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ZAHORANSKY Completes India Plant Expansion

Expansion of the Coimbatore plant in India will strengthen global market position and delivery capacities

After a year of construction, ZAHORANSKY has completed the expansion of the plant in Coimbatore, India, and is now on course for the sustainable expansion of its business in developing state-of-the-art solutions for toothbrush production in price-sensitive markets. By doubling the production capacities and adding office and meeting spaces, ZAHORANSKY can now leverage the Coimbatore location to meet the increasing demand from customers from India, Asia, and Latin America for molds and machines to manufacture toothbrushes. 

“With the completion of the new construction project, we are starting a new chapter for ZAHORANSKY Coimbatore. We will ensure clear optimizations in our future production and logistics processes, and with that shorter delivery times, with additional 3,200 square meters. Moreover, this opens up additional room for our models produced in India, the Z.ORCA, Z.SWORD, and Z.SHARK,” says Robert Dous, Head of Sales/Marketing of ZAHORANSKY AG. 

The expansion was accompanied by the optimization of workplaces and processes, to lay the foundation for quicker, more efficient and more flexible production. Furthermore, programs for employee qualification and motivation make ZAHORANSKY an even more attractive employer.

Prior to the groundbreaking for this current expansion in October of 2018, the Indian subsidiary had already relocated from Mumbai to Coimbatore roughly ten years prior. ZAHORANSKY started by using rented premises for production. However, the development of Asian business allowed for the opening of the company’s own plant in 2013. And now, the Indian branch has developed into the second-largest location of the ZAHORANSKY Group overall, employing around 160 professionals. The constant growth in demand from India, as well as China, Indonesia, and South Africa, resulted in the plant reaching the limits of its capacity. Every square inch of space was being used, especially in the assembly hall and storage. This restricted delivery capacity and flexibility in realizing customer solutions, which also limited the actual growth potential of the location. 

More space, greater flexibility

With this new expansion, approximately 6,000 square meters will be available for offices, parts manufacturing, assembly and storage. Additionally, perfect conditions have been created for order processing and customer care in the existing buildings with modern office and meeting rooms included in the effort. 

“The expansion allows us to respond to customer requests with even greater flexibility, while simultaneously meeting the growing demand of our customers for a higher degree of automation in the production of their toothbrushes,” says Dous. “With these measures, we also ensure that the production in Coimbatore will be able to follow the very strict standards of quality that apply to our German parent company, thus keeping the promise we make to our customers of delivering ‘Black Forest Quality,’ made in India.”

Creating perfect working conditions

Further initiatives in ensuring the long-term competitiveness of the company, revolve around digitalization, workplace design and employee qualification as well as motivation. Relative to di digitalization, the focus is on the digitizing technical documentation, which has already become the standard in Germany. The measures in workplace design, further education and motivational training are geared toward establishing the ZAHORANSKY benefits, such as the exemplary integration of employees and attractive social benefits, to set a trendsetting role in creating a positive work environment. 

“We strive to attract young and highly motivated individuals to work for us. They will help us further develop our location and make it future-proof,” says Dous. “This is why we offer working conditions far beyond the local standards. This applies to both the work activities themselves as well as the physical work environment. To give you an example, our new building saves an incredible amount of resources and is the first factory certified with Platinum by the Indian Green Building Council (IGBC) in Southern India. This means that it fulfils the most discerning standards of sustainability and environmental protection.”

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