Zahoransky: Tool Concept for More Efficient Autoinjector Production in focus

The “Z.Sonic turn” tooling concept for high-volume production of autoinjector housings is in focus – (Photo: Zahoransky).

Zahoransky will present its “Z.Sonic turn” tool concept for the high-volume production of pen and autoinjector housings at Fakuma 2026. Developed jointly with Netstal, the solution is designed in particular to enable higher output within limited cleanroom space. The system will be showcased in combination with a fully electric “Elion Med” injection molding machine.

The background is the growing demand for pen and autoinjectors, driven in part by increasing demand for GLP-1 medications for the treatment of diabetes and obesity. Manufacturers are therefore faced with the challenge of expanding production capacity without increasing cleanroom space and machine footprints to the same extent. At the same time, requirements for process quality, cost efficiency and automation are rising.

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“Z.Sonic turn” therefore takes a different approach from the conventional method of increasing productivity by adding more mold cavities. Instead of using larger injection molds, the concept is designed to shorten individual production cycles. To achieve this, the remaining cooling phase of the molded parts is moved outside the cavity. A further-developed index plate with a servo-driven rotary unit also allows demolding to take place outside the mold in parallel with the subsequent injection cycle.

According to Zahoransky, a four-cavity mold using this concept achieves a cycle time of twelve seconds. Conventional lift-and-strip molds require around 18 seconds for a comparable application. In a sample calculation, this increases annual production output from approximately 8.5 million to more than 12.8 million parts. At the same time, unit costs are said to fall by 23 percent. For the application used as the basis of the calculation, Zahoransky specifies a payback period of around nine months.

In addition to reducing cycle time, the weight of the mold has also been lowered. According to the company, the “Z.Sonic turn” mold weighs around 3,500 kilograms, approximately one metric ton less than a conventional comparable mold. The more compact design is intended to reduce the amount of cleanroom space required and lower the energy needed to heat the mold.

For higher production volumes, Zahoransky says it is preparing versions with 16 and 32 cavities. At Fakuma 2026, the tool concept will be presented as part of an integrated production solution linking moldmaking, the injection molding process and downstream automation.

Fakuma 2026
Friedrichshafen, Germany
October 12–16, 2026
Hall A2, Stand 2309

More information: www.zahoransky.com

Zahoransky AG, Todtnau-Geschwend, Germany

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