Troubleshooting Flatwork Ironers

Understanding and troubleshooting flatwork ironers (also known as a flatwork dry irons), is essential for any commercial and industrial laundry operations who dry and press large, flat linens as part of their usual laundry processes. If a flatwork ironer is breaking down regularly, or running inefficiently or inconsistently, it can throw off the entire laundry room’s productivity. These machines are designed to handle high volumes of fabric, eliminating the need for separate drying before ironing and they can be an amazing addition to a commercial laundry room, but they can also be a PITA if you’re not taking good care of them or using them properly!

Before we get into troubleshooting all the issues that can come up with flatwork dry irons, here’s a bit more about them.

Common Uses of a Flatwork Ironer:

Hotels & Resorts – Pressing and finishing bed linens, pillowcases, and tablecloths for a crisp, professional appearance.
Hospitals & Healthcare Facilities – Ensuring sanitized and wrinkle-free bed sheets, patient gowns, and surgical drapes.
Restaurants & Catering Businesses – Ironing napkins, table linens, and uniforms for a polished dining presentation.
Industrial & Commercial Laundries – Processing bulk linens and uniforms for various businesses, including spas and fitness centers.
Airlines & Cruise Ships – Preparing seat covers, table linens, and crew uniforms for a professional look.

Key Benefits of Using a Flatwork Dry Iron:

Saves Time & Labor – Linens are ironed directly from the washer without the need for separate drying.
High Efficiency – Processes large volumes quickly, improving workflow.
Consistent Quality – Provides a uniform, wrinkle-free finish.
Energy Efficient – Many models use steam or heated rollers to reduce drying time and energy consumption.

Flatwork ironers are essential in commercial laundry operations, but like any heavy-duty equipment, they can experience issues that affect performance and efficiency. Below, we’re going to get into the ins and outs of troubleshooting flatwork ironers with issues, causes, and possible solutions for each.

Common Issues Affecting Efficiency in Flatwork Ironers & Their Solutions

Haddon’s service technicians are called out for flatwork ironer issues regularly. Here are some of the most common issues we see come up, along with causes and solutions we have found for each.

Issue	Cause	Solution
Wrinkled or Creased Linens	Incorrect feeding, insufficient heat or pressure, uneven roller pressure	Train staff on proper feeding techniques, adjust temperature/pressure settings, check and calibrate roller alignment
Linens Not Drying Properly	High moisture content in fabrics, low heat settings, fast ironing speed	Adjust moisture extraction in washers, increase ironer temperature, reduce speed
Burn or Scorch Marks on Fabric	Excessive heat, prolonged contact time, wax buildup on rollers	Lower temperature, clean rollers regularly, use proper ironer settings for fabric type
Yellow or Brown Stains on Linens	Wax residue, mineral deposits, fabric overheating	Clean and maintain rollers, use distilled water, inspect detergent and chemical usage
Ironer Belt Wear or Breakage	Overuse, improper tension, poor maintenance	Regularly inspect and replace belts, maintain proper tension, schedule routine maintenance
Roller Malfunctions (Skipping or Jamming)	Worn bearings, misalignment, foreign objects in rollers	Inspect and replace bearings, align rollers, clear debris
Excessive Energy Consumption	Inefficient heating elements, worn-out insulation, improper speed settings	Upgrade to energy-efficient models, maintain insulation, optimize speed/temperature balance
Linen Sticking to Rollers	Wax buildup, insufficient lubrication, incorrect temperature	Regularly clean and reapply approved wax, maintain proper roller temperature
Steam Leaks or Insufficient Steam Production	Faulty valves, clogged steam lines, boiler issues	Inspect and replace steam valves, clean steam lines, check boiler pressure
Uneven Ironing or Pressure Issues	Misaligned or worn rollers, inconsistent air pressure	Adjust roller pressure, replace damaged components, ensure even air pressure distribution

Preventative Maintenance Tips for Flatwork Dry Irons:

Perform regular cleaning to remove wax, detergent, and mineral buildup.
Train your ironer operators to use proper feeding and tension techniques (see below for specifics).
Inspect belts, bearings, and rollers frequently for wear and misalignment.
Monitor temperature and speed settings to prevent damage to linens.
Schedule professional servicing to prevent costly breakdowns.

Troubleshooting a Jamming Flatwork Ironer

One of the most common issues we see coming up time and again is jammed flatwork ironers. Jams caused by operator error are easily preventable, while mechanical issues leading to jams need a service technician to come in and repair them.

If your flatwork ironer is jamming, it could be due to several factors, including misaligned rollers, worn bearings, fabric feeding errors, or foreign objects in the system.

Here’s a table outlining issues, causes and solutions for troubleshooting a jammed flatwork ironer:

Possible Cause	Solution
Incorrect Feeding or Overloading – If linens are not fed properly, they can bunch up and cause jams.	Train staff on correct feeding techniques. Make sure linens are laid flat and evenly distributed before entering the rollers. Avoid overloading.
Misaligned or Worn Rollers – If the rollers are out of alignment or damaged, linens may not pass through smoothly.	Check roller alignment and pressure settings. If rollers are uneven, adjust them per manufacturer guidelines. If worn out, replace the rollers.
Worn or Damaged Bearings – Bearings help the rollers move smoothly; if they are worn, the machine may jam.	Inspect and replace worn bearings. Listen for grinding noises, which indicate bad bearings.
Incorrect Feeding or Overloading – If linens are not fed properly, they can bunch up and cause jams.	Train staff on correct feeding techniques. Make sure linens are laid flat and evenly distributed before entering the rollers. Avoid overloading.
Foreign Objects in the Rollers – Small debris, like buttons, strings, or stuck fabric, can cause jams.	Turn off the machine and carefully inspect rollers for debris. Remove any obstructions before restarting.
Tension or Belt Issues – If belts are too tight or too loose, the machine may not pull fabric through evenly.	Check belt tension and condition. Adjust if too tight or loose and replace if frayed or broken.
Steam or Heat Imbalance – Uneven heating can cause some sections of fabric to stick, leading to jams.	Ensure steam and heat are evenly distributed. Clean steam valves and check for clogs.
Sensor or Motor Malfunctions – If the sensors or motor controlling the rollers fail, fabric movement may stop.	Test the motor and sensor systems. Reset the machine, and if the issue persists, consult a technician for repairs.

Troubleshooting Flatwork Ironer suggestions for jams:

Turn off and restart the machine to reset any error codes.
Check for obstructions and remove any stuck fabric or debris.
Adjust feeding technique to ensure linens are entering the rollers smoothly.

If the problem continues after these steps, you’ll need to call a service technician to inspect the motor, sensors, or roller mechanisms.

Key Features of Continental Girbau Flatwork Ironers

two different sizes of flatwork ironers made by continental girbau sitting side by side

Around here, the most common flatwork dry iron we sell is made by Continental Girbau, designed for commercial and industrial laundry operations. These machines are engineered to efficiently dry and press large volumes of flat linens, such as sheets and tablecloths, directly from the washer, eliminating the need for separate drying.

No-Wax Technology: These ironers utilize machined-steel cylinders that are mirror-polished and chrome-plated, eliminating the need for wax application and removal. This design reduces maintenance efforts and costs while preventing linen damage associated with wax contact. citeturn0search1
High Efficiency: Capable of processing linens at speeds up to 50 feet per minute, these ironers enhance productivity in medium- to high-volume laundry facilities. citeturn0search0
Durable Construction: Built with heavy-duty components, including multiple lateral bearings, these ironers ensure longevity and consistent performance under continuous use. citeturn0search1
User-Friendly Design: Features such as expanded feeding tables and metallic feeding trays facilitate efficient linen feeding and improved ironing results. Quick-release side panels and accessible lint drawers simplify maintenance tasks. citeturn0search1
Safety Measures: Equipped with emergency stop buttons, pressure-sensitive hand guards, and other safety features to protect operators during use. citeturn0search1

These ironers are available in various models with different roll diameters and finishing widths to accommodate diverse operational needs. If you need help troubleshooting a flatwork ironer or if you’re looking for the best size and type of flatwork dry iron for your facility, give Haddon a call today (or get in touch through our website) and one of our sales staff can give you the lowdown on the different flatwork irons available for your commercial laundry operation.