Total design liberty for toothbrushes (seal plates)

.AERO
Total design liberty for toothbrushes (seal plates)
nTop
technology for anchorless toothbrushes
nHighly automated modular concept
nFor high output and maximum end rounding quality coupled with impeccable hygiene
Our latest solution for
anchorless toothbrush production
Z.AERO
Total flexibility and design
choice for toothbrush heads
The days when toothbrushes were sold by function alone are long
past. This is a keenly-fought market. Brush head designs and special
functions helps to stand out in the market: Replaceable heads, flexible plastic handles, additional tongue cleaners and variously angled
tufts in different colors and hardnesses. And so much more. All this
places special demands on production and final functionalality of your
toothbrush.
The breakthrough in this area has been made by the anchorless
technology of the new Z.AERO high performance unit. It opens up
practically unlimited tuft design ideas combined with highest output:
 Free choice of tuft geometry (tuft in tuft)
 Free choice of brush pattern
 Free choice of tuft angle (up to 14°)
 Free choice of tuft topography with at least
90 % end-rounding quality
Z.AERO represents efficiency, flexibility, reliable production and return
of investment in toothbrush manufacturing. Top technology from
ZAHORANSKY. “Made in Germany”, of course.
The Z.AERO high-performance production unit
produces up to 40 anchorless seal plates
(each with 60 tufts per brush).
 Up to 2,400 brushes / hour

Up to 48,960 brushes / day

Up to 14,8 million brushes / year
(300 working days)
Seal plate production:
Almost any tuft shape (seal plate) can be manufactured fully automatically on the Z.AERO unit
with the highest end-rounding quality. The seal
plate can be over molded to create the finished
brushes using the in-mold method.
Seal plate produced on the Z.AERO ...
... further processed to form the brush
The anchorless technology makes
a huge variety of different bundle
shapes possible
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Z.AERO
Fully automatic and contact-free production
of seal plates and toothbrushes
 Modular unit system for fully automatic
inline production or partial automation
 High productivity
Anchorless toothbrush production is a totally new production process. Rather than making hole
plates and then tufting these with filaments, the Z.AERO makes the tuft plate first when anchorless technology is used. And then molded using in-mold technolgy. All with “No human touch”
and totally hygienic. Ready for fully automatic processing.
End-rounding of
the filament ends and
transfer to the
filament box
The filaments are placed in
hanks into the HG filament
end-rounding machine,
where they are end-rounded,
polished and cut to length.
The end-rounded filaments
can be fed manually or
automatically to the Z.AERO.
n12 stations
n8 end-rounding /
polishing stations
sorted end
rounding
nFor almost all filament
types
nCorrectly
End-rounding result
better than 90 %
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Shape of the
tuft pattern
Separator discs separates
the filaments in the filament
box, so they can be transported to the first hole field
plate by vacuum. The finished shape of the bundle
field is created in a number
of steps (funneling, compression and topography).
The bundle field is pushed
into mold bars.
nHigh
Welding
the filaments
Fully automatic transport
to the welding station
where the filament ends
are welded together at the
non-rounded end.
nContact-free welding
nHigh process reliability
 Minimal manpower required
 High flexible product design
 Very reliable production
Over molding
of filaments
Ejection station for
seal plates or adapt
molding of handles
The welded filaments will be
over molded in the next
step. The seal plate is finished.
The finished anchorless seal
plates can be released or
alternatively linked to the
injection molding machine
for handle molding.
nVariable head design
nImpeccable hygiene
nFully controlled process
nUp to 12 cavities
output
nComplex tuft patterns
n10 filament boxes, manual
Packaging
A packaging unit, such as
the ZAHORANSKY Z.PACK
or Z.VIPA can be connected
to the Z.AERO.
nFast
nLow
changeover
investment for
further handle designs
nCamera control (optional)
nUp to 24 cavity injection
molding machine for
handle
nIdeal for TPE elements in
the head area
or automated loaded
Mold bar
Welded hole pattern
Finished seal plate
Finished toothbrush
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Best product quality
by using anchorless technology
Z.AERO: A system solution with the
ZAHORANSKY PLUS
Brush heads produced by this method are:
 Totally hygienic
 Without any gaps, so no bacteria can build up
 Fully recyclable (no metal)
 Very attractive due to the free and absolutely
precise design of the filament bundles
(e. g. topography, profile shape and tuft angles)
Packaging Machines
+ Mold Making
+ Systems Technology
= Innovative complete solutions
for highly efficient packaging processes
Preparation of the filaments
Contact-free welding
Over molding of the filaments to make
seal plates
Further benefits of the Z.AERO
nHighest
quality of the end-rounded and polished filaments
different filament colors or types are possible
nTuft retention of the tufts above 25 N
nOptional camera inspection for the empty mold bars
(fully automatic version only)
nOnly one operator required
nOrientated brush ejection for further processing
nImpeccable hygiene by “no human touch” production
nReduced logistics as no in-between storage is necessary
n10
The Z.AERO demonstrates particularly well how all the
ZAHORANSKY business departments work together to develop machines and units: Machine Building, Mold Shop,
Systems Technology und Packaging Machines. It is this concentrated expertise of people from different areas that allows
us to create convincing and high innovative system concepts.
It is exactly this that makes us to the right partner when you
are looking for customized solutions for your production.
We also guarantee:
nShort delivery times
nStand-by support
nPerfect project management and
direct communication channels
nCustomized training courses
nService – fast, convenient and available worldwide
Technical knowledge and manpower
from all our departments are involved
in the development of your complete,
integrated solution.
It will be our pleasure to support you.
Why not give us a call.
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German Engineering with
Passion & Perfection
More than a century ago, Anton Zahoransky marked the start of a new era in brush production
when he developed the first drilling and tufting machine for brushes. The company has grown
into an international business offering complete solutions in the field of machine building and
automation technology. It now has four divisions: Mold Making, Systems Technology, Packaging
Machines and Brush Machines.
The driving force is and always has been more than just solid “German Engineering” and
concentrated innovative strength. It is the unbroken spirit of “Passion & Perfection”: lifeblood,
persistence and an absolute desire to develop solutions that deliver exactly what they promise.
Status: 09 /13. Errors and changes excepted.
ZAHORANSKY – Perfectly different
ZAHORANSKY AG
Anton-Zahoransky-Strasse 1
79674 Todtnau-Geschwend
Tel. +49 7671 997-0
Germany
www.zahoransky.com