Rising material and energy costs, coupled with increasing competitive pressure, particularly from Asia, present a challenge for many manufacturers of so-called “private label” toothbrushes (affordable store brands, such as those sold by supermarkets and drugstores). These manufacturers must balance the need for competitive pricing with maintaining profitable margins. A key to achieving this is an efficient production process that minimizes manufacturing costs while providing the flexibility to adapt to new customer or market demands. In Europe, manufacturers are turning to ZAHORANSKY’s CUBE machine concept to meet these challenges. A set-up with a total of four production cells (so-called base units) offers maximum output of up to 120 brushes per minute in the production of anchor-loaded toothbrushes. The modular machine concept can also be easily reconfigured for new production orders.
One CUBE Can Replace Several Existing Machines
Thanks to its modularity, the CUBE concept allows producers to replace existing individual machines with combined CUBEs, maintaining – or even increasing – performance. For instance, one potential configuration is replacing two twin machines with a single CUBE 4.48, which achieves a performance of up to 120 toothbrushes per minute. This approach can give producers a significant advantage, especially for cost-sensitive products with high production volumes.
The CUBE is a revolutionary machine concept from ZAHORANSKY for manufacturing anchor-tufted toothbrushes. Its modular structure, comprising a Base Unit, Supply Unit, and Cover Unit, allows for seamless customization based on production requirements, whether for increased output or more complex toothbrush designs. Multiple Base Units can be linked together, either to boost production or to manufacture intricate brush designs. Paired with the advanced ZMI 4.0 machine control system, both parallel and serial production processes can be executed, and the sequence of tufting and finishing units can be flexibly adjusted. This provides the foundation for a scalable, flexible production system tailored to individual customer needs.
Maximum Output in Minimal Space
The demand for high production volumes in limited spaces is rising. To address this, ZAHORANSKY recommends connecting four Base CUBEs. Each of these four cells can produce up to 30 toothbrushes per minute in parallel operation, resulting in a total output of up to 120 toothbrushes per minute. Thanks to the advanced ZMI 4.0 control system, the tufting speed reaches an impressive 4,800 bundles per minute.
Additionally, the CUBE is equipped with four finishing cells, two of which can handle trimming and grinding, while the other two are available for optional features such as laser engraving and camera inspection. This CUBE concept enables fully automated production in a compact footprint, which is especially advantageous in modern manufacturing environments with limited space. A single CUBE can reduce the need for operating personnel as well as maintenance and servicing costs.
Investment Security Through Flexibility
The CUBE machine concept offers customers high investment security thanks to its flexibility. It can adapt to changes in demand or product specifications without requiring new machines or extensive reconfigurations. For instance, the CUBE can be divided into two standalone units or expanded with additional Base Units to meet new customer or market requirements. With the advanced ZMI 4.0 control system, no mechanical retooling of the CUBE is necessary. The operator simply loads the appropriate program via an intuitive touch interface, allowing the same CUBE to produce a different toothbrush model.
