Revolutionary toothbrush production
65 million years ago, the dinosaurs died out when the Earth was hit by a giant meteorite. In the world of oral care brush production, the CUBE is a comparable event. Everything is changing. Many „dinosaur machines“ are dying out because they no longer meet today’s standards. These „dinosaur machines“ are not carnivores or herbivores, but are the worst cost, resource, personnel and time guzzlers of all time. And the CUBE is their natural enemy.
THE REVOLUTION IN TOOTHBRUSH
PRODUCTION STRIKES THE WORLD LIKE
With a big bang, the CUBE revolutionizes toothbrush production and makes the long-established dinosaur machines look old.
With its clear, modular three-part design – consisting of a base unit, supply unit and cover unit – in conjunction with the new ZMI 4.0 machine control system,
the innovation sets new standards in the manufacture of anchor-tufted toothbrushes.
Up to six CUBEs can be combined to increase the number of units or adapt to new market requirements.
The sequence of the tufting and finishing units can be variably adjusted in the process.
Unique product designs (diff. hole diameters / complex trim profiles)
No limits in design in manufacturing of manual
toothbrushes or power toothbrush heads
Time to market of a new toothbrush model
approx. 4 months
Always one innovative step ahead
Are new toothbrush designs always limited by rigid machine technology, or are they impossible without new equipment? Even if, from the existing idea to the launch, two years or more roll by? Then say goodbye to your innovation guzzler and always be one innovative step ahead of your competitors from here on out.
„Our designs are copied over and over again. We have to continuosly invest in new toothbrush designs that are difficult to copy and therefore also complicated.“
„The market is very fast-moving. We have to recognize trends and transfer them into new design accents. That’s where simple implementation in everyday productions is important.“
„As a production manager, I love it when a standard solution of machine technology can handle any special solutions of toothbrushes.“
„Our production is our flagship. Here we want to convince our customers with a smart overall solution. Innovative machinery & production facilities are our most important marketing tool. This gives our customers security for the future.“
Fast installation of the CUBE: max. 5 days
Short changeover times: 2-4 hours
Delivery time CUBE-Line: 4- 6 months
Delivery time new brush sample kit: 6-8 weeks
Whether it’s replacing parts, making adjustments to the system or carrying out tests, changeovers in your production are time-wasting nightmares that cost a lot of money. In addition, there are long delivery times for individual systems which require very long-term planning. Put an end to these time guzzlers with CUBE.
„From the product idea to the launch on the market, we sometimes need 2 years. This is also due to the way the machines are and systems are made: long prototyping, time-consuming project planning and long delivery times.“
„We need universal machines that give us a 50% time-to-market.“
„The point in time at which variants can be created for a specific toothbrush model must be possible at the latest.“
„Change overs become a time consuming nightmare for us: part replacement, adjustments, tests, again and again. Machine manufacturers never really take on our role as a manufacturer.“
High flexibility = ZERO investment risk
50 & less downtime
(e.g. production continues during maintenance)
No additional handling needed between interlinked CUBE- Lines
Technical availability: up to 98%
Maximum process reliability
Linked production lines are always problematic. If individual modules or stations fail, the entire system quickly grinds to a halt. This leads to massive losses. Machines that are prone to failure are fatal flaws in maximum process reliability.
„Interlinked production lines are always problematic. If individual modules or stations malfunction or fail, the entire line quickly comes to a standstill. This causes massive losses. Process reliability is the critical point.“
„Maintenance on machines is so costly because the line stands for the interval and does not produce. This drives up our manufacturing costs and affects our competitiveness.“
„Process reliability is crucial for me as a supervisor. Machines that are susceptible to malfunctions are a nightmare. I can never reach the required production figures.“
„If one tufting unit fails in interlinked lines, the total availability is zero. I need the remaining tufting modules continue to produce and remaining 70% availability.“
Free accessibility to all working stations
Ergonomic one-side operation = 80 % less walking distances
Software-controlled monitoring and changeover system (ERCO)
Ergonomics is a foreign word for the toothbrush machines of the last generation. The systems have basically been strung together like puzzle pieces and have grown into an impractical, gigantic monster, which often means long walking distances of at least 5 km a day for the operator. In addition, many areas of such systems are difficult to access and are always associated with assembly and disassembly work. With the CUBE, all of this will change.
„Focusing on workplace health is business owner’s duty. Our employees are our most important asset. Workplace health is a top management topic. Ergonomics and operating concepts are critical for purchasing decisions.“
„You don’t just feel bad ergonomics, you see it in the production volume at the end of the day.“
„Every manager should once spend a full day working on a machine that leaves a lot to be desired ergonomically. That is a very valuable experience.“
„I am a machine operator in toothbrush production. Good ergonomics of my machines is crucial for me. That’s why I quit my last job.“
Suitable for manual- and/or power toothbrushes
Freely up or down scalable
according to production demand
CUBE high output mode or CUBE all around mode for
demanding toothbrushes/hole patterns
Upgrade possibility of additional functions
Scalable without limits
These days, you have to respond quickly changing market requirements. Extra deliveries and quick system changeovers are part of everyday life. Add to that the complex and time-intensive training of staff. Sluggish, inflexible and complicated systems are a no-go.
„As an OEM we need to react quickly to changing market requirements. We have to invest into production equipment before the toothbrush model is known. This is where we need flexible and variable toothbrush lines.“
„We need manage fluctuations in retail sales. Otherwise we lose shelf space and risk our listing. That’s why scalability of production capacity and performance is essential. Here we want expandable, modular solutions.“
„We simply can no longer afford to invest in machinery and equipment for just one toothbrush model. When demand drops we have massive overcapacities. Low utilization rates are no longer acceptable. We need highly flexible units.“
„As a supervisor, I am responsible for the flexible operation of different toothbrushes on several machines. I want simple, logical and intuitive operating concepts which gives me that flexibility.“
20 % reduced capital investment due to standardized components
40 % reduced changeover costs to less sample specific parts
Only 1 operator for entire CUBE line
(Output: From 40 to 160 toothbrushes per minute)
Cost savings from out of this world
Expensive toothbrush machiens often cost more than €1 million. In addition, there are high expansion costs and high running costs, which increase the investement risk. With CUBE, these cost guzzlers are finally dying out.
„We always take a critical look at our investments. We only invest in what is absolutely necessary and future-proof. We focus our attention on modular, expandable systems. We buy what we need“.
„We supply toothbrushes to large discounters. Time and again, we have to deliver additional quantities at short notice due to fluctuations in demand. Complex and time-consuming changeover on the machinery is a No-Go.“
„Training staff is a real challenge for us. Machines are too complex. O & M require expert knowledge and experience. Recruiting & training right staff takes time and is expensive.“
„I come from the nonwoven sector. Lines are switched automatically from baby diapers to sanitary napkins. The oral care world was a shock for me. The conversion costs are enormous.“