ZAHORANSKY EDGE Transforms Toothbrush Manufacturing Through Innovation Customization and Sustainability
The oral care sector is seeing a convergence of innovative brush design, cost-effective, environmentally friendly production methods, and the high demands on dental health. In order to meet all design, environmental, and cost-effectiveness requirements, ZAHORANSKY has introduced EDGE, a compact production technology that makes it possible to manufacture anchor-free monomaterial toothbrushes efficiently. Handles, heads, and filaments can all be made of the same kind of plastic thanks to the novel anchor-free production method that thermally attaches filament bundles to the brush head.
This not only allows for head designs that are up to 70 percent thinner, but also ensures a constant output of up to 30 brushes per minute – regardless of head geometry or number of filament bundles. The toothbrushes, which are made entirely from a single material and without anchor wire, are 100 percent recyclable and therefore particularly resource-efficient. “The innovation carousel in the highly competitive oral care market is spinning faster than ever. At the same time, manufacturers are under increasing cost pressure when introducing new products. In addition, recyclability and sustainability are becoming increasingly important to end consumers. We are delighted with the first joint projects and the positive customer feedback on EDGE. This confirms our solution expertise for hygienic, stylish, and environmentally friendly products,” says Kevin Eisemann, Head of Development at ZAHORANSKY.
The benefits for end users begin at the very end of the manufacturing chain: thanks to extremely delicate geometries, the EDGE achieves head thicknesses of only about 1.5 millimeters. The edge distances between the filament and the brush contour shrink to just 0.8 millimeters. This is ideal for better reaching the rear areas such as wisdom teeth and molars during daily dental care. In addition, the filament bundles are not pressed together with anchors, but thermally bonded. This prevents the formation of cavities in which saliva, water, or germs could collect, reducing the risk of contamination of the oral cavity, gums, and teeth by germs or mold.
New Design Freedom for Form and Function
From a design perspective, EDGE sets new standards: “Since pre-drilled holes are no longer required in the head, EDGE offers manufacturers great design freedom,” explains Eisemann. Bundles for interdental focus, large-area tufts for massage, and even complex mixed forms can be set in a single production step and then fused with a counter profile at the desired height. Another advantage for manufacturers: this variety of options can be produced more easily and cost-effectively on the EDGE, as magnetically fixed pattern parts are used instead of expensive mold bars for injection molding tools. Most design changes can therefore be made quickly, without tools, and without risk of mix-ups.
Faster Time to Market
To implement new designs quickly, precisely, and cost-effectively, ZAHORANSKY also supports manufacturers with its own rapid prototyping service. New product designs are reviewed at an early stage in collaboration with the customer. Findings, such as how new hole field geometries or profile heights affect haptics, cleaning performance, and brand image, are thus directly incorporated into the further development process and accelerate time to market.
Output That Pays Off
The EDGE also sets standards in terms of business efficiency. “Since the process feeds in all bundles simultaneously, the cycle time of up to 30 toothbrushes per minute remains constant, regardless of the complexity of the brush head,” explains Eisemann. At the same time, there are no costs for anchors or the purchase of multiple injection molding inserts. Thanks to its compact design, requiring only 11 square meters of space, the EDGE can be integrated into existing production environments. Installation and commissioning by the ZAHORANSKY service team on site can often be completed within one working day thanks to the machine’s extensive preconfiguration. During operation, the intuitive ZMI 4.0 control unit guides the operating personnel safely through all production and maintenance processes. In addition, the automatic feed mechanism for brush bodies and filaments means that only occasional human intervention is required for refilling. In times of skilled labor shortages, the EDGE not only provides a stable basis for calculable unit costs, but also makes the entry into anchorless monomaterial technology economically attractive and feasible for medium-sized manufacturers.
Standard-Compliant Manufacturing
The EDGE meets all international testing criteria for manual toothbrushes. Internal measurement series conducted by ZAHORANSKY also prove that the thermally bonded tufts of the EDGE can withstand much higher pull-out forces. It also passes the pendulum impact test for breakage resistance of ultra-thin heads, which is mandatory in Europe and the USA, despite a head thickness of only 1.5 millimeters, which is far below the industry standard of 4 to 5 millimeters. This exceptional stability forms the basis for worldwide approvals – from FDA registration in the USA to CE marking in the European Economic Area. “The EDGE therefore not only offers hygienic and economic advantages, but also provides our customers with the regulatory security to be able to sell their products in all relevant target markets,” says Eisemann.
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