Industry News

New Interbrush Dates Set: May 4-6, 2022

In response to the rising number of cases of persons infected with the new coronavirus (COVID-19) at the time in Europe and worldwide, Messe Freiburg made the decision in mid-March to postpone the leading international trade fair in the broom and brush industry to 2022. The trade fair was originally set to take place from May 6–8, 2020. 

The first-rate international trade fair normally takes place every four years, bringing together about 7,000 visitors from over 90 countries. 

In close coordination with the international industry associations as well as the leading Interbrush exhibitors, Messe Freiburg has decided to postpone the exhibition to May 4–6, 2022

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ZAHORANSKY Coronavirus Vial Capability Draws Large Order

With the ZAHORANSKY automation systems, 600,000 coronavirus vials can be processed daily.

A US company has placed a major order with a value of 25 million euro for eleven automation lines and six removal units for vaccine containers (vials) with ZAHORANSKY AG. With a global research drive for a vaccine against COVID-19, the preparations to manufacture the ampules with vaccines are already in full swing. Already from August, ZAHORANSKY will supply the manufacturer of coated COP (cyclo olefin polymer) vaccine containers with the first automation lines required for production; others will gradually be delivered afterwards. The Z.SIROC, Z.MISTRAL, and Z.LODOS models are used for this purpose. To guarantee both continuous automation as well as consistent quality in the manufacturing process, a total of 120 cameras and 53 robots will be installed. As soon as the lines are fully assembled and put into operation, they will be able to process 600,000 vials per day. Michael Schmidt, Managing Director of ZAHORANSKY Automation & Molds GmbH, adds: “Handling COP containers for delicate vaccines is no easy matter. However, we managed to convince our client with our years of experience in integrating our lines into the production facilities of our customers, as well as with our ‘Made in Germany’ quality.”

Vaccines consist of compounds with high molecular weight. These have a sensitive reaction to, among other things, heavy metal particles in glass containers, which are created during the hardening process. This lowers the shelf life of the vaccine. Plastic vials made of COP (cyclo olefin polymer) are an alternative to glass. These are manufactured in an injection blow-molding process. They stand out with their high breakage resistance as well as glass-like transparency but offer poorer oxygen tightness. Therefore, the US manufacturer uses an additional silicon dioxide nanocoating. This reinforces the oxygen barrier and also allows for low-temperature storage. As a result, the plastic container can be transported more securely compared to the glass alternative, and it has a longer shelf life – invaluable benefits when it comes to a vaccine in global demand.

The US company put its trust in ZAHORANSKY because it is the only company with the necessary cumulative experience to cover all aspects of the production process. Michael Schmidt explains in more details: “This project was, in many ways, challenging. We needed to cover a range of demands – starting with the integration of the injection blow-molding machine at the customer, through to seamless documentation as well as traceability (track & trace) with laser engraving and integration into the MES system, up to continuous camera controls using algorithms developed specifically for this application.” After full assembly of the automated production line, the eleven Z.SIROC automation lines take the COP vials from the injection blow-molding machine and transfer them to the Z.MISTRAL. Here, the vaccine containers are cooled and a laser engraves an individual marking. The Z.LODOS now removes the processed and checked parts and passes them on to the NEST/TUB for finishing with a nanocoating. The vials are constantly checked for quality by various cameras during all phases of production.

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Video: Borghi’s OVALE Broom and Brush Machine

See Borghi’s OVALE brushmaking machine in action. The OVALE is a universal, high-output, fully automatic broom and brush manufacturing machine that features two filling tools, two drills and finishing equipment.

The revolutionary OVALE is a universal machine with five-axis CNC control, continuously drilling and filling for higher output with no index time on most brush models, thanks to the innovative machine design with independent shuttle motion carriages. The OVALE offers a quick and easy to fill brush block conveyor feeder, electronic trimming by means of servomotors and excellent accessibility for change-over and maintenance. The operator workspace is kept compact, with a well-thought-out layout, which adds to the overall efficiency and safety of the machine.

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ZAHORANSKY: Improved Output with ZMI 4.0, Z.LYNX 3 and Z.SAILFIN


The Z.LYNX 3 has been redeveloped from the ground up and now boasts an output increase of up to 85 percent in producing twisted-in-wire brushes

Larger Quantities and More Operating Comfort

With its new ZMI 4.0 machine controls, ZAHORANSKY AG not only offers greater operator efficiency, but also significantly increases the output of twisted-in-wire brushes.

Running on new software, the Z.SAILFIN now boasts an output increase of 12 percent in the production of mascara, medical and interdental brushes. Instead of 85 brushes, the machine can now produce up to 95 brushes per minute with more precise controls of the servo motors. The output of the completely redeveloped Z.LYNX 3 for the production of twisted-in-wire brushes increases almost two-fold, depending on the brush model – from four to up to 7.5 brushes per minute (an increase of 85 percent).

Robert Dous, Director Sales & Marketing of ZAHORANSKY AG, explains, “After Interbrush was postponed, we are now even more delighted to finally present our new machines, systems and technologies to the market and to our customers. The new ZMI 4.0, reworked Z.LYNX 3, as well as greater output figures of the Z.SAILFIN are only a first taste of what’s to come. We will introduce more innovations in the coming weeks and months.”

ZMI 4.0: Smart Machine Controls

Reprogrammed from the ground up, the new ZAHORANSKY Machine Intelligence 4.0 (ZMI) features new upgrades at the operator panel with controls consistently geared toward the requirements of the operator. The modern and intuitive touch controls with clear icons and wizards reduce training effort all down the line, with programming for specified motion sequences of the machine presented in predefined building blocks. As an example, test users managed to reduce the time to program trimming profiles by five to 10 minutes, with the time required to put the machine into operation reduced accordingly. The control center also benefits from greater transparency: production figures are visualized and can be tracked over set periods of time.

ZAHORANSKY Machine Intelligence 4.0

The reprogrammed ZAHORANSKY Machine Intelligence 4.0 (ZMI) offers operators modern and intuitive touch controls

ZMI 4.0 takes processes that logically follow each other into account, minimizing operating errors. If anything is unclear during operation or if questions arise, “Help me” wizards suggest suitable solutions. The integrated service mode makes it easier to request international support and overcoming language barriers. ZMI 4.0 utilizes a unique ID number stored in every field of the display (for example, in the settings of the filament feed). The ID only needs to be mentioned when making an inquiry, for easier identification of faults which speeds up the support process. Besides the new operating concept, the ZMI 4.0 makes it possible to achieve quicker and more precise control times for the servo motors on machines such as the Z.SAILFIN and Z.LYNX 3. They run more quietly and quickly, which is reflected in higher outputs.

Z.LYNX 3: Redeveloped for Greater Performance

Z.LYNX 3, the specialist in the production of twisted-in-wire brushes, has been redeveloped from the ground up. The machine concept was above all reworked to allow for conversion to parallelized production. Up to now, one brush was produced completely before producing the next brush. Now, half a brush is produced at one station, and further processing or finishing takes place at the next station. Output increases by up to 85 percent, depending on the brush model, with an increase of four to 7.5 brushes per minute. This is also largely attributable to the gentler motor controls of the ZMI 4.0. Even with these greater performance specifications, the machine can still process wire core diameters of one to four mm, but much quicker.

Zahoransky Z.LYNX 3

The Z.LYNX 3 for twisted-in-wire brushes in action

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ZAHORANSKY Launches Customer Magazine

ZAHORANSKY has now offered a new online customer magazine published with new information on the latest technologies and machines. The browser-based magazine is offered in three languages at the following links:






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2020 Brushware July-August Digital Edition Now Available

The 2020 Annual Summer Buyers’ Guide / July-August digital edition of Brushware magazine is now available to readers. Considered “The Bible” of the brush industry this special issue includes a complete supplier and manufacturer directory with an extensive category index that allows users to quickly locate company capabilities. In addition, veteran writer Bob Lawrence takes an in-depth look at 3D printing in the industry. Readers will also find year-to-date US Import/Export stats along with a May PMI report with charts tracking data for several regions and countries.


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Video: Borghi’s GALAXY Brush Making Machine

Watch Borghi’s GALAXY brushmaking machine in action. The GALAXY is a fully automatic tufting machine with two filling tools, two drills and two trimming units for the production of cylinder brushes. 

The GALAXY is designed for high volume production of industrial cylinder brushes with minimum supervision by the operator. GALAXY is a three-station carrousel machine with automatic feeding of the blocks and automatic transfer of the brushes to the trimming unit. The block loading is operated by a robot that loads the blocks from the feeder and places them into the first station of the machine, while the machine is drilling and filling in the other two positions. Every time the drilling/filling operation is completed, the machine indexes bringing the brush automatically to the next station. When the working cycle is completed, the filled cylinder brushes return to the first station where the robot transfers them to the trimming units for finishing. The finished brushes are ejected by conveyor belt.

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Video: MGG Srl Paintbrush Production Technology

MGG Srl is your company for production technology in the paintbrush industry. MGG capabilities cover the entire production value chain, from basic design and detail engineering, in-house manufacturing and testing and after-sale services. Customers benefit from MGG’s organization by competence, lean processes, fast decision making and reliable service.

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