What are the disadvantages of microfiber mop?

Best practices for wipes and mops in cleanroom environments encourage the use of single-use disposable products. This approach minimizes the risk of cross-contamination and guarantees the removal of contaminants from the cleanroom environment at the conclusion of a session. However, many facilities opt to launder and reuse mops to potentially save on costs associated with single-use items.

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Even the smallest cleanroom facilities can spend tens of thousands of dollars on consumables annually. In larger facilities, this amount can reach hundreds of thousands of dollars. Transparency Market Research, a leading analytics and advisory service for Fortune 500 companies, indicates that the cleanroom consumables market is growing steadily, with a compound annual growth rate (CAGR) of 4.2%, projected to reach a valuation of $11.3 million by 2025.

It is crucial to consider whether reusing mops, particularly microfiber mops, could compromise the quality of consumables, thereby increasing the risk of environmental and product contamination.

What is Microfiber?

Microfiber textiles were introduced in the late 1950s. A microfiber is defined as a fiber with a thickness of less than 1 denier, a measurement indicating the fineness of individual fiber threads. Generally, the diameter of a microfiber is under 10 micrometers (µm). To illustrate, this is finer than the diameter of a silk strand and approximately one-fifth the thickness of human hair. These tiny fibers are used to create yarn, which can be knitted or woven into various fabric constructions. Microfiber fabrics can mainly be categorized into two types: split microfiber and straight filament microfiber.

Straight filament microfibers are primarily made from 100% polyester. In contrast, split microfiber comprises very fine threads of polyester and polyamide (nylon) amalgamated to form a singular thread. The nylon is utilized to bond the small fibers together, which are then split later in the manufacturing process. Split microfiber possesses many wedges, as opposed to the rounded threads in non-split yarns. These wedges enhance the ability to capture microscopic particles from surfaces. This expanded surface area, combined with the capillary action of the fine threads, significantly boosts the absorbent capacity and rate of microfiber wipes.

The Increased Use of Microfiber Mops

The superior absorbency of microfiber, along with its ability to pick up and trap small particles, has resulted in the growing adoption of these mops in cleanroom environments. Nevertheless, microfibers are less durable than standard filaments, leading to increased levels of fine particle contamination. To be feasible for cleanroom applications, microfiber is often laundered during manufacturing and before distribution and use, to lower contamination levels. However, this processing and the cost of the microfiber yarn itself mean that most cleanroom microfiber mops are too costly for single-use, necessitating laundering, re-sterilization, and reuse for cost-effectiveness. This process typically involves a contract with an external industrial laundry facility. If a sterile product is necessary, it may require an autoclave process or an irradiation provider.

The relaundering and, when applicable, re-sterilization of cleanroom mops carry risks. Microfiber is delicate and can easily be harmed by high heat or harsh chemicals, which can degrade a mop or wipe over time, affecting both its cleaning performance and absorbent capacity.

Risks of Relaundering Microfiber

The relaundering and re-sterilization process for cleanroom mops are fraught with risks. Microfiber is susceptible to damage from high temperatures or harsh chemicals, leading to the deterioration of mops or wipes over time and impairing their efficacy. Laundries utilize mechanical, thermal, and chemical processes during washing and drying, potentially causing irreversible damage to the fragile microfiber structure.

The properties that make a microfiber product an effective cleaning tool also contribute to their cleaning difficulty. The fine filaments and delicate fiber structure are intended to gather and retain dirt, organic matter, and microbes. Consequently, consistently removing these contaminants in each laundering cycle poses a significant challenge. Laundry facilities face a dilemma: expose the products to effective laundering conditions that could compromise the fibers’ cleaning efficiency or shield the products from degradation by minimizing harsh laundry conditions, consequently risking inadequate cleaning and disinfecting performance.

Contec Study

Contec’s Healthcare team investigated this dilemma in detail, publishing their findings in a white paper titled "Clinical Advantages of Disposable Microfiber Mops." The study compared hospital relaundered microfiber mops with single-use disposable microfiber products. The mops were evaluated before and after laundering to assess how the laundry process affected product performance. The study quantified levels of organic and inorganic residues trapped in the microfiber structure, along with the bioburden present after laundering. Additional factors examined included the impact of residual organics on subsequent quat binding and the actual cleaning efficacy of relaundered versus disposable mops using ATP analysis.

Though the study parameters may not be directly applicable to cleanroom environments—especially regarding bioburden collection—the overall findings warrant consideration.

Visual and Microscopic Analysis

The impacts of repeated laundering can often be visible, especially with colored mops. This visual degradation can only be monitored and managed if rigorous inspection routines for mops during the relaundering process are established. However, damage from recurrent laundering can also occur without visible signs, as demonstrated by scanning electron microscope analyses showing stark differences between "new" microfiber and microfiber that underwent just a few laundry cycles. The intrinsic qualities of synthetic microfibers render them vulnerable to damage, and the laundry process itself can be harsh due to the involvement of chemicals, heat, and abrasion. Laundered fibers can appear distorted and fused, resulting in diminished performance regarding absorbency and capacity to hold particles and microbes. Particulate contamination not eliminated by laundering—or introduced during the laundering process—can be visible as white specks.

Residues in the Mops

Alongside particles, the laundering process may be ineffective at removing trapped residues of disinfectant or detergent. This can be easily measured by soaking the mop in clean water, then squeezing the extract into a clear beaker. If the water appears dirty, cloudy, or foamy, it indicates that the laundering process inadequately removed trapped chemical residues.

A comparative extraction test involving 18 samples—9 laundered re-usable microfiber mops and 9 new microfiber pads—was conducted using recommended practices from the Institute of Environmental Sciences and Technology. Each mop sample was taken solely from the microfiber fabric portion. The analysis results for residues displayed that laundered mops had an average residual level of 0.099 ± 0.102 g/m², while disposable microfiber mops exhibited residues nearly five times lower (0.020 ± 0.012 g/m²) with significantly lesser variability over the nine samples.

Impact of Trapped Residues on Binding and Inactivation of Disinfectants

The accumulation of organic particulates and residues on laundered mops can cause complications once the mops are put back into use. Disinfectants and sporicides are highly reactive and can bind to or be deactivated by organic materials, impacting their efficacy. If mop heads are contaminated with residual detergents or organic debris post-laundering, they can hinder or inactivate disinfectant chemistry even before contact with the target surface. Previous studies have demonstrated similar reactions where quaternary ammonium disinfectants (quats) tend to bind to cotton-based cleaning wipes and mops. This binding effect has also been noted with residual organics present in laundered synthetic mop heads.

The study contrasting laundered mops with single-use microfiber mops using a common quat-based disinfectant showed that both mops immersed in a 100 ppm solution experienced a 20% reduction in active disinfectant levels within the first minute on a laundered microfiber mop. Further testing revealed that levels continued to drop over time, eventually falling below the level required for disinfection within 15 minutes. In comparison, the disposable mop showed a similar decrease initially; however, the active disinfectant level stabilized after one minute and remained effective throughout the study duration. While lower levels of active quat were retrieved from stainless steel coupons treated with disposable mops, higher concentrations were consistently observed when using single-use mops, indicating that residual organic matter can indeed diminish the efficacy of disinfectants applied with re-laundered microfiber mops.

Summary

The approach to single-use mops is straightforward: employ a new mop for cleaning a designated area, either downgrading it for less critical use or discarding it after primary use. The surface area cleaned per mop is assessed through critical metrics sampling, ensuring sterility if necessary. The particle and fiber shedding of the mop is measured based on laboratory evaluations provided by manufacturers. The validated disinfectant application and required contact time are also monitored and documented for both reusable and single-use mops.

Since single-use mops are constructed from fresh materials via validated processes, they offer predictable performance and outcomes. This reliability persists even over extended periods as new mops with similar parameters are used consistently. As highlighted in preceding studies, repeated laundering can cause performance degradation and quality decline over time, given the inevitable wear of reused mops. The laundry process can inflict irreversible damage on the sensitive microfiber structures essential for cleaning, while retained particles or residues can adversely impact the effectiveness of disinfectants applied with these mops.

For any reusable mop evaluation project, tracking performance and quality over time is crucial to estimate lifecycle costs. The actual performance, contamination profile, and quality of reusable mops will deviate as time progresses, potentially leading to unintended and unacceptable risks to users' environments and finished products. Understanding the genuine risks associated with reusable mops requires continuous validation throughout the relaundering process, with the costs of such validation factored in. The decision to utilize single-use versus laundered reusable mops may ultimately rely on a simple inquiry: Do you truly know the mop you're using?

Karen Rossington acknowledges the contributions of Pier de Jong and David Nobile from Contec’s Technical Service Department to this article.

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References

1 Textile Terms and Definitions, 11th Edition, The Textile Institute

2 David J. Flynn, Peter K. Kang, Ph.D. K. Mark Wiencek, Ph.D. Contec White Paper Clinical Advantages of Disposable Microfiber Mops

3 Institute of Environmental Sciences and Technology (IEST). Evaluating Wiping Materials Used in Cleanrooms and Other Controlled Environments. Recommended Practice (RP), IEST-RP-CC 004.3

4 MacDougall, K. D., & Morris, C. (2012). Optimizing disinfectant application in healthcare facilities. Infection Control Today, 10, 62-67.

5 Engelbrecht, K., Ambrose, D., Sifuentes, L., Gerba, C., Weart, I., & Koenig, D. (2013). Decreased activity of commercially available disinfectants containing quaternary ammonium compounds when exposed to cotton towels. American Journal of Infection Control, 41(10), 908-911.

6 Boyce, J., Sullivan, L., Booker, A., & Baker, J. (2016). Quaternary Ammonium Disinfectant Issues Encountered in an Environmental Services Department. Infection Control & Hospital Epidemiology, 37(3), 340-342.

Microfiber presents several benefits, including:

High Absorbency and Breathability: Microfiber's large surface area and microporous structure allow for quick absorption and effective moisture release, ensuring a dry and comfortable experience.

Lightweight and Soft: Its fine fiber structure renders microfiber light and soft, providing comfort while in use.

Durability and Abrasion Resistance: Microfibers typically demonstrate high strength and abrasion resistance, enabling them to endure frequent use and washing for extended lifespans.

Antibacterial and Deodorizing Properties: Microfiber displays excellent abilities to inhibit the growth of bacteria and reduce unwanted odors.

High Cleaning Power: The fine fibers easily capture and trap small stains and particles, facilitating an effective cleaning process.

ECO-FRIENDLY AND SUSTAINABLE: Microfibers are frequently composed of synthetic or recycled materials, which help conserve natural resources and provide recyclable options.

In general, the advantages of microfiber include high water absorption, breathability, lightweight nature, softness, durability, antibacterial features, and strong cleaning capability. These attributes make microfiber widely used across various industries such as textiles, cleaning products, and medical supplies.

However, there are also notable disadvantages to consider:

Cost: Microfibers are often more expensive than conventional fibers due to their intricate manufacturing processes and high-quality materials.

Environmental Impact: Certain microfibers, particularly those crafted from synthetic materials, may have adverse environmental effects during production and disposal, potentially leading to pollution and waste issues.

Special Care Requirements: Some microfibers necessitate specific care instructions, such as gentle washing or avoiding high temperatures, to sustain their properties and extend their longevity.

Despite these challenges, the advantages of microfiber typically surpass the disadvantages, making it a favored choice for diverse applications.

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