.AERO. Total design liberty for toothbrushes (seal plates)

Transcription

1 .AERO Total design liberty for toothbrushes (seal plates) n Top technology for anchorless toothbrushes n Highly automated modular concept n For high output and maximum end rounding quality coupled with impeccable hygiene

2 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 The Z.AERO high-performance production unit produces up to 40 anchorless seal plates (each with 60 tufts per brush). Z.AERO represents efficiency, flexibility, reliable production and return of investment in toothbrush manufacturing. Top technology from ZAHORANSKY. Made in Germany, of course. 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 2 3

3 Z.AERO Fully automatic and contact-free production of seal plates and toothbrushes 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. Modular unit system for fully automatic inline production or partial automation High productivity Minimal manpower required High flexible product design Very reliable production End-rounding of the filament ends and transfer to the filament box Shape of the tuft pattern Welding the filaments Over molding of filaments Ejection station for seal plates or adapt molding of handles Packaging 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. 12 stations 8 end-rounding / polishing stations Correctly sorted end rounding For almost all filament types 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. High output Complex tuft patterns 10 filament boxes, manual or automated loaded Fully automatic transport to the welding station where the filament ends are welded together at the non-rounded end. Contact-free welding High process reliability The welded filaments will be over molded in the next step. The seal plate is finished. Variable head design Impeccable hygiene Fully controlled process Up to 12 cavities The finished anchorless seal plates can be released or alternatively linked to the injection molding machine for handle molding. Fast changeover Low investment for further handle designs Camera control (optional) Up to 24 cavity injection molding machine for handle Ideal for TPE elements in the head area A packaging unit, such as the ZAHORANSKY Z.PACK or Z.VIPA can be connected to the Z.AERO. End-rounding result better than 90 % Mold bar Welded hole pattern Finished seal plate Finished toothbrush 4 5

4 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 Highest quality of the end-rounded and polished filaments 10 different filament colors or types are possible Tuft retention of the tufts above 25 N Optional camera inspection for the empty mold bars (fully automatic version only) Only one operator required Orientated brush ejection for further processing Impeccable hygiene by no human touch production Reduced logistics as no in-between storage is necessary 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: Short delivery times Stand-by support Perfect project management and direct communication channels Customized training courses Service 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. 6 7

5 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. ZAHORANSKY Perfectly different Status: 09 /13. Errors and changes excepted. ZAHORANSKY AG Anton-Zahoransky-Strasse Todtnau-Geschwend Tel Germany