Special interbruSh 2012 - Zahoransky

The Customer Magazine of the ZAHORANSKY GROUP 

Special 

interbruSh 

2012 

art Of technOlOgy 

highlightS 

SMart phOne app 

plantS & Machinery 

1/2012 

in-hOuSe exhibitiOn

2 EDITORIAL 

CONTENTs 

spECial MEdia fOr 

a spECial OCCasiON 

Dear readers, 

The interbrush, our industry‘s summit, is approaching. 

We are looking forward to this specialist forum right on 

our doorstep in freiburg. We have done a lot to meet 

the expectations of the many visitors. if you are reading 

this you are already experiencing the first change: our 

customer magazine CONTaCT is now also appearing in 

digital form – for your computer or ipad. at our trade fair 

stand, according to the slogan “art of Technology”, we 

are presenting innovations for the entire process chain: 

from the filament up to the injection molded and packaged 

toothbrush. On the following pages, you can find out what 

other highlights we are offering and how ZaHOraNsKY 

will soon be accompanying you on your smartp hone. 

sincerely, 

Ulrich Zahoransky and dr. Bernd stein 

Dr. Bernd Stein and Ulrich Zahoransky

interbruSh 2012 

¼ Art of Technology 

¼ Highlights 

hOuSehOlD 

& inDuStry 

packaging injectiOn MOlDing 

¼ Rotation Cut Achieves 

Countless Blister 

Contours 

Oral care 

These symbols will accompany you through the magazine and show where you can find interactive elements: 

� 

¼ The Right Brush for 

Every Requirement 

¼ success Formula 

for Toothbrushes 

¼ Future-Proof 

Toothbrush Production 

iMagE gallErY VidEO liNKs 

iNfOrMaTiON 

We 

¼ Leading the Way 

Worldwide 

¼ In-House Exhibition 

¼ Freiburg in the Breisgau 

CONTENTs 

CONTENTs 

3

4 INTERBRUsH 2012 

CONTENTs 

MaY 9 – 11, 2012 

arT Of TECHNOlOgY 

The interaction of aesthetics and function 

a 

trade fair booth becomes an exhibition: for machines, 

for works of art for innovations. at the interbrush 

2012, ZaHOraNsKY will be presenting 

its technology from a different perspective. The combination 

of art and craftsmanship, of aesthetics and functions 

is what distinguishes the machines of the company from 

the Black forest. 

This idea was taken up for the trade fair presence and 

expressed in a special way on more than 1,000 square 

meters of booth area. as well as the ten exhibited machines, 

visitors can expect expert contacts from all service 

fields and extensive information covering the entire pro- 

duct spectrum. 

a special novelty is the new ZaHOraNsKY app. More 

about this on the next page. n

HigHligHTs 

Well informed all-around 

The guide through the trade fair booth: the information 

on this page guides visitors through the exhibition 

“art of Technology”. Which service area will you 

find where? at each exhibit there is additional data on the 

respective machine. n 

Explanation 

1 

2 

3 

4 

5 

Qr Code 

ipad station 

Works of art 

HOUsEHOld & iNdUsTrY 

Oral CarE 

paCKagiNg 

iNjECTiON MOldiNg 

lOUNgE 

2 

2 

4 

2 

NEW! THE ZaHOraNsKY 

sMarT pHONE-app 

INTERBRUsH 2012 

get the ZaHOraNsKY app on your smart phone, 

quickly and simply! 

1. News 

2. gallery 

3. Contact 

4. Qr reader 

2 

1 

5 

3 

1 

1 

1 

¼ Booth No.: 4.2.12 

1 

CONTENTs 

5

6 HOUsEHOLD & INDUsTRy 

CONTENTs 

THE rigHT BrUsH 

fOr EVErY rEQUirEMENT 

The widest variety of materials, colors and forms with simultaneous 

improvement of the product characteristics with a view to performance, 

care and cleaning – the wide range of requirements in the household 

brushes segment demands versatile production solutions. 

at the interbrush, ZaHOraNsKY will be presenting 

selected machines from the field “HOUsEHOld 

& iNdUsTrY”: The Z.TigEr will be producing 

dishwashing brushes at the trade fair and the Z.pard will 

be showing the production of car wash brushes. in addition 

to this, the machines of the Z.liON series will be on 

display, which are available from the single version up 

to a fully automated twin-design version and also for the 

production of strip brushes. 

Strip brushes produced More profitably 

produce limited and endless strip brushes cost-effectively: 

for a small initial investment, the user receives a highperformance 

brush production system in the form of the 

Z.liON 1114. The 4-axis machine processes natural fibers 

and nylon filaments up to 320 millimeters and brush 

handles made of wood or plastic. n 

iNfOrMaTiON 

Z.TIGER 8225 MT 

Fully Automated 4-Station/5-Axis 

Twin Carousel

fUTUrE-prOOf 

TOOTHBrUsH prOdUCTiON 

From individual machines for tufting or for finishing over linked machines up to 

solutions for the complete manufacturing process including injection molding. 

The ZaHOraNsKY toothbrush 

machines offer 

a wide range of 

options for the production 

of electrical and 

hand toothbrushes. at 

the interbrush the company 

will be presenting the 

Z.OrCa and the Z.sHarK 

series. also, ZaHOraNsKY is 

showing Z.aErO for the contact-free production 

of anchorless toothbrushes and Z.idp, the solution 

for the production of interdental brushes along the entire 

manufacturing process – from the granulate to the packaged 

brush. 

The toothbrush machines of the Z.OrCa series for tufting, 

trimming and end rounding are tailor-made for the varied 

requirements of users and can be modularly expanded: 

from the compact machine up to the twin production machine 

with maximum output. With the Z.sHarK, ZaHOraNsKY 

is offering machines for high production performance 

– available as an individual machine (tufting) and as 

iNfOrMaTiON 

Z.AERO – new machine 

generation for anchorless toothbrushes 

ORAL CARE 

a linked twin system with trimming and end rounding units. 

With the new Z.aErO machine, customers can implement 

complex toothbrush head geometries, bundle shapes and 

bundle positions. The ‘No-Human-Touch’ production process 

allows for the highest hygienic standards in production. n 

CONTENTs 

7

8 PACKAGING 

CONTENTs 

rOTaTiON CUT aCHiEVEs 

COUNTlEss BlisTEr CONTOUrs 

Produce external cutting contours and perforations efficiently – 

ZAHORANsKy shows the possibilities of Z.PACK 6. 

rotation cut is used for cutting external 

contours and perforations 

for blister packaging. all blister 

contours, such as curved shapes, can 

be achieved. a rotating cylinder, to 

which a so-called cutting jig is attached, 

produces the cut contours. 

With a straight cut, no waste accumulates. 

This has advantages in comparison 

with a full cut. Thus, waste 

is reduced by up to 20 percent (film 

and cover material). 

The integrated handling ensures 

swift, smooth removal and enables 

further processing of the 

cut blisters through an aligned 

output. rotation cut is controlled 

via the tried and tested ipC unit 

and is thus fully integrated into 

the automated production process. 

pVC, aluminum and pET materials 

can be processed by rotation cut, 

as well as cardboard mounted on 

plastic film. n 

Z.PACK 6

sUCCEss fOrMUla 

fOr TOOTHBrUsHEs 

The foundation for high-quality and functional 

toothbrushes is laid in the production of the brush 

handles. 

ZaHOraNsKY formenbau develops 

mold concepts for the varying 

requirements of manufacturers. 

This starts with the low-cost entry 

solution Basic line: this new standard 

solution allows the efficient production 

of high-quality toothbrushes by 

means of a well-thought-out mold concept. 

The ZaHOraNsKY hot runner 

system is the basis for good products. 

More possibilities are offered by the 

injection molding system concept plat- 

Platform Line 

form line, which can be expanded 

virtually any way the user wants. The 

new mold system is ideal for users 

who produce changing products or 

large production quantities with the 

highest quality and cost-effectiveness. 

The modular construction of the injection 

molding system allows rapid 

changing: tool costs for new models 

are thus significantly reduced. The 

users are also equipped for swiftly 

changing market requirements. The 

Entry-level solution Basic Line 

ZAHORANSKY mold concepts: variety and high-quality products 

INjECTION MOLDING 

platform mold is also versatile when 

it comes to capacity: the cavity blocks 

are identical – it is thus no problem to 

expand the machine to 4, 8, 12, 16, 

20 or 24 blocks. n 

CONTENTs 

9

10 WE 

CONTENTs 

lEadiNg THE WaY WOrldWidE 

The highest quality, reliability and technical expertise – around the globe 

for more than a century, 

ZaHOraNsKY has stood for 

reliability, precision and fully-developed 

technology – Made in germany. 

from a small family business, 

a globally active group of companies 

has developed. The products, the 

industry and the world have changed 

yet the love of technology and perfection 

has remained the same. around 

600 people at nine sites work in this 

spirit every day. n 

OVErViEW Of sErViCEs 

• Machines for the production of brooms and brushes for 

household and technical applications 

• production lines for toothbrushes 

• Mascara and interdental brush machines 

• injection molds for the packaging, 

personal care and medical segments 

• automation solutions for medical technology, 

healthcare & beauty, consumer, industrial and automotive segments 

• Blister packaging machines 

• Worldwide consulting and service, customer support in product 

development and production design 

�

iN-HOUsE 

ExHiBiTiON 

Close and direct 

straight after the interbrush, 

on 12th May 2012 (9 aM 

to 3 pM), the ZaHOraNsKY 

in-house exhibition will be taking 

place at the headquarters in Todtnau. 

Those who are interested can take a 

look behind the scenes of the machine 

technology. also, technology specialists 

will be ready for discussions. food 

and drinks in the beautiful Black forest 

atmosphere will be arranged for. as 

a special highlight, a helicopter flight 

frEiBUrg iN THE 

BrEisgaU 

Nature, sports, high-tech 

This city in the Breisgau region, 

on the edge of the Black forest 

is known for its university, the local 

football club (sC freiburg) and, at 

least to the readers of this magazine, 

as the home of interbrush. landmarks 

of the southernmost large city in germany 

are the historic district and the 

Home of the Interbrush: Freiburg in the Breisgau 

12th May 2012 

9 aM – 3 pM 

over the summits of the Black forest is 

offered to every visitor. a shuttle bus 

will be provided from freiburg and 

back again. n 

WiN aN ipad 

Take part in our 

lottery and win 

an ipad! 

cathedral. freiburg is located on the 

river dreisam, the business region 

has over 600,000 inhabitants. 

This sunny city traditionally hosts the 

interbrush, which takes place every 

four years. n 

iMpriNT 

publisher: 

ZaHOraNsKY ag 

anton-Zahoransky-straße 1 

79674 Todtnau-geschwend 

germany 

phone: +49 7671 997-0 

fax: +49 7671 997-299 

www.zahoransky-group.com 

editorial Staff: 

robert dous 

phone: +49 7671 997-447 

E-mail: dous_r@zahoransky.de 

jörg schroer 

phone: +49 2204 9756-20 

E-mail: schroer@c-g-gmbh.de 

concept, layout and 

realization: 

C&g: strategische 

Kommunikation gmbH 

Olper straße 10 

51491 Overath 

germany 

Text: Tobias Hartmann 

graphics: jörg schroer 

PERsPECTIvEs 

CONTENTs 

1

ZaHOraNsKY ag 

anton-Zahoransky-straße 1 

79674 Todtnau-geschwend 

germany 

Tel.: +49 7671 997-0 

ZaHOraNsKY fOrMENBaU gmbH 

Bebelstraße 11a 

79108 freiburg 

germany 

Tel.: +49 761 7675-0 

the customer Magazine of the ZahOranSky grOup 

ZaHOraNsKY sYsTEMTECHNiK 

Hanferstraße 21 

79108 freiburg 

germany 

Tel.: +49 761 88509-0 

www.zahoransky-group.com

THaNK YOU 

VErY MUCH! 

We hope that you have had an enjoyable read! 

CONTENTs 

www.zahoransky-group.com

14 RubRiken Gallery 

CONTENTs 

Image gallery 

¼ Z.TIGER 8225 MT 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Brush production with Z.TIGER 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Z.PARD 6224 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Brush production with Z.PARD 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Z.LION 6325 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Brush production with Z.LION 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Z.LION 1114 

BaCK TO arTiClE

InformatIon 

CONTENTs 

Z.TigEr 8225 MT 

Technical DaTa 

BaCK TO arTiClE 

• fully automated 3-station/5-axis twin carousel: 

integrated trimming unit 

• fully automated with feed, equipped with 

a 6-axis industrial robot for feeding and 

unloading as well as automatic material 

insertion for filaments 

• up to 1,200 bundles per minute 

• short stand still times (1.5 sec) 

• output at 85 %: 

approx. 12 brushes per minute

InformatIon 

CONTENTs 

Z.pard 6224 



• 3-station twin machine, 4 axis 

• manually operated 

• external trimming machine "ZaHOraNsKY 

by giori" rp12 with flagging unit 

• approx. 1,100 bundles per minute 

• only 2.3 kW power consumption 

• output at 85 %: 

approx. 6 brushes per minute

InformatIon 

CONTENTs 

Z.liON 6325 

aUTOMaTEd WiTH p 500 

(piCK aNd plaCE UNiT) 



• operational mode: semi-automated, 

continuous operation 

• 1,000 bundles per minute 

• automated with manual feed, pick 

and place unit and automatic removal 

• output at 85 %: approx. 5 brushes per minute

InformatIon 

CONTENTs 

Z.liON 1114 



• economical, highly-efficient machine for 

production of strip brushes 

• same bundle density and distribution as 

with clamped or welded strip brushes 

through special technical feature 

• strip meters (twin row): 

approx. 2.5 meters per minute 

• 600 bundles per minute


CONTENTs 

Image gallery 

¼ Z.ORCA 116 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Z.ORCA simultaneously processes 

up to 6 filament colors 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Center for production of anchorless toothbrushes 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Z.sHARK 4 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Rotating Turret 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Z.IDP 2 Integrated Dental Production 

BaCK TO arTiClE


CONTENTs 

Image gallery 

¼ Manufacturing of interdental brushes with Z.IDP 2: 

from granulate to the packaged brush 

BaCK TO arTiClE

InformatIon 

CONTENTs 

Z.OrCa 116 



• unbeatable technical availability of up to 98 % 

• high variety of topographies 

• perfect end rounding 

• visualization and software tailored to machine 

• no human touch 

• output: up to 30 brushes per minute 

• rotating turret for production of 

complex hole fields (anchorless look)

InformatIon 

CONTENTs 

Z.aErO 



• center for contact-free production 

of anchorless toothbrushes 

• unique possibilities for the production 

of high-quality toothbrushes 

• complex toothbrush head geometries, 

bundle shapes and bundle positions 

• high variety of filament types, 

thicknesses and colors 

• highest toothbrush quality through filament end 

rounding before bundle generating

InformatIon 

CONTENTs 


Z.sHarK 4 

HigH-pErfOrMaNCE TUfTiNg 

MaCHiNE fOr prOdUCTiON 

Of TOOTHBrUsHEs WiTH 

rOTaTiNg TUrrET 


• extension of machine with manual feed for 

multi-component handles 

• processing of very complex hole fields at 

almost unchanged performance through 

rotating turret 

• precision positioning of extra functions through 

application of several CNC-driven axis 

• comfortable sample change 

via touch screen operation 

• up to 1,000 tufts per min.

InformatIon 

CONTENTs 

Z.idp 2 



• production requires almost no operators; 

twist-in machine and molding process 

require little human resources 

• interdental brushes with complex 2K handles 

possible, which cannot be fed via a vibration 

conveyor 

• no further assembly of handle required 

• various product variants possible by 

adjusting trimming profile with little 

conversion efforts 

• further product variants by exchanging 

cavities in master mold


CONTENTs 

Image gallery 

¼ Z.PACK blister packaging 


PACK


CONTENTs 

Image gallery 



PACK


CONTENTs 

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PACK


CONTENTs 

Image gallery 



PACK

Special interbruSh 2012 - Zahoransky

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