soil sorting technology, the system automatically sorts the linen based on article category and wash program requirements, or other criteria set by the laundry’s operational needs. Sorted bags are then returned to the same storage area, but this time they are precisely organised and staged in front of the tunnel washer, fully prepared for the production line. This eliminates the need for operators to manually sort and move laundry in the early hours of the morning. When the next shift starts, production can start immediately since all laundry is already sorted and staged, enabling a continuous and efficient workflow with zero downtime. This automation improves operational speed and also reduces errors and variability, ensuring consistent quality in every batch.
Benefits of the Dark Factory approach
Implementing the Dark Factory approach brings a wide array of tangible benefits to industrial laundries looking to modernise and improve their operations. First and foremost, it significantly reduces dependence on manual labour for the sorting process and allows this task to be performed fully automatically at night, after normal working hours. This reduction directly lowers labour costs and decreases staffing-related issues such as operator absence and turnover. Through the targeted implementation of robotics, the approach addresses these staffing challenges while enabling a smarter use of existing infrastructure. This lowers the financial barrier to automation and makes robotic solutions available sooner. By fully automating sorting and storage,
laundries can extend their sorting capacity into a second or even third shift and consistently achieve their daily sorting goals. With a Dark Factory, a smaller robotic sorting system can handle the same production volume as larger systems and easily adapt to fluctuations in daily demand. This ensures a smooth start to the day with an organised and full production buffer for tunnel washers.
Soiled sort automation minimises human error, regardless of whether your linen is chipped or not, and improves process reliability and product quality. With continuous operation during extended hours, laundries can process higher volumes without interruptions or the need for costly facility expansions. The optimised workflow removes bottlenecks and increases efficiency, leading to a faster return on investment and helping laundries move closer to full automation while remaining competitive in the long term. Furthermore, if the storage for unsorted and sorted linen is large enough, you save floor space and reduce your linen inventory, which shortens the total lead time of your linen process.
Why choose our solution? The Jensen solution stands out in the laundry automation market because of its unique combination of patented technology and deep industry expertise. Unlike many competitors who offer partial or standalone automation components, our system integrates both primary and classified sorting processes into a single, seamless workflow. This integration is made possible by incorporating Inwatec’s industry-leading soil sorting technology, which ensures the
SUN UP: Sorted bags staged in front of the tunnel washer—ready for production at sunrise
highest accuracy and efficiency in classifying all types of textiles, whether chipped or not. With more than 170 Inwatec soil sort systems installed worldwide, our technology has been proven across diverse laundry operations, demonstrating reliability and superior performance. Jensen’s commitment to innovation means it continuously refines and improves its solutions to meet the evolving needs of industrial laundries. By choosing the Dark Factory system, customers gain access to cutting-edge technology and also partner with a market leader dedicated to driving the future of laundry automation. Jensen goes beyond supplying equipment by helping laundries revolutionise their soil side operations to achieve greater efficiency, cost savings, and scalability.
Dark Factory: The future of soiled sorting starts at night As the laundry industry evolves, embracing automation is no longer a luxury but a necessity to remain competitive and efficient. The Dark Factory concept offers laundries a way to overcome persistent labor challenges, increase production capacity, and improve operational reliability by automating critical overnight processes. By enabling a fully autonomous operation during hours when staff availability is limited, laundries can maximise their throughput and reduce costs while preparing themselves for a future dominated by smart, connected, and automated solutions.
SEAMLESS START: A seamless start in the morning sets the tone for happier, more productive shifts
The Dark Factory redefines what is possible in laundry operations, combining automation, innovation, and efficiency in one solution. It turns challenges into opportunities, giving laundries the power to run stronger, smarter, and faster than ever before. The future of automation doesn’t wait for daylight, it starts now.
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