Dryer myths that drain your margin

If you run a laundry or dry cleaners, you feel the squeeze: labour, textiles, effluent and energy all pulling at margin per kilo.

Dryers sit right in the middle of that pressure. They’re often the least efficient stage, and the data-focused operators we speak to track kWh/kg because small changes here move the P&L.

Myth 1: “Hotter dries faster”

Turning the heat up sounds logical, but it often slows drying. High temperatures can seal fibres and reduce evaporation, so the dryer runs longer and risks scorching. Focus on airflow and controlled heat, not maximum heat. The Textile Services Association’s good-practice notes stress controls such as humidity/temperature sensing, vent recirculation and heat recovery rather than simply raising setpoints.

Fix: Keep setpoints within the machine’s recommended band and prioritise airflow (see Myth 5). If your dryers support infrared temperature or humidity control, enable and calibrate it.

Myth 2: “Run it until the load is bone-dry”

Over-drying wastes gas or power and shortens linen life. TSA guidance calls it out directly: avoid over-drying, only about a third of the energy added actually finishes the job once you push past “just dry”.

Fix: Dry to the requirement of the next step (e.g. “ironer-ready” rather than cupboard-dry). Use moisture sensing over fixed timers where possible.

Myth 3: “Extraction doesn’t move the needle”

It does. Every extra point of moisture left after the washer goes straight to dryer energy. Higher G-force dramatically lowers moisture retention (MR) before drying. Published figures show MR on 100% terry dropping from 98% at 100G to 64% at 400G.

Fix: Push your extract program and check actual MR by fabric class. Where ageing washers limit G-force, consider a staged spin or longer final extract on heavy cottons to take time and cost out of the dryer.

Myth 4: “Stuff the drum. Fullest loads give best efficiency”

Overloading chokes the airstream and tumbles rather than dries. Underloading wastes airflow. You want the “Goldilocks” fill that lets air travel through the load and lift/turn items.

Fix: Follow each dryer’s loading window by linen type. Track kWh/kg by load class; your best fill point will show up in the data. (Your peers measure kWh/kg and L/kg daily to drive decisions.)

Myth 5: “Filters once a day is enough”

Restricted airflow is the silent margin leak. Lint on screens and duct bends adds backpressure, lengthening cycles and lifting energy use; trade sources emphasise keeping air paths clear for productive drying. Lint accumulation is also a recognised fire risk in commercial laundry equipment. Keep filters and ducting on a documented clean schedule.

Fix: Clean lint screens every load or per batch, and schedule ductwork cleaning; many providers link clean ducts to lower energy use and reduced fire risk. Keep a simple airflow checklist on the wall.

Myth 6: “Timers are fine. Operators know best”

Timers make over-drying the default when product mix changes. Humidity or temperature-based control cuts this waste and stabilises quality. TSA specifically recommends humidity control and cool-down settings to avoid needless energy burn.

Fix: Move priority loads to sensor-controlled programs. Where you must use timers, shorten by a few minutes and train teams to check “just-dry” not “crispy”.

Myth 7: “Waste heat is just a by-product”

Dryers throw away valuable heat. Studies on commercial gas-fired tumble dryers show only about 55% of input energy goes into drying; exhaust gas recirculation and heat recovery can capture part of the rest. Heat‑recovery on suitable dryers can deliver meaningful reductions in energy use; actual outcomes depend on duty, machine design and controls.

Fix: Start simple: verify dampers and seals, then assess a basic exhaust heat exchanger or condenser. If volumes justify it, evaluate heat-pump recovery feeding back to process air or pre-heating incoming water. Keep a clear payback window for the board.

Myth 8: “Mixed loads are fine; they all dry the same”

Mixed fabrics and thicknesses extend cycle time to the slowest items, which hides in your averages and drags throughput.

Fix: Split by fabric and thickness where possible(e.g. terry vs. sheeting). Log cycle time and rewash by class to see the gain.

Quick actions this month

• Clean screens every load; book a duct inspection.
• Calibrate humidity/temperature control, trim timer programs.
• Lift extract G-force and re-check moisture retention by product.
• Baseline kWh/kg by dryer and load class; focus on the outliers.

Want to talk it through?

Get in touch and we’ll answer your questions about dryers, energy use and practical next steps for your site.