PortAventura World boosts its operational efficiency with a sustainable industrial laundry developed by Girbau

In this project, Girbau was responsible for planning, developing, equipping, and commissioning complete industrial laundry for PortAventura World, incorporating advanced technological systems and an approach focused on performance, process optimization, and sustainability. The project was designed as a turnkey solution, so the resort did not have to manage any phase separately, from planning to commissioning, thereby achieving its initial goal of having a fully integrated and ready-to-operate solution. To accomplish this, strategic consultancy throughout the entire process was combined with customized design, high-capacity machinery, and automation.

Before implementation, Girbau conducted technical tests at its factories to determine the best way to process 100% recycled and recyclable polyester garments, the type of clothing used at the resort, operating at lower-than-usual temperatures and controlling key aspects such as static and the final finish of the garments. In parallel, the engineering team designed the laundry in 3D, optimizing flows, safety, and scalability.

The industrial laundry integrates a complete high-capacity Girbau solution designed to ensure efficient, automated, and fully coordinated operation. In the washing area, a TBS-50/12 MULTI STEAMLESS washing tunnel was installed. This system operates without a steam boiler and uses hot water directly, reducing maintenance complexity while improving energy efficiency.

Alongside the tunnel, an SPR50 extraction press, ST industrial dryers, and high-capacity washers were installed, capable of processing large volumes of linen with maximum reliability. To increase tunnel efficiency, systems such as the MWB ZW50 were incorporated to recirculate water in the main wash module, together with the LINT ROTOR and EMS ROTOR systems, which filter wash and prewash water and reuse the heat from the filtered water for rinsing and neutralization processes, significantly reducing the energy required per kilogram of linen. In addition, the TB4 tank reuses already filtered and tempered water for washers that require cold water, optimizing overall water consumption.

In the finishing area, HX-E and HX-C heat recovery units were installed to capture energy from vapors and gases from the burners of the PC120 ironers in order to heat water, supplying all the energy required for the washing systems. The finishing process is completed through three fully integrated ironing lines—DRE, PC120, and FR—ensuring uniform and high-quality treatment of flat linen.

The installation was completed with logistics solutions such as overhead rail loading, enabling a connected ecosystem that minimizes manual intervention and optimizes resources. The facility has the capacity to process up to 15 tons per day and is prepared for future growth.

Sustainability was a central pillar of the project. PortAventura World, a BCorp-certified company, placed this criterion at the core of the laundry design. Thanks to the installed equipment, the plant achieves significant energy and water savings.

The TBS-50/12 MULTI STEAMLESS tunnel eliminates the need for a steam boiler, while the MWB ZW50 recirculates water from the main module, saving energy and ensuring optimal temperatures. The combination of LINT ROTOR and EMS ROTOR reuses filtered hot water, reducing the energy required to process each kilogram of linen, while the TB4 tank allows filtered water to be reused for washers that require cold water, lowering total water consumption. Meanwhile, HX-E and HX-C heat recovery systems capture residual energy from ironing vapors and gases to heat water, covering the entire energy demand of the washing systems.

This technological integration allows the laundry to operate efficiently, reliably, and sustainably, reducing water consumption by 35% and energy consumption by 25%, fully aligning with the resort’s environmental commitments.

Faced with the challenge of launching a completely new laundry at PortAventura World, Girbau provided a comprehensive 360º consultancy approach, supporting the client from the initial analysis through to commissioning.

A two-month theoretical and practical training plan was developed for the operators, designed in collaboration with the laundry management team. This was followed by a ramp-up process with on-site support to ensure the correct operation of the equipment and daily workflows.

In this way, the laundry began operations with full reliability, and the Girbau team remained as a constant support, ensuring the smooth operation of all processes. In a short period, an empty facility was transformed into a fully operational industrial plant.

Today, PortAventura World operates a fully functional Girbau industrial laundry, demonstrating how the integration of consultancy, automation, and sustainability can turn a laundry into a strategic asset in large-scale tourism operations.