Automated Solutions for Plastic-Based Medical Products

Zahoransky Automation & Molds GmbH presents its solutions for the manufacturing of plastic-based medical products, including primary packaging, such as pre-filled syringes or vials, systems for drug delivery or dialysis device components.

The company also provides tailored consultation and product design to the development and manufacturing of injection molds, as well as design and installation of automated no-human-touch production systems in modular construction. This approach is intended for optimal implementation, planning and process reliability in order to increase overall equipment effectiveness and reduce unit costs, personnel and resources.

A recent example is an automation solution developed by Zahoransky, which features internal mold handling, intended for the two-component injection molding of applicator closure caps for digital diabetes sensors. The compact system, with minimal mold opening and a high degree of automation, can provide increased output and process reliability while saving space and cost.

During the creation of this customer-specific solution, the thread of these caps presented a challenge — it needed to be unscrewed rather than simply ejected from the mold. Additionally, the customer requested a compact system with a high degree of automation for mass production due to space constraints. Zahoransky then employed the “Z.Warp move” mold. With this mold, the freshly molded base component is removed by an integrated automated handling unit, while the pitch dimension can be compressed before the semi-finished product is placed for the second component.

The distances between the cavities are then optimally set for the subsequent injection molding process. The finished caps are then removed parallel to the injection molding process by a six-axis robot. According to the company, this process offers customers several advantages: in addition to a shorter cycle time, the associated injection molding machine can also be smaller and thus less expensive due to its design.