Whether you’re designing a new laundry facility, renovating an existing plant, expanding operations, or installing new equipment, it’s crucial to approach layout and infrastructure planning strategically. A well-designed plant layout ensures smooth process flow, supports utility efficiency, and prepares your business for future growth.
Why Layout Planning Matters
In an ideal scenario, a new facility would begin as a blank slate. Architects and engineers would collaborate with the laundry operator to design a production environment optimized for current needs and long-term expansion. Unfortunately, most laundry projects fall into the categories of renovation or expansion—making them more complex due to the need to maintain ongoing operations during implementation.
At GA Braun, we understand these challenges and partner with clients to implement efficient, safe, and cost-effective equipment installation strategies. Our team helps design layouts that maintain production continuity while supporting strategic business objectives.
Common Challenges in Existing Facilities
Many healthcare, commercial, and industrial laundry operations function in older buildings with limited space and outdated layouts. Expansion often takes the form of patchwork additions, resulting in inefficient workflows and restricted equipment capacity.
We often find tunnel washers installed in building corners with no room for growth. These “jigsaw puzzle” layouts may solve short-term issues but can hinder long-term success. That’s why our approach emphasizes comprehensive design planning that includes:
- Space allocation for future equipment
- Optimal process flow
- Equipment flexibility
- Minimizing the need for future structural changes
Braun includes placeholders for future machines in layout renderings, helping clients visualize and prepare for scalable growth.
Key Design Considerations
Whether building new or renovating, every layout should support both current and future operations. Key planning elements include:
- Process Flow Optimization: Equipment should be arranged to minimize manual handling and support efficient material movement.
- Ceiling Height & AFF Clearance: Sufficient clearance is essential for monorail systems and overhead equipment.
- Utility Infrastructure: Design must support current equipment needs and future expansion in electrical, water, steam, and gas systems.
- Support Areas: Include dedicated spaces for chemical storage, linen storage, loading docks, office space, maintenance, employee facilities, and parking.
- Truck Access & Logistics: Ensure routes accommodate large transport and delivery vehicles.
Clients often approach us wanting to add equipment to boost production, but equipment alone may not solve underlying workflow issues. That’s why we begin by analyzing material flow, production metrics, and equipment interaction—often unlocking higher throughput without additional equipment.
Automation for Space and Labor Efficiency
Automation is key to improving efficiency and reducing labor costs in today’s competitive market. Braun has partnered with third-party rail providers for decades to implement automated solutions including:
- Monorail systems for tunnel and conventional washers
- Conveyors to reduce cart usage and manual handling
We’ve recently advanced this innovation with our patent-pending chute-loaded tunnel system dryer. This breakthrough allows automatic rail loading directly into the dryer via a static chute, reducing maintenance and mechanical complexity.
Benefits of chute-loaded dryers:
- Increased layout flexibility
- Reduced motion hazards
- Storage queue before dryers to eliminate scheduling delays
- Industry’s first true side-by-side dryer configuration, saving floor space
Strategic Planning and ROI
Successful laundry design is data-driven. Braun uses tracking tools and analytics to deliver turnkey projects that align with production goals and financial targets.
For example, in a recent healthcare laundry redesign, we proposed a strategic facility upgrade that improved production efficiency, reduced labor and utility costs, and modernized equipment. Here’s the return on investment breakdown:
- Estimated Project Cost: $898,032
- Annual Electrical Savings: $21,000
- BTW Maintenance Savings: $65,000
- Dryer Gas Savings: $10,819
- Ironer Gas Savings: $17,646
- Labor Savings: $279,864
- Total Annual Savings: $349,329
- ROI: 2.28 years
These results show how strategic facility planning and process optimization can deliver immediate and long-term value.
Why Partner with GA Braun
Braun has extensive experience in laundry plant renovations, new facility construction, automation integration, and high-efficiency equipment upgrades. Our project managers collaborate with your internal team, architects, contractors, and engineers to deliver scalable, cost-effective solutions—from concept to completion.
Let GA Braun help design your laundry operation for long-term growth, operational efficiency, and maximum ROI.