ZAHORANSKY AG
Automation from A to Z: ZAHORANSKY at Fakuma 2026
Z.SONIC turn tool concept for high-volume production of autoinjector housings takes center stage
Pharmaceutical and medical device manufacturers are facing greater pressure than ever before. They must scale production capacities, reduce unit costs, and ensure the highest levels of process and product quality, all while navigating increasingly stringent regulatory requirements, limited cleanroom space, and a growing shortage of skilled labor. To address these challenges, ZAHORANSKY brings toolmaking, injection molding integration, and downstream automation together under one roof, positioning itself as a comprehensive solutions provider. From October 12 to 16, the company will showcase its Z.SONIC turn tool concept for the highly efficient production of pen injector and autoinjector housings at Fakuma 2026 in Friedrichshafen (Hall A2, Booth 2309). The solution was developed in collaboration with Netstal.
Demand for pen injectors and autoinjectors is growing rapidly, driven primarily by the boom in GLP-1 medications used for weight management and diabetes treatment. Manufacturers therefore need to expand production capacities quickly, but are typically constrained by existing cleanroom facilities. Rather than increasing productivity solely through additional cavities, which would require larger injection molds, ZAHORANSKY’s Z.SONIC turn concept focuses on maximizing efficiency in every production cycle. The Z.SONIC turn mold concept shifts the residual cooling of the produced parts outside from the mold. Using an advanced indexing plate with a servo-driven rotary unit, further cooling and demolding takes place outside the mold in parallel with the injection cycle.
Using a four-cavity mold, a cycle time of just 12 seconds was achieved, compared with 18 seconds for conventional lift-and-strip molds. Based on a sample calculation, annual output increases from approximately 8.5 million to more than 12.8 million parts, while unit costs are reduced by 23 percent. This results in a payback period of approximately nine months. At 3,500 kilograms, the mold is also around 1,000 kilograms lighter than a conventional counterpart and features a significantly more compact footprint, reducing both cleanroom space requirements and the energy needed for heating. In addition, 16-cavity and 32-cavity versions are already being prepared for large-scale production. At Fakuma, ZAHORANSKY will present this innovative tool concept in combination with Netstal’s fully electric Elion MED injection molding machine as a fully integrated manufacturing solution.
Further information:
ZAHORANSKY AG
Product Marketing
Anton-Zahoransky-Straße 1
79674 Todtnau-Geschwend
Tel.: +49 (0) 7671 997-0
E-Mail: info@zahoransky.com
www.zahoransky.com
Press and public relations:
Press'n'Relations GmbH
Nataša Forstner und Christoph Buck
Magirus-Deutz Str. 14, 89077 Ulm
Tel. +49 731 146 156-77 / -74
E-Mail: nfo@press-n-relations.de and cb@press-n-relations.de
www.press-n-relations.de
Background information ZAHORANSKY
ZAHORANSKY AG is known for cutting-edge technology in machine engineering and mold making for over 120 years and is today an internationally active technology provider which is 100% family owned. Based on decades of experience combined with foresight and a culture of innovation, ZAHORANSKY is a full-service provider and technology partner for companies in the brush industry, medical technology and other sectors. Market-leading manufacturers of oral care and cosmetic products, producers of household and industrial brushes as well as pharmaceutical companies worldwide rely on the comprehensive consulting, development and service expertise of ZAHORANSKY.
One of the company‘s proven strengths: on request, ZAHORANSKY provides customers with complete solutions from a single source for the manufacture of complex plastic, hybrid and glass replacement products. This includes injection molds, upstream and downstream automation solutions and quality control as well as the integration of injection molding machines and other system components for turnkey, fully automated production lines. About 690 people are employed at our headquarters in Germany and the sites in Spain, China, India, Japan, Brazil and the USA.
| Copyright © 2026 Press'n'Relations |
|