Reduced set-up times, higher output, more flexibility in production: The new development from the innovation department of Roth Composite Machinery in Burgwald scores with numerous advantages. The fully automatic concept can be used to produce brushes that are completely different in terms of length, geometry and material - without the need for time-consuming retooling.

"During development, our main focus was on speed, flexibility and efficiency," explain Dennis Brückner, responsible for the Burgwald plant at Roth Composite Machinery, and sales engineer Thomas Halbrucker, "the machine concept fulfils the requirements of flexible mass production and meets our high standards of quality and sustainability."

The new brush filling carousel scores with two filling tools, i.e. it works according to the twin principle. With five electronic axes and the interchangeable carrier transfer design, the high-performance carousel machine can pick up brush bodies made of all common materials such as plastic or wood at extremely high speed, drill holes between 1.8 and 8.5 millimetres in diameter and fill them with the corresponding bristles.

Finishing processes such as splicing the bristles, cleaning and even labelling or embossing the brush body are also fully automated. A shearing unit has been integrated for the production of toilet brushes, which can simply be called in if required.

The speed is also impressive: each filling tool can produce 610 bundles per minute, meaning that the new machine can produce a total of 1220 bundles per minute. The innovative "Roth Flying Cabinet" system also ensures speed: the high-performance carousel rotates permanently in one direction, thus guaranteeing continuous operation without the carousel having to turn forwards and backwards.

"This new process has several advantages," explains Sales Engineer Thomas Halbrucker, "the maintenance effort is almost zero, which means that the machine has even less downtime. In addition, the 'Roth Flying Cabinet' is even less susceptible to external influences such as vibration or dirt."

Another important plus point is that the machine consumes less energy thanks to its very even operation.

Manufacturers of household or industrial brushes can therefore significantly reduce their production costs with the innovation from Roth Composite Machinery due to the higher output quantity, shorter set-up times, lower maintenance requirements and energy-saving operation.

In line with the Roth companies' aspirations, the aspect of sustainability took centre stage in the development of the new high-performance carousel. It is not only the operating principle of the machine that saves energy, but also its production. The system was developed entirely at the Burgwald site and manufactured using 100 per cent green electricity. No long transport routes are or were necessary for its manufacture. Only solvent-free paints were used, but above all the machine scores points for its durability and longevity: "We guarantee 25 years of spare parts availability," emphasises Dennis Brückner.