Manufacturers of premium toothbrushes, especially in the OEM (Original Equipment Manufacturer) sector, are constantly faced with the challenge of delivering high-quality products while remaining flexible in order to respond to different customer requirements. Swiss-based Ebnat AG, a specialist in the production of oral care and household brushes, relies on ZAHORANSKY’s innovative CUBE technology for this purpose. The high flexibility and efficiency of the system, which enables a wide variety of different brush designs to be produced quickly and in top quality, was a decisive factor for Ebnat.
Innovation Through the “Circular Principle”
One of Ebnat’s core requirements for the new machine was the ability to manufacture toothbrushes entirely within a single system using two rotary cycles. Specifically, this means that the brush fields are produced on two levels with different filament heights. Previously, this process required multiple machines or complex conversions. The innovative CUBE technology now enables seamless brush production. In the first production cycle, shorter filaments are tufted, trimmed, and end-rounded. In the second cycle, longer filaments are added, tufted, and precisely finished.
This special configuration of the CUBE allows toothbrushes to pass through multiple tufting and finishing processes without the need for additional machinery. The innovative “circular principle” enables Ebnat to manufacture complex brushes with special profiles and multiple filament types seamlessly and efficiently. Of course, the machine is also capable of producing simpler toothbrushes with a single filament type at the touch of a button – in equally high quality. This eliminates the need for separate systems, significantly reducing complexity and production costs.
Focus on Precision and Quality
The precision with which the CUBE operates is particularly evident in the high quality of the finished products. Thomas Stolz, Head of Mechanical Engineering at Ebnat, emphasizes that this is also a major advantage of the new production method: “The quality has significantly improved, especially regarding end-rounding and the precise trimming of the filaments.” As a result, the finished brushes meet the highest quality standards, which are essential in the premium segment.
The integration of all necessary processes into a single machine not only reduces investment and space requirements but also significantly reduces the need for mechanical adjustments and conversions. This saves time, lowers operating costs, and reduces maintenance effort. Software-based settings via the intelligent ZMI 4.0 machine control system also enable fast and straightforward product changes, with minimized setup times and increased efficiency. Thanks to this flexibility, Ebnat can respond quickly to market changes while still meeting demanding quality standards.
Reliable Partnership and Excellent Service
Thomas Stolz is very satisfied with the collaboration: “ZAHORANSKY is highly reliable and keeps us up to date at all times.” ZAHORANSKY also scores with fast response times in terms of service, which is not least due to its geographical proximity. “If a problem arises that our in-house technicians cannot solve, help is quickly available. And even with older systems, we receive excellent support,” adds Stolz.
With the CUBE, Ebnat AG relies on forward-looking manufacturing technology that combines quality, efficiency, flexibility, and cost savings in an optimal way. The successful integration of this innovative system highlights the importance of close partnerships between manufacturers and technology suppliers to meet the highest customer requirements.
You can find out more about the innovative CUBE technology used at EBNAT in this video. Further information can be found on the ZAHORANSKY homepage.
