MoldMaking Technology

SEP 2018

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10 MoldMaking Technology —— SEPTEMBER 2018 Profile Images courtesy of Zahoransky USA Inc. At NPE2018, Zahoransky USA Inc. exhibited and featured an array of injection moldmaking capabilities. What capabilities seemed to catch the most attention from potential customers? Product Sales Manager, Molds, Andrew Cummings: We have many years of mold building experience and have gained a reputation for engi- neering molds that perform with extreme reliability. Where Zahoransky Automation and Molds (ZAM) really brings value to the table is with turnkey solu- tions and our ability to integrate automation in or around the injection molding process. At Zahoransky USA Inc. (Zahoranksy), we say, "from the pellet to the pal- let—we can provide solutions." For example, some of our customers have full lines that we built entirely, from the sub straight to the over-molded, inspected and packaged product. Cells like this run production 24/7 and can have as few as one operator for four machines. Another example, we run 100 percent all of the design and builds for all GUM brand inter- dental brushes. We impress potential customers by showing them that the right manufacturing solution for their prod- ucts can be attained with only one vendor. 1601 Atlantic Drive Suite 133 West Chicago, Illinois 630-507-9872 • Was founded in 1902 in Todtnau, Germany, by Anton Zahoransky to produce tufting machines for brush making. • Is known as the pioneer in brush production. • Has more than 800 full-time employees working in 10 branches in seven countries, including the United States. • Is family-owned and operated. • Is currently led by Managing Director Ulrich Zahoransky, member of the family's third generation and a grandson of the company founder. • States in its motto, "We are not perfect, but we are perfectly different." One example of a modular automation system that Zahoransky offers is the Z.SIROC, which seamlessly fits around any injection molding machine, like Legos. This modular automation cell is used for taking parts out of the injection molding machine and into the next station for assembly or to re-insert parts back into the mold for a secondary molding process. A Conversation with … Zahoransky USA Inc. A market leader in mold and tool making for toothbrushes and related dental products, Zahoransky also builds custom injection molds for medical technology and medical devices, packaging, consumer and personal care products. When did Zahoransky first introduce "in-mold" and "near-mold automation" to its moldmaking services, and how does the company determine what is required? Cummings: We are implementing in-mold automation for much of our customer base. We also have superb standalone injection tools, specializing in two- and three-component applications. We are continually refining how we design the molds and automation systems, and of course this begins by being completely dependent on the molded product. Typically, we work with customers that have injection molding needs beyond just the tool. We make extremely reliable tooling, but with our expertise in integrating automation, we go far beyond that. We ask customers for more than just part specifications. We ask them what they want to do with the product after it is molded. We discuss assembly processes and packaging options. After initial discussions with the customer, we send the infor- mation to Germany where our engineers develop two to three possible solutions. Take, for example, a project for a three- piece cap and closure for e-cigarette liquid caps. The mold is a 48-cavity tool times three, or 144 cavities total. The mold pro- duces three separate parts, each molded from different materi- als, and uses the end-of-arm tooling to grab the 144 parts and assemble them right outside the mold as the mold closes and begins molding another 144 parts. This is accomplished with a 500-ton Arburg machine and three injection units, each of which injects a different resin. This is a standard configuration

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