Smart Molding International 3-2022

31 molding technologies www.smart-molding.com pipette tips, cuvettes, laboratory con- sumables, and blood sampling tubes. Here, too, plastic is used universally as a substitute for glass. This enables these products to be manufactured in a short time, with high quality, short start-up times, and little waste. O.K. status ensured throughout The risk of malfunctions and defec- tive parts is minimized in all facilities through continuous quality and process controls. Depending on the product and requirements, this can be guaranteed by 100% camera inspections, integrated X-ray modules, and leak tests. Even at maximum production utilization, such as the daily manufacture of 600,000 co- rona virus vials at the US company SiO 2 , the O.K. status of parts and components is ensured at all times. Manufacturing 4.0 Byusing thedigital twin, ZAHORANSKY can simulate the manufacturing and as- sembly of a variety of products – such as pre-filled syringes, various drug dis- pensers, and electric toothbrushes – in advance and calculate their cost- effectiveness. This reduces the time to market as the digital processes can be optimized in advance and then quickly transferred to the actual machines. The decoupling of functional units also in- creases the Overall Equipment Effec- tiveness (OEE). Plastic in medical technology: the ideal glass replacement material Plastic is the ideal alternative to glass, particularly in medical products such as pre-filled syringes, due to its material properties and advantages in process- ing and handling. In the manufacture of these hybrid components, such as pre-filled syringes with pre-filled med- ication, instead of risky bonding pro- cesses with drying and cleaning times, tried-and-tested processes are used where the needles are overmolded in a process-safe manner. This also makes it possible to manufacture inhalers and interdental brushes, as well as to over- mold electronic components. This one- step production approach reduces not only the total number of production steps but the costs as well. Background information The name ZAHORANSKY has stood for reliability, precision, and sophisti- cated technology since 1902. Anton Zahoransky laid the foundation for this with his small workshop in Todt- nau, where he manufactured the first devices and machines for the automa- tion of brush production. Based on the experience and exper- tise gained since then, ZAHORANSKY is today a full-range supplier and technology partner for companies in the brush industry, medical technol- ogy, and other sectors. With injection molds, engineering, and automa- tion technology, as well as packaging equipment, ZAHORANSKY provides comprehensive solutions for individ- ual requirements. Approximately 900 employees, including 70 trainees, in ten locations in Germany, Spain, Chi- na, India, Japan, Brazil, and the United States work toward this goal every day. ZAHORANSKY www.zahoransky.com Continuous quality and process control ensures the OK status of parts and components at all times Staked-needle-syringes with the glass substitute plastic and overmolded cannulas