ZAHORANSKY at K 2025: Innovations for Plastics and Medical Technology in Focus

From October 8 to 15, 2025, ZAHORANSKY will present pioneering technologies for the plastics and medical technology industries at the K trade fair (Hall/Booth 1C97) in Düsseldorf. At the center of attention will be the PRIMA Z syringe production system in the new Medical Design – an all-in-one solution for the reliable and cost-efficient manufacturing of plastic syringes made of COC/COP.

The innovative Z.SONIC turn mold concept will celebrate its premier at the K trade fair at the stand of ZAHORANSKY partner NETSTAL Maschinen AG (Hall/Stand 15/D24). With significant cycle time reductions and maximum precision, this innovation sets new standards in the high-volume production of pen and autoinjector components.

Completing the trade fair line-up is the new Z.ORCA 18. With this, ZAHORANSKY is introducing its most compact and flexible single-filling machine for industrial toothbrush production to date, delivering maximum performance in the smallest space. With all three exhibits, ZAHORANSKY demonstrates how cutting-edge technology, space-saving design, and intelligent process solutions can be combined into highly efficient manufacturing systems.

Z.ORCA 18 – Maximum performance in minimum space

A key highlight at the ZAHORANSKY booth is the new Z.ORCA 18 – the most compact yet versatile single-filling machine the company has developed to date. Designed for production environments with limited floor space, it combines maximum flexibility with impressive performance. With a footprint of just 4.77 m², the machine produces up to 30 toothbrushes per minute – and with special designs featuring fewer drillings, such as children’s toothbrushes with dual tension, even up to 60 units. Quality remains uncompromised. The proven robust design ensures low vibrations, quiet operation, and machine availability of up to 98%. With up to eight freely selectable finishing stations, a wide variety of brush designs and decorations can be realized – including custom embossing such as logos or mascot motifs.

PRIMA Z syringe – Efficient production of plastic syringes

The centerpiece of ZAHORANSKY AG’s trade fair presence is the PRIMA Z syringe in the new Medical Design. This turnkey production system with a 4-cavity mold is optimized for the highly cost-efficient production of staked needle syringes made of plastic, but it is also suitable for Luer and Luer-lock syringes. COC- and COP-based materials offer clear advantages: they facilitate the filling and storage of sensitive pharmaceuticals, reduce breakage risk, and extend the shelf life of delicate drugs thanks to excellent barrier properties. This is particularly true for pre-filled syringes (PFS), since the needle can be positioned more flexibly before overmolding and is neither melted nor glued in place. The result: increased process reliability and reduced effort in transport, storage, and handling

Thanks to its fully integrated automation concept, the PRIMA Z syringe also ensures maximum output with consistently high product quality and minimal operator workload. Another efficiency booster of the machine comes from two tools provided by ZAHORANSKY’s partner plus 10 GmbH: The AI tool Hopper reduces scrap through situational parameter recommendations based on high-resolution live process data, shortens ramp-up times, and increases transparency of validated injection molding processes. Shannon, in turn, supports operators directly at the machine by providing situational recommendations in the event of stops or disruptions. Visitors to the ZAHORANSKY booth can experience both solutions live.

Z.SONIC Turn – New mold concept for pens and autoinjectors

With Z.SONIC turn, ZAHORANSKY is publicly unveiling its entirely newly developed mold concept for high-volume production of pen and autoinjector components. Driven by the rising demand for GLP-1-based weight-loss medications, the need for both reusable and disposable pen injectors is growing rapidly. However, many existing mold solutions still date back to the 2000s and are no longer state-of-the-art. Z.SONIC turn sets new standards: the mold architecture, tailored to the high demands of medical technology, enables cycle time reductions of up to 20% through innovative cavity arrangements and externalizing residual cooling time from the mold – all with minimal space requirements and optimized energy consumption. The outcome is not only higher output but also a significant reduction in unit costs. Z.SONIC turn will be on display at the booth of ZAHORANSKY’s partner NETSTAL Maschinen AG (Hall/Booth 15/D24).

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