged, bent at the waist and lift together.

4 What is the care label symbol for wash at 40 with reduced mechanical action?

Wash tub with 40 °C and a bar below.5 What is the care label symbol for use of chlorine bleach permitted?

Triangle with CL inside it.6 What is the care label symbol for tumble drying at high heat?

Square with a circle inside it, and a 2 inside the circle.


Self-check questionnaire (continued)

7 Can you name five types of marking systems used in the laundries?

• 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 workwear

3.12


3.13


Suggested answers: Sorting contract laundry

Activity 10

1 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.

Local answers

Activity 11

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.

Local answers

Activity 12

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.

3.14


Activity 13

Produce a list of activities you would complete at the end of your shift to close down your sorting workstation.

Local answers

Activity 14

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 may 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 questionnaireUse this self-check questionnaire to make sure that you now know all that you need to know about sorting contract laundry.


1 Document HSG (95) 18 describes what actions should be taken with healthcare linen. Can you explain what these are?

Workwear MUST be worn because of the potential risk of infection to laundry staff from blood, bacteria and viruses on soiled linen. All cuts and exposed lesions on the skin must be covered by a waterproof dressing, and gloves MUST be worn. Workwear should be changed at the end of every shift.

3.15


Self-check questionnaire (continued)

2 What checks should be made to the cages/barrows and bags used in the laundry?

• All wheels are on and turning.• No loose metal is in the cages.• They are fit for the purpose they are being used for.

3 What are the advantages of using weighing scales?

They enable the sorter to measure the weight of each load accurately.

4 What are the nine factors you should take into account when assembling wash loads?

• 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 or sequence• disinfection — thermal or chemical• special fabric finishes — fire retardant• rewash — for what reason?

3.16


3.17


Suggested answers: ClassificationActivity 15

Complete the following table to see how many different classifications the linen hire company with the white-cotton-only policy* would need:

Laundry service Washing classifications

Bed linen Sheets

Towelling Bath towels Hand towels

Bath mats Dressing gowns

Face cloths

Table linen Banquet cloth

Local answer — for example, sheets and towels by colour/material/staining.

* 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.

Activity 16

List the natural fibres used to make up fabrics washed in your laundry.

Local answer

Activity 17

How would you prevent polyester garments from creasing during processing in the laundry?

Thermal — the wash and drying process has to include a cool-down period when the temperature is slowly reduced to about 52 °C (or approximately 4 °C per minute).Pressure — this is caused by the weight of the work during the hot wash in a large capacity machine, and by over-extraction when items are still hot.

3.18


Activity 18

Imagine that you are holding a soiled chef’s jacket with red trimming. What would you have to consider before classification?

• type of material• type of material trim• colour-loose dyes• degree of soiling• fats and oils• temperature of wash for the trim• type of bleach to be used (if any)• finish requirements

Activity 19

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?

You would either wash it as a wool process at 30 °C with a much reduced mechanical action, or as a hand wash.

3.19


Activity 20

Give two reasons why white and blue overalls should not be washed together.

• Colour run• Whites are usually washed by adding bleach and whitening

agents

Activity 21

1 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?

You would not use a bleach, as this takes out the fire retardancy from the material.

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 and hair fibres

Weakened Weakened, but slowly

Resists attack

Cotton Rots Weakened Weakened

Polyester Weakened Resistant Resistant

3.20


Activity 21(continued)

3 Which of the following process classifications would you use for a heavily blood- stained 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 Over 38 °C

White mineral oil with peroxide bleach

✕

White protein with hypochlorite bleach rinse

✕

Self-check questionnaireUse this self-check questionnaire to make sure that you now know all that you need to know about classification.


1 What types of stains will not wash out in the wash process?Protein soiling left in the fabric after a high wash will set in and be very difficult to remove.

2 How would you document any damaged item at classification?You would mark the item number on the item list and state that it is not being washed because it is damaged and will be returned to the customer.

3 What could happen if you failed to remove extraneous objects?They could damage the machine, catch fire in the dryer and damage the garments.

4 Why is it important to identify existing damage to garments in sorting?If the existing damage isn’t identified at the sorting stage, and the customer then comes back to complain about the damage,

3.20


the laundry can’t prove that it didn’t cause the damage.

4


2GC8N 22


FN4F 04Inspect and prepare laundered and cleaned items for dispatch (LDC17)

iii



4.14.14.24.24.24.3

Suggested answers: Retail packing and dispatchActivity 1Activity 2Activity 3Self-check questionnaire

4.54.54.54.6

Suggested answers: Bulk packing and dispatchActivity 4Activity 5Self-check questionnaire

4.94.104.11

4.1


IntroductionAbout this UnitThis Unit — Inspect and prepare laundered and cleaned items for dispatch (LDC17) — is designed to help candidates fold items and make up orders for dispatch. Their role will involve:• preparing items and inspecting them for quality• making up orders and dispatching items

As a competent person, the candidate must:• inspect items• remove and redirect any items that are substandard as per company procedures• pass items to packing and dispatch• make up and label orders• store items in the correct location• transfer items to the dispatch point• maintain the finish and condition of the items• prepare items for dispatch• manage and redirect substandard items

Key areas of knowledge and understandingThis Unit will help candidates to develop the following key areas of knowledge and understanding:• 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.

4.2


Skills and techniquesAfter working their way through the Unit, candidates 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


Substances Hazardous to Health (COSHH)• Manufacturer’s instructions• Other legislation as necessary


• Communicate effectively with colleagues and customers• Comply with written instructions• Complete forms, records and other documentation• Keep accurate records

About this learning and teaching packThis part of the learning and teaching pack is designed to help candidates 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 candidates apply what they have learned. At the end of each section there is a self-check questionnaire to help candidates check their knowledge and understanding so far. You should discuss their answers with them.

4.3


Evidence RequirementsIn this Unit, the candidate will require to inspect items coming from the main laundry process checking the following:• That the item has been washed correctly, and has no soiling or staining.• That the item is folded as per the customer’s instructions.• That the item is not creased.• Show that they know what the acceptable quality level is for the items being inspected.• Show that they know how to make up a customer’s order whilst maintaining the level of

quality.• Show that they know how to use any packaging machinery and understand any

problems that they may encounter in this task ie packing damp items causing mildew.


The minimum requirements are:• observing the candidate make up two customers’ orders.



4.4


4.5


Suggested answers: Retail packing and dispatch

Activity 1

1 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?The customer would be notified of the stain, and asked if they wanted the laundry to attempt to remove the stain.

2 If a customer’s order was complete except for a missing handkerchief, what action would you take?The customer would be notified on uplift or delivery that their laundry was complete, with the exception of the missing item.

Activity 2

List five types of packaging used to distribute washed goods to your customers.Local answers

Activity 3

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.

The six tasks are as follows:• Leave your workstation neat and tidy.• Leave any messages that might help them.• Ensure that there is a ready supply of the items they need to

carry out their task.• Ensure that all areas are wiped down with a disinfectant solution.• Ensure that all racking and trolleys are fit for use.• Ensure that no finished items are left lying in this area.

4.6


Self-check questionnaireUse 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 dispatch’ mean?

This is a term used in some laundries to describe the process of checking and packing washed items that are to be returned to an individual customer.

2 What does the workstation preparation involve?It involves making sure that the racking system is hygienically clean by dusting down and wiping all surfaces that will come into contact with the washed articles with a damp cloth.

During this preparation, checks should be made for any sharp edges or protrusions that may damage the items. Any litter or debris should be removed.

3 How should articles be received at this area?The dispatch person should check that the items are not damp. They should also check the quality of the finish and cleanliness. If for any reason the dispatch person is not happy with either, they should return the articles to the appropriate department for action.

4 What standards of hygiene would you expect in this area?All staff involved in packing clean linen should be aware of their responsibility to maintain a high standard of personal hygiene.Any recontamination of the washed articles will undermine all the work previously carried out by their colleagues in other departments, and put the reputation of the laundry and the health of the customers at risk.

4.7


Self-check questionnaire (continued)5 Explain the quality control standards expected in this department.

The person responsible should check for the following:• cleanliness• evidence of staining• does the item appear to be bright and smell clean and

fresh?• are the items folded correctly and to a standard size and

shape?6 What are the various methods of packing finished items?

Fabric bags, plastic hampers, boxes, plastic bags and wrapping polythene or paper are the most common types of packaging used.

7 What health and safety implications are there in this department?If a packaging machine is used, all the safety features should be in place.The lifting and carrying of items should be carried out using recommended lifting techniques that reduce the risk of injury.Pushing and pulling trolleys should not place any undue strain on the body.

8 What communication skills are required in this department?Good communication skills are required when dealing with customers, and when dealing with other departments.Good internal communication skills are a must for this area.

4.8


4.9


Suggested answers: Bulk packing and dispatch

Activity 4

1 List five preventative measures that can be taken to prevent washed and finished work getting contaminated with dust and lint in the packing department.The five measures are as follows:• Cover windows that are open with a gauze mesh.• Restrict the opening of doors.• Establish a good cleaning routine.• Wash trolleys and barrows with a chemical solution.• Wash and thermally disinfect bags.

2 What methods could be used for communicating information between shifts in the packing department?Message board.


Activity 5

1 List five possible sources of contamination of clean but uncovered workwear stored on coat hangers.Sources of contamination are:• airborne germs• damp work• unhygienic receiving area• open doors• operators — they should wear protective clothing to prevent

cross-contamination2 Give three reasons why sheets should not be packed into a hamper

bag on the floor.These are as follows:• the weight of the load for lifting• contamination• there could be dampness on the floor


Self-check questionnaireUse 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?

It should weigh what you know you can safely lift or carry without damaging yourself.

2 Why should trolleys be checked prior to you using them?To make sure that there are no sharp edges that could damage the items.

3 What PPE equipment should be used in this area?Gloves and aprons.

4 What method is used in your laundry to ensure that the correct items get to the correct customer?Local answer.

5 In what ways might an item be substandard, so that you would be unable to return it to the customer?It might:• not be clean• be stained• smell and look dirty• be folded incorrectly, and to a non-standard size and

shape6 What cleaning routines are in place for your laundry?

Local answer.

7 How do you ensure that the quality of the finished items remains constant until delivered?They should be stacked or packed neatly, off the floor, and in an area where the minimum of people are allowed.

5


2GC8N 22


FN4C 04Carry out the washing process

(LDC4) FN4H 04Clean items safely by continuous tunnel washing processes (LDC5)

FN4K 04Process cabinet

roller towelsin one stage (LDC6)

iii


ContentsIntroductionAbout these UnitsCarry out the washing process (LDC4)

Key areas of knowledge and understanding Skills and techniques

Clean items by continuous batch washing processes (LDC5) Key areas of knowledge and understandingSkills and techniques

Process cabinet roller towels in one stage (LDC6)Key areas of knowledge and understanding Skills and techniques

Regulations, rules and guidelines About this learning and teaching pack Evidence Requirements

5.15.15.25.25.35.45.45.55.65.65.75.75.8

Suggested answers: Health and safety and maintenance proceduresActivity 1Activity 2Activity 3Activity 4Activity 5Self-check questionnaire

5.115.115.115.125.125.13

Suggested answers: The ingredients for a successful wash processActivity 6Activity 7Activity 8Activity 9Self-check questionnaire

5.155.155.165.175.18


Suggested answers: The wash processActivity 10Activity 11Activity 12Self-check questionnaire

5.215.215.225.23

Suggested answers: The continuous tunnel washerActivity 13Activity 14Activity 15Activity 16Activity 17Activity 18Activity 19Activity 20Activity 21Activity 22Activity 23Activity 24Activity 25Activity 26Activity 27Activity 28Activity 29Activity 30Activity 31Self-check questionnaire

Suggested answers: Troubleshooting

5.255.255.265.265.275.275.285.285.285.295.305.305.315.315.325.325.325.335.335.34

5.38

IntroductionAbout these UnitsThe following three Units are designed to help candidates cover all that’s required for the various methods of the washing process:• Carry out the washing process (LDC4)• Clean items by continuous batch washing processes (LDC5)• Process cabinet roller towels in one stage (LDC6)

We have condensed these three Units into one section here, because there is a lot of information that’s common to all, and we want to avoid unnecessary duplication.

Carry out the washing process (LDC 4)In this unit, candidates’ 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, the candidate must:• make services and machinery ready for use• select correct programmes for classification• operate machinery in accordance with the 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• select the work required• identify any problems that may arise in carrying out the work• communicate with colleagues and check that they understand what work they must do• control the washing process• check that work is being carried out as planned

5.2


Key areas of knowledge and understandingThis Unit will help candidates to develop the following key areas of knowledge and understanding:• Operational settings and the range of performance from machines.• Care labels.• Understanding fibres and fabrics.• How the complete washing process works.• How to carry out routine machine maintenance as per company procedures.• Who to report faults to.• 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 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 techniquesAfter working their way through this Unit, candidates should be able to:• make services and machinery ready for safe use• use machines and machine controls• report faults 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• check loads for classification and process requirements• identify and redirect unsuitable items• use detergents, chemicals and additives• check thermostats, temperature gauges and dip levels• check the progress of selected work

5.3


Regulations, rules and guidelinesCandidates 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 COSHH (Control

of Substances Hazardous to Health)• manufacturers' instructions• all of the above which are relevant to the organisation

Workplace SkillsCandidates should be able to:• communicate effectively with colleagues and customers• comply with written instructions• complete forms, records and other documentation• keep accurate record

Clean items safely by continuous tunnel washing processes (LDC 5)This Unit is for those who wash items using a continuous tunnel washer (CTW) and organise and control the wash process in a safe manner.In this Unit, the candidate's role may involve:• using a continuous tunnel washer• maintaining operating standards, equipment and supplies• washing items using a continuous tunnel washer• planning the work for continuous tunnel washing processes• controlling continuous tunnel washing processes• correctly and safely operating the continuous tunnel washer

As a competent person, the candidate must:• make services and machinery ready for use• select programmes correct for the classification• make sure that thermostats and temperature gauges have the correct settings• operate machinery safely in accordance with manufacturers' instructions• handle items with care• direct items to the next process• select the work required making the best use of resources available under prevailing

conditions• identify any problems that may arise in carrying out the work, continually checking the

process flow

5.4


• communicate with colleagues and check that they understand what work they must do• control the washing process• operate machines according to instructions• report any machine faults• check that work is being carried out as planned

Key areas of knowledge and understandingThis Unit will help candidates to develop the following key areas of knowledge and understanding:• Operational settings and the range of performance from machines.• Programme selection, the difference between wash programmes and temperature

settings.• How to find the classification of loads.• How over/under loading of the CTW can occur.• What can cause blockages and why constant monitoring of the CTW is necessary.• Reading and understanding risk assessments and following HSE procedures.• Common faults.• What the problems are with high and low dip levels.• How the complete washing process works.• How to carry out routine machine maintenance as per company procedure.• Stopping a malfunctioning tunnel washer.• Who to report faults to.• Why it is important to identify any possible problems at the planning stage and report

these to their supervisor.• Recognising faults and malfunctions and the actions to take.

Skills and techniquesAfter working their way through this Unit, candidates should have developed the following skills and techniques:• Communicating with colleagues on what they must do and checking that they have

understood their brief.• Identifying and reporting component part malfunctions.• Regularly checking and calibrating weighing devices and keeping test weights for this

purpose.• Calculating the correct weight for each classification of work.• Ensuring that the machine is not under or overloaded.• Monitoring the loading area and raising the alarm if any abnormality is found, shutting

down the CTW until the fault is corrected.• Checking there is sufficient water for each type of classification to ensure that the work

is loaded cleanly into the hopper/first stage compartment.

5.5


• Ensuring that there is still an amount of free liquid after wetting out is completed.• Checking that water levels are correct by checking various dip levels of the machine to

ensure a clean transfer.• Ensuring that the correct levels of water are available to provide sufficient lubrication to

transfer the load cleanly as a complete batch.• Monitoring the dip levels and bath level sensor faults.• Checking the proximity sensors that control the rotation of the drum during transfer for

correct operation.• Checking for faults from the computer diagnostics to ensure that any reversing fault

issues are diagnosed and corrected immediately.• Checking for overloading and/or lack of water which causes blockages.• Monitoring fault alarms and diagnostics within the CTW to provide early warning to

prevent blockages.• How to disinfect the CTW.• Using the machine safely, understanding the machine controls.• Checking thermostats and temperature gauges.• Using detergents, chemicals and additives.

Regulations, rules and guidelinesCandidates 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 COSHH (Control

of Substances Hazardous to Health).• Other legislation as necessary.

Workplace SkillsCandidates should be able to:• Communicate effectively with colleagues and customers.• Comply with written instructions.• Complete forms, records and other documentation.• Keep accurate records.

5.6


Process cabinet roller towels in one stage (LDC 6)This Unit is for those who process roller towels using continuous processing and who set up a CTW or continuous towel washer and wash, dry and finish cabinet roller towels.

In this Unit the candidate's role may involve:• preparing machinery, equipment and supplies for continuous processing• washing, drying and finishing cabinet roller towels• setting up continuous processing operations

As a competent person, the candidate must:• prepare machinery and supplies• carry out routine machine maintenance• select the correct machine programmes• operate the machine according to the manufacturer's instructions• clean, dry and roll towels• unload and separate towels• prepare towels for dispatch• store towels so that they do not become contaminated• select the work required• identify any problems that may arise• check that colleagues understand what work they must do• identify and deal with unsatisfactory towels• identify and deal with faults in the process• check the work is carried out as planned• locate and repair faults or damages in the towelling length

Key areas of knowledge and understandingThis Unit will help candidates to develop the following key areas of knowledge and understanding:• The start-up and close-down sequence.• How to operate machines.• Common machine faults.• Routine maintenance procedures as per company procedures.• Loading levels for accumulators.• Water pressures and spray bars distribution.• What is needed to process cabinet roller towels.• What types of problems met when setting up continuous processing operations, ie re-

threading of towels, cleaning the J box.• How to plan work, making the best use of resources available.

5.7


• Why it is important to identify any possible problems at the planning stage, and why they should be reported to the supervisor.

• How to make the best use of resources available.

Skills and techniquesAfter working their way through this Unit, candidates should have developed the following skills and techniques:• getting services, machinery, mobile equipment and supplies ready for use• keeping work areas and surfaces clear and clean• disposal of waste and spillages• selecting detergents and chemicals• operating the machine• cleaning, drying and rolling towels• securing, wrapping, polytubing, stacking and storing towels• loading and separating towels• identifying and dealing with unsatisfactory items• identifying and dealing with faults and hazards• passing items to the next process• briefing colleagues on what they must do and checking that they have understood their

brief• successfully carrying out supervisors' instructions, ensuring they have made

appropriate plans, identified any problems, obtained and acted on necessary advice for completion of the task.

Regulations, rules and guidelinesCandidates 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 COSHH (Control

of Substances Hazardous to Health).• Manufacturers' instructions.• Other legislation as necessary.

5.8


Workplace skillsCandidates should be able to:• Communicate effectively with colleagues and customers.• Comply with written instructions.• Complete forms, records and other documentation.• Keep accurate records.

About this learning and teaching packThis part of the learning and teaching pack is designed to help candidates 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• The ingredients for a successful wash process• The wash process• The continuous tunnel washer• Troubleshooting

Each section contains information and follow-up activities to help candidates apply what they have learned. At the end of each section there is a self-check questionnaire to help candidates check your knowledge and understanding so far. You should discuss their answers with them.

5.9


Evidence Requirements — (LDC4)In this Unit, the candidate will require to carry out the wash process using a washer extractor with knowledge of the following:• Checking the machine safety features prior to starting work.• Know what the common faults are that occur in the day-to-day running of the machine,

and how to stop the machine if this happens.• Know what chemicals and additives are used, and in which part of the process they are

used, and what the consequences are of mixing or using the wrong chemical in the wash.

• Understand what the care labels mean for the wash process, and know what wash process to use for different fabrics and materials.

• Know how the complete wash programme works and knows what is happening at each stage of the programme, this includes temperature, dip levels and correct weight loading.

• Know how to check the load has been classified correctly, the correct programme selected for washing, the load has been washed correctly and show how to deal with items that have not been washed satifactorily.

• Show what the different programmes are on the machine and know what type of material they would use them for.

• Show they know how to use the machine correctly.• Know how to unload the machine and pass on to the next stage.These tasks will be observed by recording the candidate’s practical and knowledge evidence of the Unit.

The minimum requirements are:• observing the candidate over two washing loads in machines of different types. The machinery requirements are a washer extractor of any size.

Evidence Requirements — (LDC5)In this Unit, the candidate will require to carry out the wash process using a CBW with knowledge of the following:• Checking the machine safety features prior to starting work.• Know what the common faults are that occur in the day-to-day running of the machine,

and how to stop the machine if this happens.• Know what chemicals and additives are used and in which part of the process they are


• Know what each compartment of the CBW does and at what stage in the process they relate to.

• Know how the machine loads and unloads.• Know what the safe entry procedure is for your CBW.• Show what the different programmes are on the machine and know what type of

material they would use them for.

5.10


• Show they know how to use the machine correctly.• Know how the complete wash programme works and knows what is happening at each

stage of the programme, this includes temperature, dip levels and correct weight loading.

• Know how the press works and that the items move to the next stage.These tasks will be observed by recording the candidate’s practical and knowledge evidence of the Unit.The minimum requirements are:• observing the candidate over at least two cycles of the CBW. The machinery requirements are a CBW of any size.

Evidence Requirements — (LDC6)In this Unit, the candidate will require to carry out the wash process for processing cabinet roller towels with knowledge of the following:• Checking the machine safety features prior to starting work.• Know what the common faults are that occur in the day-to-day running of the machine,

and how to stop the machine if this happens.• Know what chemicals and additives are used and in which part of the process they are


• Know how the complete wash programme works and knows what is happening at each stage of the programme, this includes temperature, dip levels and correct weight loading.

• Know how to check the towels have been prepared correctly, the correct programme selected for washing, the towels have been washed correctly and show how to deal with towels that have not been washed satisfactorily.

• Show what the different programmes are on the machine and know what type of material they would use them for.

• Show they know how to use the machine correctly.• Know how to unload the machine and pass on to the next stage.These tasks will be observed by recording the candidate’s practical and knowledge evidence of the Unit.

The minimum requirements are:• observing the candidate over two washing loads in the machine.

The machinery requirements are a washer of any size.


Finally, you should inform candidates that they will be formally assessed by an assessor once they have completed these Units.

5.11


Suggested answers: Health and safety and maintenance procedures

Activity 1

1 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 pressureReportable high steam pressure

Local answers

Activity 2

You are washing the last load of your shift. What would you do if you noticed that the chemical dosing pumps were not working?Inform your supervisor and see if you can get the pumps working — it might only be a fuse or power failure. If not, call the engineer.

Activity 3

What special clothing or other personal protective equipment would you expect to use during a day working in the washroom?Apron, mask, gloves and overalls.

Activity 4

5.12 G8C8 22 — Laundry Operations Level 2

1 What are the safety features built into the washing machines in your laundry?

2 How would you check that these are working?The safety features are the door interlock, the master power switch and the out of balance switch.• If the door interlock is working, the machine will not start.• The master power switch must be on for the machine to start.• The out of balance switch will show when the incorrect load

weight is in the machine, and it goes into a spin.

Activity 5

1 What faults might you find on fabric movement equipment (such as trucks or trolleys) in the washroom?• Wheels missing or jamming — if metal they might be loose.• Sharp pieces of metal, which could damage the linen or the

operator. Ensure that they are clean and, if painted, that they are not rusting.

2 What health and safety precautions should you take when handling soiled fabric items?You should be wearing the approved PPE — ie gloves, mask, apron, overalls and long gauntlet gloves that can be washed. The items should be handled as little as possible to avoid the risk of infection.


Self-check questionnaireUse 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?Shut down the machine and inform the supervisor.

2 If you deem it safe to put the fire out, what do you do first?Ensure that the electricity is switched off.

3 Which extinguisher do you use to put out a motor fire?Powder.

4 Which is the nearest fire exit?Local answer.

5 How do you minimise manual handling injury when loading/unloading a washer extractor?• Use spring loaded trolleys if available. If not, do not lift

too much at a time.• When unloading the machines, loosen the items from

the side of the drum before starting to unload.

6 You get a tingle when you press the start button of the washer extractor. What does this tell you?That there is an electrical fault in the machine.

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?Ensure that the power is switched off before administering first aid.

8 You spill detergent powder into a large puddle of water over the floor. How do you make the area safe?Isolate the area by using the chemical spill kit (which hardens the powder) then lift up and dispose of safely.

.


Suggested answers: The ingredients for a successful wash process

Activity 6

1 Find out what your laundry’s raw water hardness is.

2 What level is it softened to?

Water hardness before softeningWater hardness after softening

Local answers.

Activity 7

Obtain information about the following washer extractor wash processes in your laundry and complete this table.

Textile Soiling 1st wash temperature

2nd wash temperatureWhite

cottonProtein

White cotton

Mineral Oil

Local answers.


Activity 8

1 Detail the types and number of washing machines you have in your laundry.

Machine type NumberCBW

Open Pocket W/ex

Y Pocket W/ex

D Pocket W/ex

Local answers.2 Select a washer extractor in your washroom and find out what

weight of load would be selected for the following classification.

Name of machineDrum design Open

pocketY pocket D pocket

Maximum loading capacity

Item Loading weightPolycotton sheets

Duvets

Cotton towels

Polycotton workwear

Local answers.


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

Local answers.2 What are the five main ingredients of a fully built detergent?

• soapless detergents• alkalis• soil suspension agents• polyphosphates• optical brightening agents (OBA)

3 What bleach do you use in your laundry and at what temperature is the bleach process carried out?Local answer.


Self-check questionnaireUse this self-check questionnaire to make sure that you now know all there is to know about the ingredients for a successful wash process.


1 At the start of each shift, what would you look for?• Ensure that there are no obvious reasons why you should

not turn the machine on.• Check for messages or notes from the previous shift

about breakdowns or faults.• Check that there are no warning signs from the

engineering department, or evidence that there is work in progress.

2 What would happen to the washer extractors if the steam pressure drops? The machines will not operate properly, or will stop altogether.

3 What are the main causes of the water pressure dropping?Pump failure, or empty storage tanks.

4 What are the consequences of the dip levels not being at the correct levels for washing?• A high dip on a wash will result in poor quality. Reducing

the detergent concentration and reducing the wash action gives a better finish.A low dip level on rinses will result in poor rinsing and increased re-wash (due to detergent retention), yellowing of white work and skin contact reaction in the finishing department.

5 What action should you take at the end of your shift in the laundry?• Sweep the floor, empty the bins and clear away all debris.• Empty washer extractors as unwashed or partially washed

fabrics can be a fire risk if left.• Leave any messages about production requirements or

machine faults for the next shift.• If production finishes with you, all machines and

equipment must be left in a safe condition.


Self-check questionnaire (continued)6 What are the main elements of a wash process?

• mechanical action• temperature• chemical activity• time• water

7 What are the problems caused by hard water?Hard water:• destroys some of the detergent• can make loads feel greasy if soap is used• leads to scale build-up in washer extractors• leads to hard skin forming around greasy and oily soiling,

making it harder to remove• makes fabrics feel hard and harsh

8 Can you name the six critical wash temperatures?• 40 °C — protein set above this temperature.

Optimum temperature for enzyme activity.• 50 °C — maximum temperature for sodium

hypochlorite bleach use.• 65 °C — maximum temperature for thermal

disinfection (10 mins UK) — minimum temperature for hydrogen peroxide bleach use.

• 71 °C — thermal disinfection temperatures (three minutes).• 80 °C — minimum temperature for heavy mineral

oil removal.• 90 °C — minimum temperature for thermal

disinfection (most of Europe).9 What is the correct temperature for a pre-wash?

Below 40 °C — preferably 38 °C.

10 What are the three main factors that govern the mechanical action of a wash process?• design of machine• degree of loading• level of water

5.20


Self-check questionnaire (continued)11 What are the dangers of over-or underloading the machine?

• Overloading — mechanical action will be reduced by the restricted movement and drop of the linen, resulting in poor wash quality.

• Underloading — the work might be carried too high in the cage and will either drop late or not drop at all, therefore reducing the mechanical action.

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?Local answer.

5.21


Suggested answers: The wash process

Activity 10

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?• 2–3 mls/kg of dry weight work is used.• It is inactive below 60 °C and becomes fully active only

at temperatures above 80 °C.• It would go in on the main wash.

Activity 11

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 may wish to complete this process as a group exercise.

Operation Time Dip °C Temp Additions °C MinsWash (1) 8 Med 35 Detergent

Drain 1

Wash (2) 12 Low 80 Detergent

Cooldown 10 Med

Bleach rinse 7 Med 45 Hypochlorite

Drain 1

Rinse 3 High Cold

Drain 1

Rinse 3 High Cold

Extract 2

5.22


Activity 12

1 How do you start a loaded washer extractor on your standard used sheet programme?Local answer.

2 How do you programme your machine to achieve a standard towel wash?Local answer.

3 Follow a standard cycle on one of your washer extractors and note the times, temperatures and chemicals at each stage.

Step Step time Water temperature

ChemicalsWash (1)

Wash (2)

Drain

Rinse (1)

Drain

Interspin

Rinse (2)

Drain

Interspin

Rinse (3)

Drain

Final Extract

Total programme time

Local answer.

5.23


Self-check questionnaireUse this self-check questionnaire to make sure that you now know all there is to know about the wash process.


1 Explain what the following wash processes are and what they do? Wash 1As 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.Wash 2This 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.

5.24


Self-check questionnaire (continued)2 What are the functions of the rinses in the

process? Rinse 1The 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.)Rinses 2–3These 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.

3 What length of time should you allow for a 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.

4 Name another wash process.Coloured polycotton workwear.

5.25


Suggested answers: The continuous tunnel washer

Activity 13

1 Can you think of two of more health and safety risks associated with a continuous tunnel washer?

2 What procedures could be put in place to reduce these risks?

• All of the area should be caged off and machine guards put in place securely to prevent accidental injury.

• Water might leak from the machine. There should be a system in place to mop this up or cone the area off as soon as possible.

Activity 14

Find out what your laundry's raw water hardness is and what level it is

softened to: Water hardness before softening is: Local Answer

Water hardness after softening is: Local Answer

Activity 15

5.26


Obtain information about the following CTW wash processes in your laundry and complete this table. Local answers

Fabric type Soiling Pre-wash temperature

Main wash temperature

White cotton Protein

White cotton Mineral oil

Activity 16

Select a CTW in your washroom and find out what weight of load would be selected for the following classifications?

Machine name: Local answersMachine type: single skin/double skin/double-single skinMaximum loading capacity per compartment:

kg. Target water flow rate: cubic metre/hour

Classification Loading weight

Polycotton sheets

Duvets

Cotton towels

Polycotton workwear

5.27


Activity 17List the names of all the chemicals pumped into the CTWs in your laundry and detail what hazard warning symbol they have on the bag or drum eg corrosive, toxic, etc. Local answers

Product name Hazard warning

Activity 18

List the types and number of CTW machines you have in your laundry.

Local answers

Machine name Machine type (Single/Double skin)

Number of compartments

Load weight per compartment

Activity 19

5.28


What are the five main ingredients of a fully built powdered detergent?

1 Alkalis2 Carboxyl methylcellulose (CMC)

3 Sodium tripolyphosphate (STPP)4 Soap5 Enzymes

Activity 20

What bleach do you use in the laundry? Local answersInto which compartment is the bleach dosed?At what temperature is the bleach process carried out?

Activity 21

If you were to use hydrogen peroxide bleach instead of sodium hypochlorite in the CTW where would you add it?

Main wash zone

How much would you use per kg of dry weight work?

2 – 3 ml of bleach per kg of dry weight work

5.29


Activity 22Follow a standard cycle on one of your CTWs and note the cycle time, temperatures and chemicals at each compartment. Local answers

Machine cycle time: ........ Mins ........ Secs Classification ...................................Compartment number

Temp (°C)

Detergent (ml/g)

Alkali (ml/

Bleach (ml/g)

Sour (ml/g)

1

2

3

4

5

6

7

8

9

1011121314151617181920

5.30


Activity 23

The CTW appears to be holding for excessive periods and not processing the full amount of work required. Give three common possible reasons why it would go into hold.

1 Bags jamming, causing empty compartments

2 Blockages

3 Tumbler efficiency

Activity 24

Having identified the possible reasons for the CTW holding, what actions can you take to reduce the holding times?

1 If the bag gets stuck – and is not quickly ‘un-jammed’ – the CBW will assume a load has been discharged into the loading hopper and continue operating.

2 Blockages can also occur if the water levels in the washing machine are incorrectly set. If the water level is too high it is possible for larger items to ‘float’ over the compartment divider and then, with the regular oscillation of the CTW action, become entangled and cause a blockage.

3 There are a variety of reasons why tumblers may lose efficiency, ranging from low steam pressure to blocked air-intakes on heater batteries, blocked filters and lint screens, poorly fitting door seals, fans not functioning correctly and so on.

5.31


Activity 25How do you programme your machine to achieve a standard towel wash?

Local answer

Activity 26

Look at the illustration of the CTW. Assume that you are washing white cotton bedlinen, and that sodium hypochlorite is being dosed into section 8.

In the table below, write what temperatures you would set in sections 1, 3, 5 and 8 — bearing in mind what you have learned about wash process temperatures.

CTW section Selected temperature1 35/38

3 60

5 71/75

8 60

5.32


Activity 27

Find out what the steam pressure gauge on the main supply line to the CTW should read and at what high and low reading you should report a fault.

Normal steam pressure: Local answer

Reportable low steam pressure: Local

answer Reportable high steam pressure:

Local answer

Activity 28

What special clothing or other personal protective equipment would you expect to use during a day working in the washroom?

Shoes

Gloves

Goggles

Activity 29

What would you do if, while washing the last load of your shift, you noticed that the chemical dosing pumps were not working?

Stop the machine and inform your supervisor

5.33


Activity 30

What are the safety features built into the CTWs in your laundry?

Local answer

How would you check that these are working?

Local answer

Activity 31

If your laundry has a CTW, find out which design it is (single skin, twin skin or combined) and whether it transfers work at the top or bottom of the machine.

Machine nameDesign typeTransfers work at the

Local answer

5.34


Self-check questionnaireUse this self-check questionnaire to make sure that you now know all there is to know about the continuous tunnel washer.


1 To achieve a good wash quality, what do you have to control?You would have to control the following:• temperature• chemical action• cycle time• mechanical action• water flows in the same way that you would with a

washer extractorin the same way you would with a washer extractor

2 When would the following be added to the process• detergent?

pre-wash and main wash• bleach?

first rinse• starch?

final rinse3 Does the water flow have an effect on the mechanical action?

The water flow settings have no effect on mechanical action, but do have a major influence on wash and rinse quality. The flow meters are set following a calculation involving process time, loading factors and the manufacturer’s recommendation on water volume per kg processed.

4 What are cycle times set to achieve?Cycle times for the CTW are set to achieve required production targets. Consideration is also given to tumble dryer capacity and soil removal requirements.

Activity 16Can you think of any other problems and possible solutions?

Local answer

5.35


Self-check questionnaire (continued)5 Explain the process for the following:

LoadingThe automatic loading of a pre-weighed batch of linen into the hopper feeding is the first-stage compartment of the batch washer.At the beginning of the cycle, a signal is given to trigger the conveyor, or bag system, to discharge the load.This is then flushed in with a mixture of water and chemicals into the first compartment, commonly known as the wetting out compartment.Many tunnel washers have a larger volume first stage compartment to accommodate this.The washing action — either oscillatory or completely rotational — agitates the load during the process cycle.TransferAfter the pre-set time at each stage, the machine’s transfer sequence begins. This will only kick in once the machine senses that the water and temperature inside the machine are at the correct levels. The ‘extraction equipment ready’ signal will also be triggered.TransportAfter this, the machine control rotates the drum to transport the linen into the next compartment.When the machine is operating normally, the batch of work is transported to the extraction unit at the end of each cycle time. It is then immediately followed by a fresh load of soiled linen into the hopper/first compartment — hence the term continuous batch washer.

6 Why is it important to calculate the correct weight?Overloading can lead to a blockage.

To prevent overloading, it is essential that the correct weight is calculated for each classification of work. For example, a 50kg machine can process 50kg of 100 per cent cotton sheets, but the load must be reduced for blankets/polycotton, bulky items and 100 per cent polyester work.The weighing device(s) therefore needs to be checked regularly, and test weights should be kept for this very process.

5.36


5.37


Suggested answers: Troubleshooting

Activity 32

Can you think of any other problems and possible solutions?

Local answer

5.38


6


2GC8N 22


FN4D 04Tumble-dry

items (LDC7)

iii



6.16.16.26.26.26.3

Suggested answers: Tumble-dry itemsActivity 1Activity 2Activity 3Activity 4Activity 5Activity 6Activity 7Self-check questionnaire

6.56.56.66.66.76.86.86.9


IntroductionAbout this UnitThis Unit — Tumble-dry items (LDC7) — is designed to help candidates to prepare equipment and tumble-dry items. Their 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, the candidate must:• make machinery and equipment ready to use• carry out routine maintenance• 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• identify any problems that may arise• communicate with colleagues and check that they understand what work they must do• carry out the work as instructed

Key areas of knowledge and understandingThe Unit will help candidates develop the following key areas of knowledge and understanding:• Recognising faults and malfunctions and the action to take.• 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 prevent spontaneous combustion.• Which hazards are associated with the tumble-drying process, eg spontaneous

combustion.• 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.• How to make the best use of resources available.• Carry out routine maintenance as per company procedures.

6.2


Skills and techniquesAfter working their way through the Unit, candidates 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• communicate with colleagues on what they must do and check that they have

understood their brief


Substances Hazardous to Health (COSHH)• Manufacturer’s instructions

Workplace SkillsCandidates should be able to:• Communicate effectively with colleagues and customers• Comply with written instructions• Keep accurate records

6.3



It has one section:• Tumble-dry items.

This section contains information and follow-up activities to help candidates apply what they have learned. At the end of this section there is a self-check questionnaire to help them check their knowledge and understanding so far. You should check their answers with them.

Evidence RequirementsIn this Unit, the candidate will require to carry out the tumble-drying process for work coming from a washer with knowledge of the following:• Checking the machine safety features prior to starting work.• Know what the common faults are that occur in the day-to-day running of the

machine, and how to stop the machine if this happens.• Show what the different programmes are on the machine, and know what type of

material they would use them for.• Know the drying requirements of at least three different fabrics/materials.• Understand how different fabrics/materials react in the tumble-dryer.• Know what spontaneous combustion is and how to prevent this from occuring.• Know how the tumble-drying process works.• Know the hazards associated with the tumble-drying process.• Know what the care label instructions mean for the tumble-drying process.These tasks will be observed by recording the candidate’s practical and knowledge evidence of the Unit.

The minimum requirements are:• observing the candidate over two drying loads of different fabrics/materials in the

machine.

The machinery requirement is a tumble-dryer of any size.



6.4


6.5


Suggested answers: Tumble-dry items

Activity 1

1 How do you check that the door interlock on your tumble-dryer is operating correctly?

The drum should stop rotating when the door is opened.

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?

Step one – always programme a cool-down period on the end of a fully dried classification in the dryer.Step two – always cool-down work before transferring it to a barrow/trolley, otherwise heat can be trapped in the centre of the load and this can start a chemical reaction and, ultimately a fire.

Activity 2

1 Give two reasons why a cool-down stage may be necessary at the end of the drying cycle in a tumble-dryer.• To prevent spontaneous combustion.• Drying polyester cotton should always be followed by a

cool-down to prevent hot garments being compressed in the dryer. This results in settings pressure creasing.

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?

Because there has been no cool-down set, it should be put onto a cool-down programme. The outer valves should be checked to see if they are functioning correctly.

6.6


Activity 3

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

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

6.7


Activity 5

1 Write a list of six items that would be fully dried in a tumble-dryer.

1 towels

2 polo shirts

3 duvet

4 sweatshirt

5 underwear

6 bath mats

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

1 bed sheets calender

2 pillowslip calender

3 duvet cover calender

4 table linen calender

5 overalls press

6 catering whites press

6.8


Activity 6

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

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

Local answers.

Self-check questionnaireUse this self-check questionnaire to make sure that you now know all that you need to know about tumble-drying items.


1 What are the different types of dryers, and what are the main features of each?

Batch tumbler — stand-alone machine that can be loaded and unloaded manually or automatically by a linked conveyor.

2 What are the different types of controls usually fitted to dryers?

• timer• thermostats• drum rotation speed or action

3 What is the dryer dependent on for efficiency?

Available air flow.

4 What is the purpose of the steam battery on a steam-heated dryer?

It acts like a radiator, and warms the air.

5 What is more energy efficient — proper extraction in a washer extractor or an extended drying time?Proper extraction in a washer extractor.

6 Who is responsible for cleaning filters, and how often should they be cleaned?The operator is responsible for cleaning the filters. They should be cleaned after every drying cycle.


Self-check questionnaire (continued)7 What is the purpose of the fans?

To draw the heated air through the load in the dryer.

8 What are the main problems of poor airflow?It affects the efficiency of the dryer. Items will therefore take longer to dry and more energy will be used.

9 Why is it important to load the dryer correctly?Because this is critical to air flow efficiency and effective drying.

10 Why is it important to remove hot items from the dryer and why is there a cool-down period?

To prevent spontaneous combustion.

11 What are the requirements for tumble-drying different types of items and fabrics?Cotton can be fully dried in the dryer. Polyester cotton can also be fully dried, but a cool-down stage is required to prevent pressure creasing.

12 What are the hazards associated with the tumble-drying process?• There is a risk of fire due to high temperatures.• The dryer and its surrounding area need to be kept

clean, or there will be a build-up of lint.• All metal surfaces and pipes can become very hot,

and should therefore be insulated to prevent burning.

7


2GC8N 22


FN4J 04 Press and finish garments following laundry (LDC8)

FN4E 04 Form-finish and inspect garments using

steam/air (LDC11)

ContentsIntroductionAbout these Units

Press and finish garments following laundry (LDC8) Key areas of knowledge and understandingSkills and techniquesForm-finish and inspect garments using steam/air (LDC11) Key areas of knowledge and understandingSkills and techniques

Regulations, rules and guidelines About this learning and teaching pack Evidence Requirements

7.17.17.17.27.27.27.37.37.47.4

Suggested answers: Health and safety and maintenance proceduresActivity 1Activity 2Self-check questionnaire

7.77.77.8

Suggested answers: Types of steam, types of press and foldingActivity 3Activity 4Activity 5Self-check questionnaire

7.117.117.117.12

Suggested answers: Finishing heat sensitive fabricsActivity 6Self-check questionnaire

7.157.16

Suggested answers: Press clothingSelf-check questionnaire 7.17

GC8N 22 — Laundry Operations Level 2 iii


IntroductionAbout these UnitsThe following two Units are designed to help candidates cover all that’s required for pressing and finishing garments:

• Press and finish garments following laundry (LDC8)• Form-finish and inspect garments using steam/air (LDC11)

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 (LDC8) Press and finish garments following laundryIn this Unit, the candidate’s role may involve:

• pressing garments and items on rotary presses, scissor presses, iron and rotary iron• inspecting pressed garments and items for quality


• make sure that equipment is safe and ready to use• select thermostat settings• press garments to the finishing specification• inspect and identify garments to ensure that they are pressed to company standards, ie

stains, repairs, creasing, shrinkage, etc• identify any that are not satisfactory• identify items that are not satisfactory and direct them to the appropriate locations

Key areas of knowledge and understandingThis Unit will help the candidate to develop the following key areas of knowledge and understanding:

• How to record throughput.• What services are required to make machines work.• How to identify and take action if safety mechanisms malfunction.• What the effects are of moisture in finishing.• How to interpret care labels.• Correct steam pressures.• Common faults and how to deal with them.• How different textiles respond to heat and pressure.• How to interpret the finishing specification.

vi GC8N 22 — Laundry Operations Level 2

• What are unacceptable levels of moisture retention.

7.2


Skills and techniquesAfter working their way through this Unit, the candidate should have developed the following skills and techniques:

• follow procedures to set up and close down machines• check that machinery and equipment is safe and ready• check and adjust the locking pressure on scissor presses as appropriate• evaluate the efficiency of the vacuum as appropriate• press items to the required standard of finish• check and redirect unsuitable items• select thermostat settings• inspect, identify and deal with unsatisfactory items• pass items for packing and dispatch

Unit (LDC11) Form-finish and inspect garments using steam/airIn this Unit, the candidate’s role may involve:

• planning the work to form and finish garments• forming, finishing and inspecting garments• inspecting garments to control quality


• make sure that equipment is safe and ready to use• select 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 garments on hangers• direct garments to the correct location for dispatch• communicate with colleagues so they understand what work they must do• identify any problems that may arise• take appropriate action with any faults in the process

Key areas of knowledge and understandingThis Unit will help candidates to develop the following key areas of knowledge and understanding:

• How to operate and control equipment.

7.3


• Care labels.

7.4


• 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 the hazards associated with steam and air finishing are.• 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.• The correct steam/air/humidification settings for automated finishing equipment.• How to make the best use of resources available.

Skills and techniquesAfter working their way through this Unit, candidates should have developed the following skills and techniques:

• checking that machine clothing and the equipment are safe and ready for use• checking that garments are suitable for steam/air processing• inspecting garments for faults and foreign objects• securing, straightening and clamping garments on the former• inspecting garments• making necessary adjustments to steam/air pressure, dependent on garment/fabric

requirements• identifying and redirecting unsatisfactory garments• unloading and hanging garments• directing garments for packing and dispatch• briefing colleagues on what they must do and checking that they have understood the

brief

Regulations, rules and guidelinesFor both Units, candidates 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.• Other legislation as necessary.

7.5



• Communicate effectively with colleagues and customers.• Comply with written instructions.• Compete forms, reports and other documentation.• Keep accurate records.

About this learning and teaching packThis part of the learning and teaching pack is designed to help candidates develop the knowledge and skills and generate the evidence required to pass both 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 candidates apply what they have learned. At the end of each section there is a self-check questionnaire to help them check their knowledge and understanding so far. You should discuss their answers with them.

Evidence Requirements — (LDC 8)In this Unit, the candidate will require to carry out the pressing of items using any one of the following machines, rotary press, scissors press, iron or rotary iron, for work coming from a washer or dryer with knowledge of the following:• Checking the machine safety features prior to starting work.• Know what the common faults are that occur in the day-to-day running of the machine,

and how to stop the machine if this happens.• Know what the moisture content should be for the different fabrics/materials to achieve

the best finish, and know the consequences of too much or too little moisture content in the fabric.

• Know what the different fabrics/materials are and how they react to pressing.• Know what the correct steam pressure is for the finishing equipment being used.• Know what faults can occur to different fabrics/materials in this process, and

how to counteract these.• Know how the finishing process works.• Know the hazards associated with the finishing process.• Know what the care label instructions mean for the finishing process.These tasks will be observed by recording the candidate’s practical and knowledge evidence of the Unit.

7.6


The minimum requirements are observing the candidate over at least an hour, and the finishing of differing fabrics/materials.

The machinery requirements are finishing equipment of any size.

Evidence Requirements — (LDC 11)In this Unit, the candidate will require to carry out the finishing process for items with knowledge of the following:• Checking the machine safety features prior to starting work.• Know what the common faults are that occur in the day-to-day running of the machine,

and how to stop the machine if this happens.• Know what moisture content should be for the different fabrics/materials to achieve

the best finish, and know the consequences of too much or too little moisture content in the fabric.

• Know what the different fabrics/materials are and how they react to pressing.• Know what the correct steam pressure is for the finishing equipment being used.• Know what faults can occur to different fabrics/materials in this process, and

how to counteract these.• Know how the finishing process works.• Know the hazards associated with the finishing process.• Know what the care label instructions mean for the finishing process.These tasks will be observed by recording the candidate’s practical and knowledge evidence of the Unit.

The minimum requirements are:• observing the candidate over at least one hour• the finishing of differing fabrics/materials

The machinery requirements are finishing equipment of any size.



7.6


7.7


Suggested answers: Health and safety and maintenance procedures

Activity 1

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?Place under cold, running water and seek first aid.

Activity 2

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.The ten things are as follows:• Shut down the steam valve.• Blow down the steam system.• Check guards are in place and fit for purpose.• Check that the bed padding quality is good.• Check that all safety features are working.• Check that work surfaces are clean.• Check that the area surrounding the press is clean and tidy to

prevent soiling and contamination.• Ensure that any items recently pressed are not stacked to

prevent fire.• Leave a memo for the next person explaining the priority of

work.• Ensure that all spray water valves are shut off.

7.8


Self-check questionnaireUse this self-check questionnaire to make sure that you now know all there is to know about health and safety and maintenance procedures.


1 List the health and safety precautions you need to take while working on the presses.• Guards must be in place to prevent burns to the

operator.• If any item becomes trapped, the operator must be aware

of the risks when they attempt to free the item.• Twin button controls on air-operated machines must

operate correctly.• The emergency release buttons on all machines must be

checked regularly.• Never leave items under a hot head press for longer than

is required to dry and finish.• Never stack items on top of a rotary press — this is a fire

risk.2 What are the causes of poor vacuum?

• Hard/consolidated clothing, restricted 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 angled bends in pipework.• Vacuum valves not opening fully.• Inefficient vacuum units.• Undersized vacuum units.

7.9


Self-check questionnaire (continued)3 How do you check the pressure on a press after adjustment?

• Stand in front of the press and — holding the bottom of the paper — place approximately two thirds of the sheet over the bottom buck.

• 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.

• 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.

• If the locking pressure is too light, little or no resistance will be felt as the paper is withdrawn.

4 What are the common mechanical faults on a press?• Press locking mechanisms.• Head checks/dampers.• Rapid head closure.• Leaking valves.

7.10


7.11


Suggested answers: Types of steam, types of press and folding

Activity 3

What is the most likely cause of protein staining on butcher’s aprons that should be removed before pressing?The wash process has been incorrect. The pre-wash may have been set at too high a temperature, therefore setting the stain in the garment.

Activity 4

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.Local answers.

Activity 5

What is the main reason for using a free steam press rather than a hot head press on temperature sensitive fabrics?It uses live, low-pressure steam, which is blown into and through the garment to simultaneously eradicate creases and shape the garment.


Self-check questionnaireUse 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.


1 Explain how you would press a white coat on the rotary press.• Lay collar and lapel.• Lay yolk of coat.• Open sleeves of coat and lay with outside uppermost.• Lay front of coat with corners of the table well into top part

of sleeve.• Lay side of coat with seam near to edge of table.• Lay back of coat.• Lay side of coat with seams on far edge of table.• Lay front of coat with corner of table well into the top part

of sleeve.2 Explain how a scissor press works.

The principles of this press are very similar to the rotary press with one difference — it has a fixed padded buck onto which a heated hot head is lowered and clamped onto the work in a scissor action.

3 What are the safety features on this type of press?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.

4 Why is moisture retention essential to the pressing process?Work for the Hoffman type press or garment folder could be totally dry, but work to be finished on a hot head press needs to be damp to ensure a quality finish.

5 Why should you look at the wash quality prior to commencing pressing? Before you begin pressing, you should examine the wash quality, paying particular attention to garment collars, cuffsand underarms for residual soiling. This will prevent rejection after pressing. Any staining should not be pressed before attempts are made to remove it by spotting and rewashing first. Any residual protein stains may be permanently set in by pressing at high temperature.


Self-check questionnaire (continued)6 Explain how the following work:

• Rotary PressThis has two padded bucks that rotate alternatively into position beneath the heated head. The buck is then lifted by air-operated rams to make contact with the steam- heated metal head of the press. This allows the operator to prepare work on one buck while the other is under the head.

• Hot Head PressThis 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.

• Cabinet unitThe padded buck is fitted vertically to the machine like a tailor’s dummy. The buck travels along a track and the front and back of the garment are pressed by two steam- heated heads the same shape as the buck.

• Hoffman pressThe free steam press uses live, low-pressure steam, which is blown onto and through the garment to simultaneously eradicate creases and shape the garment.


Suggested answers: Finishing heat sensitive fabrics

Activity 6

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 Reason for pressing

eg frilly edged pillowcase High quality finish required

1 Chef’s jackets A/A

2 Jacket/trousers A/A

3 Uniforms A/A


Self-check questionnaireUse this self-check questionnaire to make sure that you now know all there is to know about finishing heat sensitive fabrics.


1 Explain what fibre types cannot be pressed, and where they would be finished.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.

2 What are the temperature settings on an iron? And what is the temperature on a commercial laundry press?Iron — 110 °C, 150 °C or 200 °CPress — 150 °C

3 How would you press PVC?PVC is extremely heat-sensitive, and will soften and shrink at very low temperatures (ie 70 °C). Finishing is therefore not recommend.

4 How would you finish Modacrylic curtains?They should be removed from the laundry/dry cleaning machine after an adequate cool-down procedure, and hung on a hanger to stabilise.

5 How do you finish wool products?Care must be taken with wool because instability can arise from hygral expansion. This 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 may result in seam pucker and the appearance of bubbling on panels, which is not caused by interlining failure. When this happens, a minimum steaming should be given.


Suggested answers: Press clothing

Self-check questionnaireUse this self-check questionnaire to make sure that you now know all there is to know about press clothing.


1 How would you re-clothe the press?• copper gauze• knitted cotton padding (KCP) or synthetic alternative• canton flannel or synthetic alternative• outer cover

2 What materials are used?• Thick felts and lightweight synthetic foam pads provide

good resilience.• Silicone foam is expensive, but has good resilience. It is

very durable, and in the long term could prove to be very cost effective.

• Light/medium weight foam pads are 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 can adversely affect steam and vacuum times.

3 What must you do after you have re-clothed the press?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.

8


2GC8N 22


FN4L 04Process flat work through calenders

(LDC9)

iii



Suggested answers: Process flat work through calendersActivity 1Activity 2Activity 3Activity 4Activity 5Activity 6Activity 7Activity 8Activity 9Self-check questionnaire

8.18.18.28.28.38.3

8.58.58.68.68.78.78.78.88.88.9


IntroductionAbout this UnitThis Unit — Process flat work through calenders (LDC9) — is designed to help candidates prepare, plan and process flat work through calenders, and dry and finish flat work. Their role may involve:

• preparing flat work for calendering• drying and finishing flat work• planning the work required for calendering• preparing the calender


• check that machinery is safe and ready to use and that loads are suitable for calendering

• select the work required• adjust the machinery to suit the type of load you are to process• wax calender beds prior to calendering• operate machines correctly• load items onto feeder/calenders at the specified rate• identify items that do not satisfactorily meet company standards and direct them to the

appropriate locations• dry, iron and fold items as required• store items so they do not become contaminated• direct them to packing and dispatch• identify any problems that may arise in carrying out the work• check that colleagues understand what work they must do• report faults in the machine or in the finish of items


• What the risks are with calenders.• The machinery speeds and settings for different classifications, fibre types and

weights.• Care labels.• Understanding fibres and fabrics.• How to identify and report faults.• How to plan work, making the best use of resources available.• How to brief colleagues clearly.

8.2


• Why it is important to identify any possible problems at the planning stage and why you should report these to your supervisor.

• The specified feeding rate for loading items.• The drying and finishing specification.• How to make the best use of resources available.

Skills and techniquesAfter working their way through the Unit, candidates should have developed the following skills and techniques:

• start up and close down machines• check loads and redirect unsuitable items• adjust and operate machines• load, dry, iron and fold items• identify and deal with unsatisfactory items• identify common faults in machines or in the finish of items• store items and direct them for packing and dispatch• check belts, feedbands, tapes, and wax the beds as required



Substances Hazardous to Health (COSSH).• Manufacturers’ instructions.• Other legislation as necessary.



8.3



It has one section:• Process flat work through calenders

This section contains information and follow-up activities to help candidates apply what they have learned. At the end of the section there is a self-check questionnaire to help them check their knowledge and understanding so far. You should discuss their answers with them.

Evidence RequirementsIn this Unit, the candidate will require to carry out the calendering process for flat work with knowledge of the following:• Know the hazards associated with a calender.• Know the services required to make the machine work.• Know the speeds and settings for different classifications, fibre types and weights.• Know what faults can occur to different fabrics/materials in this process,

and how to counteract these.• Checking the machine safety features prior to starting work.• Know what the common faults are that can occur in the day-to-day running of

the machine, and how to stop the machine if this happens.• Know what the care label instructions mean for the finishing process.• Know how the calendering process works.


The minimum requirement is:• observing the candidate over the finishing of differing fabrics/materials for at least an

hour

The machinery requirements are calendering equipment of any size.



8.4


8.5


Suggested answers: Process flat work through calenders

Activity 1

List four health and safety checks that you should make before starting up the calender at the beginning of a shift.These are as follows:• Check that the emergency stop guard is in place to stop fingers

from being trapped.• Check that the drive mechanisms are covered by substantial

guards.• Check the metal plate underneath the base of the lead band.• Check that exposed heated metal parts and pipes are guarded

and lagged to prevent burns to the skin.

Activity 2

Label the various parts of the calender in this illustration.1 Roll bed2 Gap piece3 Folder4 Roller5 Feed bands

Activity 3

8.6


What two contributions do gap pieces make to successfully calendering a tablecloth?The two contributions are:• They improve the drying performance of the calender.• The items are slightly stretched.

Activity 4

Look at the steam gauges on the calender control panels in your plant, and record the steam pressure and bed temperature of each calender while they are operating.

Calender name or number

Steam pressure Bed temperature

Local answers.

8.7


Activity 5

What problems could be caused if fluff and lint are allowed to build up in the area around the calender?

Work could be contaminated.

Activity 6

1 List three quality problems that can result from washing sheets in hard water before calendering.These are as follows:• You might not be able to remove stains and soiling.• Re-desposition of soiling may also lead to greyness of

whites.• Hard water reduces rinse efficiency. This means that linen

will still contain detergent residues, and these will give whites a yellow tinge.

2 If the white sheets coming off the calender appear yellow and smell of chlorine, what would be the likely cause?This is probably due to the effect of the wash chemicals left in the fabric. It can only be rectified by rewashing with improved rinsing.

Activity 7

Write two things that a feeding machine or manual operative must do to a sheet to ensure that it enters the calender correctly.These are as follows:• apply sufficient back and side tension to ensure that the tail of

the article is pulled out flat as it enters the calendar• ensure that the item is fed perfectly square, and that even side

and tail tension is applied

Activity 8

8.8


List three ways of reducing static in polyester cotton sheets.These are as follows:• use a special anti-static bar• reduce bed temperature• develop special wash processes with reduced extraction and

fabric softener being added to the final rinse

Activity 9

List four possible causes for rewash at the end of the calender.These are as follows:• setting stains• galling or yellowing• creasing• rust spots

8.9


Self-check questionnaire

Use this self-check questionnaire to make sure that you know all that you need to know about processing flat work through calendars.


1 What is the object of calendering?• Work that is crease and wrinkle free.• Dry work.• Presented to the folder with straight edges and square

corners.2 Why is the wash process critical to the results achieved on a calender?

• If the process is carried out in hard water, then the effectiveness of the detergents is reduced, and it might not be possible to remove staining and soiling.

• Chemical damage can be caused to cotton fabrics by poor bleaching practice during this process.

• Producing good quality table linen from the calendar usually requires a good starching operation at the end of the wash process.

3 What damage to fabrics can be caused by the chemicals in calendering?• Chlorine bleach residues that have not been rinsed

out can cause white sheets to yellow.• Poor bleaching practice during the wash process can

discolour fabric.• Chlorine bleach retained on cotton fibres will result in

accelerated damage.4 What are the three main steps in the calendering process?

Ensure that:• the work is neither too dry or too wet• the item is fed straight to the rollers for the best

finish• the correct temperature is selected for the item to be

ironed5 What are the purposes of putting wax on a calender?

• To reduce the drag and hence the energy consumption.• To put an attractive sheen on the right (face) of table

linen.

8.10


Self-check questionnaire (continued)6 Describe the controls on a calender, and their purpose.

• the main stop/start control• the finer guard at the front of the machine• speed controller, calibrated in metres per minute• steam pressure gauge• ammeter showing the amount of electric current being

used

7 What changes are needed when pressing polyester cotton sheets instead of cotton ones?• The lower moisture retention of the fabric means that the

calender can be operated at a higher speed.• The bed temperature can be reduced to prevent over-

drying and the creation of static electricity.• An anti-static bar is fitted, because static electricity

causes these items to cling to the rollers.8 What is ‘galling’ and what causes it?

Galling is white work that comes off the calender with a yellowish tinge. This is probably caused by wash chemicals being left in the fabric.

9 What causes setting of protein stains? (from blood, urine, perspiration)Poor soiling and stain removal in the wash process.

10 Explain the different types of creasing in calendering, and their causes.• Diagonal creasing can be caused by the items not being

fed squarely into the calender, resulting in differential tension.

• Puckering can be caused by excessive static, cold spot or deposit build-up on the bed.

• Wine glass creases usually indicate that one or more of the rolls are over-clothed, and the linen is being nipped as it leaves the roll.

• Crows feet creases are usually a result of a wash process in polycotton that did not include an adequate cool-down stage.

8.11


Self-check questionnaire (continued)11 Explain what is meant by and causes the following in calendering:

skewness, tearing, deposits, cold spots and damp work?

• Skewness — if an item is fed squarely, and even side and tail tension are applied, the end result should be acceptable. If not, there might be a variation in roll diameter and, therefore, variable roll-to-bed contact pressure.

• Tearing — automatic feeders apply tension to the leading edge of the items, and if there are any weak points, tears may develop.

• Deposits — deposits on calender beds are usually caused by items being washed in hard water or starch build-up. Deposits need to be removed from beds and gap pieces.

• Cold spots — damp patches on processed items are usually caused by cold spots on the bed. These in turn are caused by blockages in the heat transfer system from roll to linen. If the roll bed pressure is uneven, this may result in a stripe of dampness.

• Damp work — if all the work starts to feel damp as it comes off the calender, it is either because the linen being fed is too wet or there is a problem with the calender bed temperature. Always check the temperature and speed dials against the usual settings.

12 What do you do to start up a calender (in the right order)?

• Check the machine to see that there are no obvious reasons not to switch it on.

• Check all guide tapes.• Check the finger guard.• Switch on the electricity.• Turn on the steam/gas.• Wax the calender (if appropriate for your machine).• Check steam pressure, bed temperature and the

ammeter against normal operating perameters.

8.12


9


2GC8N 22


FN4M 04Dry-finish and inspect garments using a tunnel finisher (LDC10)

iii



9.19.19.19.29.29.3

Suggested answers: Dry-finish and inspect garments using a tunnel finisherActivity 1Activity 2Activity 3Activity 4Activity 5Activity 6Activity 7Self-check questionnaire

9.59.59.69.69.79.79.89.9


IntroductionAbout this UnitThis Unit — Dry-finish and inspect garments using a tunnel finisher (LDC10) — is designed to help candidates dry and finish garments using a tunnel finisher. Their role may involve:

• drying and finishing garments• inspecting garments to control quality


• make sure that equipment is safe and ready to use• make sure that garments are suitable for tunnel finishing• check that garments are not damaged prior to finishing and that they do not contain

foreign objects• place garments on hangers• load them onto the delivery conveyor• dry them at the correct speed and temperature• inspect garments for satisfactory drying and direct them to the correct discharge rails• identify garments which are not satisfactory• report any faults in the process


• Appropriate speeds and drying temperatures.• Care labels.• Understanding fibres and fabrics.• The fire hazards presented by garments falling inside the tunnel finisher.• How faults in the process affect garment conditions and how to identify the faults.• The correct discharge rails for garments.

9.2



• checking that equipment is safe and ready, and hangers available• inspecting garments for those not suitable for the process and for foreign objects• loading and drying garments• inspecting garments and identifying and redirecting any with an unsatisfactory finish



Substances Hazardous to Health (COSHH).• Manufacturers’ instructions.• Other legislation as necessary.

Workplace skillsCandidates should be able to:• Communicate effectively with colleagues and customers.• Comply with written instructions.• Complete forms, reports and other documentation.• Keep accurate records.


It has one section:

• Dry-finish and inspect garments using a tunnel finisher.

This section contains information and follow-up activities to help candidates apply what they have learned. At the end of the section there is a self-check questionnaire to help them check theirr knowledge and understanding so far. You should discuss their answers with them.

9.3


Evidence RequirementsIn this Unit, the candidate will require to carry out the tunnel finishing process for the items with knowledge of the following:• Checking the machine safety features prior to starting work.• Know what the common faults are that occur in the day-to-day running of the machine,

and how to stop the machine if this happens.• Know what faults can occur to different fabrics/materials in this process, and how to

counteract these.• Know how the finishing process works.• Know the hazards associated with the finishing process.• Know how faults in the process affect garment conditions, and how to identify faults.• Know what the care label instructions mean for the finishing process.• Know what the fire hazards presented by garments falling inside the tunnel finisher.


The minimum requirements are• observing the candidate over the finishing of differing fabrics/materials, for at least an

hour

The machinery requirements are tunnel-finishing equipment of any size.



9.4


9.5


Suggested answers: Dry-finish and inspect garments using a tunnel finisher

Activity 1

List three ways of reducing the fire risk when operating a tunnel finisher.These are as follows:• Restrict the build-up of combustible materials in the tunnel.• Keep internal surfaces of the tunnel clear of lint, dust and other

materials.• Check for falling garments in the tunnel.

Activity 2Label the drawing of a tunnel finisher with the name of each zone.

EndZone (1) Zone (3) Zone (5)

Garments in

Zone (2) Zone (4)

Local answers.

Activity 3

9.6


1 Some laundries occasionally process temperature test strips attached to various parts of garments. Give two reasons why this is a good practice.These are as follows:• If the operating temperatures are allowed to exceed the

guidelines, then garments might start to feel harsh and whites might lose their brightness and appear off-white.

• Even more seriously, if temperatures are too high, there will be a risk of scorching garments and, potentially, a fire hazard.

2 To maintain customer satisfaction, which of the following tasks should be performed during a quality control check at the discharge end of a tunnel finisher? Put a tick alongside the tasks that you think are important.Repair identified. Machine faults recorded. Garments sent to the correct sorting rail. Garments are not damp. Finish quality is acceptable. Rewash identified. Fabric type recorded. Identify processing problems. Good garment colour quality.

Activity 4

After a garment is washed what needs to be done to it before it is tunnel finished? There is no point in the candidate processing garments that have not been washed to an acceptable standard — they will be rejected at the quality control point and returned for rewashing.

Activity 5

9.7


Activity 5

List three health and safety precautions you should take if you have to enter the tunnel finisher to retrieve fallen garments.The three precautions are as follows:• Check that all the steam and heat to the machine have been

switched off.• Inform your supervisor and workmates that you are about to

enter the tunnel.• Ensure that you remove the operating key to prevent accidental

machine start-up.

Activity 6

1 If your laundry has a tunnel finisher, what speed and at what temperature would you operate the machine for processing the following garments?

Type of tunnel finisher

Speed Temperature

Cotton coats

Polycotton coats

Cotton-rich ‘challenger’ coats

Local answers.2 If the tunnel finisher you were working on had all the lower steam

injection jets blocked, what effect would you expect this to have on the finish quality of a polycotton boiler suit?

The garment would not be given an even temperature and moisture content from the steam, and this could therefore cause shock to the material.

Activity 7

9.8 G8C8 22 — Laundry Operations Level 2

After considering the customer’s requirements and the laundry’s productivity, which workwear fabric would you recommend for the following garments? Indicate your choice with a tick.

Workwear garment

Polycotton light weight

Polycotton heavy weight

Polycotton cotton rich

Cotton 100%

Waiter’s shirt ✓Car mechanic’s boilersuit

✓

Chef’s Jacket ✓Food factory overall

✓

Welder’s boilersuit

✓


Self-check questionnaireUse this self-check questionnaire to make sure that you know all you need to know about dry-finishing and inspecting garments using a tunnel finisher.


1 What is the principle design of a tunnel finisher?The principal design characteristics of all tunnel finishers and steam cabinets are similar. The main difference between them is the length of the machine and the influence this has on how many garments they can finish per hour of operation.The garments are fed into the tunnel finisher on coathangers.

2 How is a tunnel finisher loaded?Manual loadingThis involves the operator in picking up a coathanger, placing it inside a garment, doing up the required number of press studs and then hanging the garment on the conveyor to be transported through the tunnel.Modern loading aidModern loading aids automatically present the loader with a hanger from a stock supply. The hanger is positioned at a convenient height for a garment to be placed around it, and the required fastenings to be closed. A loading button is pressed and the garment is transferred to a buffer storage conveyor, and a new hanger is then presented to the loader.

3 What is the buffer storage area?A buffer storage area allows continuous feeding to the tunnel during breaks in garment loading. These buffer zones usually take the form of a conveyor system between the loading station and the tunnel finisher, and use a nylonspiral such as Monoflex. The garments are transferred from the rotating nylon spiral to a moving chain, which transports the garments through the tunnel finisher.

9.10


Self-check questionnaire (continued)4 Name the zones in the tunnel finisher, and describe their function?

• The pre-heating zone — this is the first zone (on some models) where the garments are warmed with hot air. This section can help drying later in the process, and reduces the formation of condensation on the inside of the machine due to the rapid change in temperature.

• The steaming zone — garments then progress to this second zone where they are saturated very quickly by carefully aimed, free-steam jets. The combination of increased temperature and moisture content from large quantities of steam swells and relaxes the fabrics. The steam jets are positioned to provide total coverage of all garments from the smallest shirt to the longest boiler suit.

• The transitional zone — the third zone allows the moisture-laden fabric to relax, and the creases to flatten out.

• The drying zone — the garments then progress to the fourth zone where very hot air is blown down at a high velocity from the top of the tunnel. The force of this airflow blowing down the full length of the moving garments creates a strong smoothing action. It dries the garments and produces an acceptable finish for the customer.

5 How are the garments sorted?Manual sorting of garments by reading a label or using a key pad is very labour intensive, so to maintain productivity, many laundries have introduced sophisticated automatic sorting systems. A member of staff can be responsible for a full quality check on each garment before it is directed to the correct storage rail by using a bar code reader or other scanning equipment. These automated sorting systems are designed to keep pace with the productivity of the tunnel finisher.

6 What is the start up routine for a tunnel finisher?• The start-up routines for tunnel finishers will be different

for each machine, and your company’s training procedures will include detailed instructions on how best to carry out this task.

• To ensure efficient operation, check that accessible lint screens are clean and, as you turn the machine on, be aware of the steam pressure, tunnel temperature and conveyor speeds.

9.11


Self-check questionnaire (continued)7 What is the close down routine for a tunnel finisher?

• Closing down the tunnel finisher and associated feeding and sorting areas involves far more than just switching off machinery.

• All garments loaded onto coathangers should be allowed to pass through the tunnel finisher before close-down or they would air-dry on the hangers and this would result in a poor finish.

• Any garments left that have to be finished later should be covered down with polythene to retain moisture and prevent contamination from airborne fluff, lint and dust.

• Once all the garments have been passed through the tunnel finisher at the end of a shift or production run, it should be turned off and allowed to cool down.

• A number of garments often fall off hangers into the inside of the tunnel finisher, and these should be retrieved. This can be done in short tunnel finishers or steam cabinets by using a rod or stick with a hook on it. In large tunnel finishers, a member of staff will have to enter the machine.

• At the end of your shift clear away all debris and litter and brush and wipe down all surfaces. Any lint screens on the tunnel finisher should be cleared to maximise machine efficiency.

8 What Health and Safety implications are there on a tunnel finisher?• High temperatures in a confined space could lead to fires

— but restricting the build up of combustible material inside the tunnel keeps the level of risk low.

• The internal surfaces of the machine, lint screens, heater batteries, fans and ductwork must be kept clear of lint, dust and other debris.

• The possible causes of ignition can be removed by checking for fallen garments inside the machine, and checking pockets for combustible materials such as matches, cigarettes and lighters prior to washing or finishing.

9.12


10


2GC8N 22


FN45 04Maintain effective

working relationships at work (LDC25)

ContentsIntroductionAbout this UnitKey areas of knowledge and understanding Skills and techniquesRegulations, rules and guidelines Workplace skillsAbout this learning and teaching pack

10.110.110.210.210.210.3

Maintaining effective working relationshipsEffective working relationships Activity 1Activity 2Conduct in the workplace: Co-operation Activity 3Activity 4Activity 5Conduct in the workplace: Safety Activity 6Conduct in the workplace: Statutory requirements Activity 7Conduct in the workplace: Grievance and disciplinary procedures Activity 8Activity 9

10.710.910.9

10.1010.1010.1010.1110.1110.1110.1210.1210.1310.1310.14

Communicating effectively with others at workTypes of communication Activity 10Activity 11Communicating with colleagues, immediate managers and others Activity 12Listening, sharing and passing on information Activity 13Acting on instructions Activity 14Activity 15Self-check questionnaire

10.1510.1510.1610.1610.1610.1710.1710.1810.1810.1810.20

GC8N 22 — Laundry Operations Level 2iii


IntroductionAbout this UnitThis Unit — Maintain effective working relationships at work (LDC25) — is designed to help candidates to maintain effective working relationships and communicate effectively at work. The candidate’s role will involve:

• maintaining effective working relationships• communicating effectively with others at work

As a competent person the candidate must:

• work closely with colleagues and line managers• be co-operative and helpful in the workplace• share and pass on information to colleagues• keep colleagues and line managers informed of work activities and any problems• behave in an appropriate way at work• act upon instructions and information promptly• seek clarification from others when necessary• report to line managers and seek to minimise difficulties and problems

Key areas of knowledge and understandingThis Unit will help candidates to develop the following areas of knowledge and understanding:

• Their own roles and responsibilities.• The roles and responsibilities of colleagues, immediate managers and others in the

workplace.• Organisational rules for conduct at work.• The importance of effective working relationships.• The importance of identifying problems and following organisational procedures when

communications break down.• Organisational grievance and disciplinary procedures.• The types of information and instructions from immediate manager.• Agreed lines of communication and reporting procedures.• Types of communication difficulties in the workplace and the importance of seeking

help.• The importance of keeping managers informed and the types of information required.

10.2



• identify their own work role and work within the limitation of their responsibilities• maintain a co-operative and responsible manner with others to ensure efficient working• carry out work instructions from their line manager accurately and promptly• follow agreed codes of conduct and behaviour within their organisation• identify misunderstandings and problems and make efforts to resolve these• report any breakdown in working relationships that cannot be resolved promptly to

appropriate people• share work-related information promptly with colleagues and managers• use agreed lines of communication with colleagues and managers• communicate clearly and accurately in a way that is appropriate to the situation and

needs of others• identify problems with communication and seek to resolve these promptly• keep their immediate manager informed of matters affecting working practices and the

working environment following agreed procedures

Regulations, rules and guidelinesYour candidates should read and get to know the following regulations, rules and guidelines:

• The organisation's rules, codes, guidelines and standards.• Limits of personal responsibility.• Reporting procedures.• Grievance and disciplinary procedures.• Responsibilities under the Health and Safety at Work Act and COSHH (Control of

Substances Hazardous to Health).

Workplace skillsThe general workplace skills candidates will aquire through this SVQ have already been outlined in the general introduction. However, as a result of working through this Unit, they should also be able to:


10.3


About this learning and teaching packThis part of the learning and teaching pack is designed to help candidates develop the knowledge and skills and generate the evidence required to pass the Unit.

It is divided into two sections:

• Maintaining effective working relationships• Communicating effectively with others at work

Each section contains the information candidates need to know about a particular topic, while the associated activities give them the opportunity to apply what they have learned. The self-check questionnaire at the end of the Unit will test how much candidates have remembered and understood.

You should discuss the candidates’ results with them individually as they work through the Unit. This will help both you and the candidates to identify their strengths and weaknesses, and will be a firm basis for their self-evaluation and assessment.

Gathering evidenceWhilst the Unit works through the various requirements for skills and knowledge, candidates should be encouraged to take a holistic approach to assessment whenever possible, and to take some responsibility for producing their own evidence.

This Unit is more conceptual and less task-based than many other Units and can therefore be more challenging to assess. It is likely to require a more imaginative approach in order to provide the necessary verifiable evidence.

There are, however, various ways in which you can help candidates to provide the evidence for this Unit:

• Use the candidate pack to help the candidate to understand how to apply the information and activities to situations in the workplace, and consider where and what types of evidence can be found or produced there.

• Candidates could collect some of their own evidence — eg they could note down examples of when they were being co-operative and helpful or how they kept colleagues and line managers informed of work activities or problems in a work log or diary. These could then be counter-signed by line managers or experienced colleagues/witnesses.

• Give candidates simple 'what if' scenarios to help them to appreciate how they can contribute in a broad sense to their workplace, how the workplace influences their development, and the consequences of not acting or behaving appropriately. The scenarios can then be discussed with the candidate, either one-to-one, or as a group. For example:

You become really proficient in part of your job, and develop a way of achieving the outcome more speedily and safely than before. Your line manager asks if you can show your colleagues how to do this by putting on a short demonstration. How would you do this?

10.4


When you left school you were quite shy and not too confident in reading or writing; you tried to avoid talking to people you didn't know very well. Through work you have found that this has all become easier. You are treated with respect, as an adult, and as someone who works hard and knows their job. How/why do you think these changes might have happened?

You get a complaint from a customer but don't tell anyone, even though, according to company policy, you should tell your line manager. What could happen as a result of this?

These are just examples to help you and your candidates to generate ideas for getting the necessary evidence to complement the activities in the candidate pack. You will be able to devise many others using your own experience.

Evidence RequirementsThis pack will help candidates to develop the specific knowledge and skills that they require to achieve the Unit. As the assessor, you will be able to gather some evidence of the candidate's knowledge and skills by observing them as they work through the activities in the Unit. However, the activities should also be used to help candidates to understand how to generate some of their own evidence during their everyday work activities whenever this is possible and practicable.

In this Unit, candidates will be required to demonstrate that they can maintain effective working relationships and communicate effectively with others at work by showing theoretical and practical knowledge and understanding of the following:

• The importance of effective working relationships at work.• Their personal role/s at work and the limitation of their own responsibilities.• The roles and responsibilities of colleagues, immediate line managers and others.• The importance of co-operation and how to co-operate with colleagues and line

managers.• The company's rules for conduct and behaviour at work; where to find and how to use

them.• Grievance procedures and how to use them.• Identification of misunderstandings and/or communication problems and how to resolve

them.• Different types of communication and when they may be required.• The importance of clarity in communication and of seeking help when there are difficulties.• Sharing and passing information to colleagues efficiently and effectively.• Using agreed lines of communication and reporting procedures.• Keeping accurate records.• The importance of keeping managers informed and the type of information they need.• Communicating clearly and accurately in a way that is appropriate to the situation and

needs of the recipient.

There is no time limit for the completion of this Unit.

10.5


Assessment can involve a range of different or combined assessment methods. Some of the most commonly-used methods are observation checklists which record the candidate's practical skills and knowledge and provide evidence for the Unit. Assessment evidence may also include personal statements and witness testimonies. Questioning can be used both for assessment and for the authentication of evidence.

You should tell candidates what the Evidence Requirements are for the Unit and remind them that they will be formally assessed by an assessor once they have completed the Unit.

Please note that the answers provided in this tutor pack are for guidance only as it is recognised that acceptable answers, like the processes and procedures of different organisations, will vary.

Simulation will not be allowed for any part of this Unit.

10.6


10.7


Maintaining effective workingrelationships at work (LDC25)About this learning and teaching packThis tutor pack is designed for you to help candidates to develop their knowledge and skills and gather the evidence they need to pass this Unit. It is not exhaustive and tutors are encouraged to use their own experience and ideas for generating evidence or enhancing it in different ways.

It is divided into two sections and has activity sheets and an end of Unit self-check questionnaire.

Maintaining effective working relationshipsEffective working relationships

• Personal roles at work and the limits of the candidate's own responsibilities.• The roles and responsibilities of colleagues, immediate line managers and others.

Conduct in the workplace: Co-operation

• The importance of co-operation and how to co-operate with colleagues and line managers.

• The company's rules for conduct and behaviour at work; where to find and how to use them.

Conduct in the workplace: Safety

Conduct in the workplace: Statutory requirements

Conduct in the workplace: Grievance and disciplinary procedures

• Grievance procedures and how to use them:— Raising a grievance— Writing to your employer— Meeting with your employer— Appeals

• The importance of effective working relationships at work.

Communicating effectively with others at workTypes of communication• Different types of communication and when they may be required.• Keeping accurate records; completing any 'official' or other paperwork accurately/as

required by management.

10.8


Communicating with colleagues, immediate managers and others• The importance of clarity in communication and of seeking help when there are

difficulties.— Tone of voice

— Body language

Listening, sharing and passing on information

• Sharing and passing information to colleagues efficiently and effectively.• The importance of keeping managers informed and the type of information they need.• Using agreed lines of communication and reporting procedures.

Acting on instructions• Identification of misunderstandings and problems and how to resolve them.

Activity sheets and end of Unit self-check questionnaireThe first two sections contain information and follow-up activities to help your candidates to apply what they have learned. At the end there is a self-check questionnaire to help them and you to check their knowledge and understanding of the Unit content. You should discuss their answers with them after they have completed the questionnaire.

You can provide additional activities for individual candidates or groups where these are needed.

10.9


Maintaining effective workingrelationshipsEffective working relationships

Activity 1

1 What are your work roles and responsibilities? What can you do and what can't you do?• Refer to job description• Possible additional duties not included in job description• Local answer

2 How can you find out what the roles and responsibilities are of colleagues, immediate managers and others in the workplace?• Local answer

3 Name the people who you work with on a daily basis:a)give their job titles and a brief outline of what they dob)explain where they work in the company, and why they do what

they do in relation to your workc) identify lines of communication and reporting procedures

• Local answer4 Make a list of your roles and responsibilities that overlap with

those of your colleagues.• Local answer

Activity 2

1 Give a brief description of what happens before and after what you do at work and why.• Local answer

2 Explain how your work fits in and contributes as part of the process, and the end product or service.• Local answer


Conduct in the workplace: Co-operation

Activity 3

Try to work on this activity in a group or with a colleague.

1 Give two examples of how you work together with a colleague or colleagues.• Local answer

2 Explain how this makes the work easier and more efficient.• Local answer

Activity 4

1 Give five examples of how you can volunteer to help in the workplace.• Local answers• Helping to clear up without being asked• Working overtime or over holiday periods• Helping someone out who is struggling with a difficult task• Cover someone's shift if they are taken ill or have an

emergency at home• Take time to explain a new practice to a colleague

2 Give two examples of help you might give (or have already given) to new or existing colleagues.• Local answers


Activity 5

1 Where at work can you find the company's rules for conduct at work? (These might be found in documents such as company codes — eg codes of conduct, organisational guidelines, or standards.)• Local answer

2 Discuss how you might overcome the problem of working with someone who often seems bad-tempered.• Ask him/her quietly and in private if there is a problem with

any aspect of your work.• If the behaviour continues and affects your own work, speak

privately to your supervisor about it.3 What strategies might help in building and maintaining an effective

working relationship with him/her?• Show him/her that you are willing to work hard, do your best

and be part of the team.• Be friendly — try to spend some time talking to him/her at tea

breaks or in the lunch hour to get to know them better.• Be patient — it might take a while to gain his/her trust and

respect.

Conduct in the workplace: Safety

Activity 6

1 Identify warning notices in your workplace and discuss whether they are easy to see/hear/understand.• Local answer

2 If you think it's necessary, can you suggest how they might be improved?• Local answer


Conduct in the workplace: Statutory requirements

Activity 7

1 At your workplace you become friendly with an Asian colleague. One day someone from a different department is particularly abusive to her, making racist remarks.• Try to find out from the person why they are making such

remarks.• Make it very clear that you find the remarks offensive and that

this behaviour is against the law.• If it persists you may have to report the person to your

supervisor or trade union representative.2 Most of the young men spend the lunch hour playing football. You

have never enjoyed the game and refuse to join in, so they call you names and make fun of you all the time.• Ask them if they want to join you with what you are doing

— eg how about a game of cards or darts instead?• Treat it as good-natured banter, and tell them you have other

things to do with your time.• Ignore them unless the behaviour escalates into bullying; if

this happens discuss the situation with your supervisor or trade union representative.

3 You are a young man and usually enjoy work but there is one department where you work which employs mainly women. Sometimes you are asked to take a message to the department's manager there, but as soon as you go in, the women start to shout comments at you. Some of the comments are amusing but some are embarrassing.• Explain how you feel to the women who are taking the joke too

far and discuss their motives with them.• Go into the department with a colleague.• Treat it as good-natured banter.• Ignore them unless the behaviour escalates into bullying; if

this happens discuss the situation with your supervisor or trade union representative.



4 Although everyone is friendly at work, jokes are often made about people's ethnic background and religion. You feel uncomfortable when these jokes are told.• Explain that like any other comments, jokes which make fun of

ethnic minorities or other religions can cause offence — even if none is intended. They can also lead to bad feeling and behaviour which can lead to harassment, bullying, and even grievance or disciplinary proceedings.

5 There is one area at work where there are lots of 'pin-up' pictures which you find offensive.• Talk to the people who put the pictures there, and explain why

you find them offensive. If they don't take you seriously and remove them, or if you feel too intimidated to speak to them, discuss the situation with your supervisor or trade union representative.

6 A person at work refers to you as 'love', 'honey', sweetie' or darling', whenever they ask you to do something.• Tell the person that you'd like them to call you by your real

name.

Conduct in the workplace: Grievance and disciplinary procedures

Activity 8

1 Where can you find the organisation's grievance and disciplinary procedures?• Local answer

2 What are they?• Local answer

3 Who would you refer to in the first instance if you had a grievance?• Local answer


Activity 9

1 Give three reasons why it is important to have effective working relationships at work.• Improves efficiency, productivity and profitability of business• Improves individual and group work satisfaction — creates a

more pleasant working environment for everyone• Effective communication can contribute to health and safety at

work2 Give three examples of what might happen if relationships

between working colleagues are poor.• Reduction in co-operative working and helping others• Reduction in general efficiency; duplication of effort• Unpleasant working atmosphere; lack of trust in colleagues


Communicating effectively with others at work

Types of communication

Activity 10

1 Make a list of the different types of written communication you see, give or receive in your workplace over a one-week period.• Local answer

2 Note whether the examples you have seen:a)directly affect youb)are clear and easy to understandc) have diagrams and/or technical jargon that you need to have explained

d)use special words (terms), initials (eg COSHH) or acronyms (eg AIDS) which don't have an explanation or which you don't understand• Local answer

3 Who would you speak to about any difficulties you have with understanding or dealing with any of the communications?

4 Produce any examples you may have of written records you are required to keep and explain why they are needed.• Local answer


Activity 11

1 Identify five rules and/or instructions from your workplace and describe:a)how each affected how you behaved

• Local answerb)how each made you feel

• Local answer2 As a group, discuss how rules and instructions can affect how you

work both positively and negatively.• Local answer

Communicating with colleagues, immediate managers and others

Activity 12

1 Working as a group, see how many ways you could say the following phrases, how your body language affects how you say something, and what the effect on other people might be:

a)Are you leaving early again tonight, Mary?b)You're so cleverc) I don't know what you meand)Did you hear what Jack said?e)What has she been doing with that?f) Don't make me laughg)I love your hair!

• Local answerEncourage candidates to try giving the statements a positive and a negative emphasis

2 See which other phrases you can think of which might upset someone if said the wrong way.• Local answer


Listening, sharing and passing on information

Activity 13

1 Give five examples of information and instructions you get from your supervisor.• Local answers• How to carry out a procedure• Customer satisfaction/complaints• Working rotas• Changes in working systems• Health and safety issues

2 What problems might occur that need to be reported immediately to your supervisor?• Local answers• Health and safety issues• Illness — yourself or a work mate• Machinery fault• Problems at home that need urgent attention• Unexpected visitors

3 Give three types of information you might need to give your manager.• Time sheets• Ideas for improvement in working practices• Official documentation relating to health and safety• Letter of complaint• Letter of resignation


Acting on instructions

Activity 14

1 Who do you speak to on a regular basis?• Local answer

2 Who do you have to pass information/instructions on to?• Local answer

3 Who passes information/instructions on to you?• Local answer

4 Who is in your own 'reporting chain' and what is it for?• Local answer

Activity 15

1 Make a short list of 'golden rules' for yourself to help you communicate effectively in the following situations:

a)producing a written notice for social event• Make it attractive/colourful• Make sure all relevant information is included• Put it in a place where the maximum number of the right

people will see itb)writing a letter to your supervisor asking for information

• Check spellings, especially names• Make sure that your request for information is clear and

accuratec) arranging a shift change with a colleague

• Have a good reason for the shift change• Try to make sure that it is of advantage to both of you• Don't do it too often• Don't take advantage of good-natured people



d)explaining a problem to a customer• Make a note of what you have to say in advance, putting

everything in a logical order• Keep calm, maintain good eye contact, watch your body

language• Discuss the issue in a reasonable and constructive way• Give the customer the opportunity to have their say

e)asking for time off to visit the dentist• Find out who the correct person to ask is• Check company policy on this issue — local issue

2 Discuss these with your tutor and your group.


Self-check questionnaireUse this self-check questionnaire to make sure that you know all that you need to know about maintaining effective working relationships at work.

When you have finished, discuss the answers with your trainer.

1 Describe your own roles and responsibilities.• Local answer

2 Describe the roles and responsibilities of colleagues, immediate managers and others in the workplace.• Local answer

3 Where can you find the organisational rules for conduct at work? Give a brief summary of them.• Local answer

4 Give three reasons why it is important to develop and maintain effective working relationships.• To enable people to communicate and interact

successfully with colleagues• Successfully complete tasks• Work in an organised and timely way• Makes working environment more pleasant

5 Give three reasons why it is important to behave in an appropriate way at work.• Laundries and dry cleaning work places are environments

where accidents can be caused if you do not behave responsibly

• Laughing and joking with colleagues is fine — in the right place and at the right time, for example during breaks, but is not a good idea when working with machinery or chemicals

• Your behaviour to colleagues must be free from discrimination and harassment

• It is illegal to discriminate against anyone6 Why is it important to identify problems and follow

organisational procedures when communications break down?• The earlier problems are identified, the easier they are to

resolve, so deal with them straight away• Organisational procedures are designed to ensure that

everyone knows what to do in given situations — so that

10.21


there's no need to guess or panic


Self-check questionnaire (continued)Use this self-check questionnaire to make sure that you know all that you need to know about maintaining effective working relationships at work.


7 Give three examples of how you might help to avoid breakdowns in communications.• Try not to take offence too easily• Don't talk too much• Work at keeping good relationships with colleagues• Be polite• Keep a balance between work and personal affairs• Look, listen and learn• Effective communication works wonders• If you cannot resolve minor problems yourself, report

them to your line manager as soon as possible in order to minimise difficulties.

• Communicate accurately and clearly in a way that is appropriate to the situation and to the needs of others

Where can you find the company's grievance and disciplinary procedures?8 How might you proceed if you were angry or very unhappy about

something or someone at work?• Try resolving the grievance informally/formally• Local answerWhat types of information and instructions might you get from your

9 immediate manager?• Local answer• Health and safety• Working instructions• Shift patterns• Changes in working conditions• Use of new machineryWhat are the agreed lines of communication and reporting procedures in

10 your workplace?• Local answer


Self-check questionnaire (continued)Use this self-check questionnaire to make sure that you know all that you need to know about maintaining effective working relationships at work.


11 What types of communication difficulties might you find in the workplace? Give five examples.• Inability of someone to explain something properly• Someone might be a poor or inattentive listener• Complicated written information that is difficult to

understand• Lack of time to explain things properly — rushing can lead

to omitting pieces of information• People use unfamiliar words, phrases or abbreviations

which are not explained to newcomers12 Why is it important to seek help?

• To make sure you understand properly what is required of you

• Missing information could be necessary for your own protection or that of your colleagues

Who would you ask for help and why?• Local answer

· web viewtick the correct statements. washing above 40 c washing above 65 c for 10 minutes....

Documents