Z.WASP 1 from ZAHORANSKY: Double Output for Industrial Large Brushes

New generation of the ZAHORANSKY machine impresses with parallel processing and flat wire technology

With the new generation of the Z.WASP 1, ZAHORANSKY is expanding its portfolio in the field of technical and industrial brushes with a machine that sets new benchmarks in terms of output and stability. Specifically designed for the production of large disc and roller brushes—such as those used in street cleaning—the further developed machine enables a doubling of production volume while requiring comparatively little floor space.

At the heart of the new Z.WASP 1 is its new base design, which leads to a significant increase in efficiency in the manufacture of large-format brush products. While previous machines of this type often required sequential processing steps, the new generation features an enlarged base structure with two separate processing stations. This enables a decisive process advantage: in a single operation, two disc brushes with a maximum diameter of up to 900 millimeters can now be processed simultaneously. While drilling takes place at one station, the tufting process is carried out simultaneously at the other. Previously, these steps had to be performed consecutively for brushes of this diameter—by parallelizing the processes, the machine’s output can now be effectively doubled.

Maximum Stability Through Flat Wire

However, the Z.WASP 1 does not only stand out in terms of quantity, but also through a qualitative expansion of its processing capabilities. Optionally, the machine can be equipped with a special flat wire unit. Processing flat wire increases the stiffness of the bundles and thus the overall rigidity of the brushes. This is a decisive quality feature, particularly for technical brushes that are often exposed to extreme loads. In addition, the servo motor on the drilling unit enables higher drilling precision, which further enhances processing quality.

The All-Rounder for Technical Brushes

Despite the new high-performance features, the proven strengths of the Z.WASP family remain intact. The Z.WASP 1 is designed as a 5-axis machine and is the specialist within the ZAHORANSKY portfolio for the production of roller and disc brushes. With an impressive tool stroke of 250 millimeters, it is designed to process filament lengths of up to 700 millimeters (unfolded), far exceeding the standard in the household sector. Production is semi-automatic: feeding the brush bodies and removing the finished tufted products are carried out manually by the operator, while drilling and tufting take place fully automatically and with the highest precision within the machine.

Technical Data at a Glance

The machine is equipped with two clamping devices and two drilling units operating at speeds of up to 12,000 rounds per minute. The tufting tool achieves speeds of up to 200 bundles per minute, depending on tool stroke and brush configuration. Two different filament colors can be processed, and two different materials – such as nylon and metal – can be mixed within a single tufting hole. Thanks to its robust design and the ability to process both wooden and plastic bodies as well as natural fibres and nylon filaments, the Z.WASP 1 offers maximum flexibility for demanding industrial applications.