In industrial laundry operations, tunnel washers, also known as continuous batch washers (CBWs), are the cornerstone of productivity.
For facilities managing high laundry volumes daily, such as hospitals, hospitality groups, or rental services, tunnel washers offer a highly controlled, scalable, and consistent cleaning process that improves efficiency while ensuring hygiene compliance.
As a result, the market for tunnel washers has grown steadily, projected to reach roughly $1.1 billion by 2030, at ~5.5% CAGR, driven by demand in healthcare and hospitality sectors for high-capacity, efficient laundry solutions
These systems are designed to process laundry in a continuous, linear flow through separate zones for prewash, wash, rinse, and extraction, minimizing handling, optimizing throughput, and reducing utility consumption per kilo of linen.
For industrial laundries seeking both speed and consistency, tunnel washers are indispensable. And the efficiency benefits extend beyond volume. Modern tunnel washers recycle water and energy between chambers through techniques like counterflow rinsing and heat recovery. As a result, they offer vastly lower water and energy usage per kilogram compared to traditional systems.
Take, for example, the latest generation of tunnel washers handling up to 110–130 lbs per load, with modular configurations of up to 12 sections. These machines offer:
These systems provide laundries not only with flexibility but also the operational capabilities they need to optimize their business and maximize profitability.
To unlock the full potential of a tunnel washer, it must operate in synergy with other key components: presses and dryers. Together, they form a Washing System—a continuous workflow that maximizes output while minimizing downtime, energy use, and labor requirements.
After the rinse stage in the tunnel washer, textiles move directly into a high-pressure press. These units reduce residual moisture dramatically — removing up to an extra half-gallon of water per load compared to conventional presses.
A well-optimized press cycle can contribute up to $30,000 in annual energy savings, depending on the laundry size and volume.
Once pressed, linen enters the drying phase—often a system’s bottleneck. But high-efficiency dryers today are designed to keep pace with tunnel output without sacrificing fabric quality.
Key features include infrared temperature sensors that monitor linen and end cycles precisely when dry, hot air recirculation systems that reclaim up to 80% of thermal energy, and tilted drum designs that automate unloading and reduce handling time.
Together, these features ensure that the drying process does not become the weak link in a high-speed tunnel system.
For professionals managing industrial-scale laundry operations, tunnel washers represent a practical and strategic solution: they offer unmatched throughput, resource efficiency, and consistent quality. As technology evolves, these systems will remain a smart investment for operations pursuing operational excellence and long-term value.
Explore how Girbau’s washing systems can empower your laundry facility to operate smarter, faster, and more efficiently.