Zahoransky: Tool concept for more efficient autoinjector manufacturing in focus

The tool concept "Z.Sonic turn" for mass production of auto-injector housings is the focus - (Image: Zahoransky).

Zahoransky presents at Fakuma 2026 the tool concept "Z.Sonic turn" for high-volume manufacturing of pen and auto-injector housings. The solution developed together with Netstal is intended to enable higher output especially within limited cleanroom space. The system is shown in combination with a fully electric injection molding machine of the "Elion Med" type.

The background is the increasing demand for pens and auto-injectors, partly due to the growing need for GLP-1 medications for diabetes and obesity therapy. Manufacturers are faced with the task of expanding production capacities without significantly increasing cleanroom space and equipment size. At the same time, requirements for process quality, cost-effectiveness, and automation are rising.

"Z.Sonic turn" therefore follows a different approach than traditional productivity increases through a higher number of tool cavities. Instead of using larger injection molding tools, the individual production cycles are shortened. To achieve this, the residual cooling of the molded parts is shifted out of the cavity. An advanced indexing plate with a servo-driven rotary unit also enables demolding outside the tool in parallel with the next injection cycle.

According to Zahoransky, a four-cavity tool with this concept achieves a cycle time of twelve seconds. Conventional lift-and-strip tools require around 18 seconds for a comparable application. In a sample calculation, this increases annual production from approximately 8.5 million to more than 12.8 million parts. At the same time, piece costs are expected to decrease by 23 percent. A payback period of around nine months is cited for the underlying application.

In addition to cycle time, the tool weight has also been reduced. The "Z.Sonic turn" tool reportedly weighs around 3,500 kilograms, about one ton less than a conventional comparison tool. The more compact design is intended to reduce the space needed in the cleanroom and lower energy consumption during tool heating.

For higher production volumes, Zahoransky is preparing variants with 16 and 32 cavities, according to their own information. At Fakuma 2026, the tool concept will be shown as part of an integrated manufacturing solution, where toolmaking, the injection molding process, and downstream automation are interconnected.