Black Forest Quality – at Home Worldwide

Home , Black Forest

02 | 2016

The ZAHORANSKY Customer Magazine

New Factory in Spain YELMEN from Turkey is Completed p. 4—5 Customer Portrait p. 10—11 2 Editorial

Quality Knows No Borders

> Robert Dous, Head of Sales & Marketing

Dear Readers,

In the old days, everything was simpler. Really?

Well, that's probably true for some things: When the ZAHORANSKY company was founded at the turn of the 20th century, communication pathways were short. Everybody knew everybody, and everyone spoke the same language. Just like a little family. We still remain an owner-operated family company today, yet our infrastructure spans the entire globe. Today we employ almost 750 people, and are represented at our own locations on four different continents. These are the challenges of our modern era, challenges we rise to meet each day. And yet we love to take on these challenges head-on. We consider it our duty as well as our aspiration to deliver the best possible technology and optimal service, no matter whether it's in our home region, the Black Forest, or any other region on earth.

For us, this means we must use our knowledge, our commitment, and our motivation to overcome boundaries. Black Forest Quality has to apply not only in Todtnau, but also in São Paolo, Coimbatore, or in the Spanish city of Logroño. It’s why we go to work every day.

Sincerely, Robert Dous Head of Sales & Marketing Contents 3

Contents

ABOUT US 6, 7, 8, 13 GROUP NEWS 4 – 5, 9, 12

How Zongye Zhang Our New Factory in Spain Our Tiger is Flexing Its Jaws Ended up at is Completed New Production Manager at ZAHORANSKY ZAHORANSKY: Moritz Seger We Are Development The New Z.PACK: Partners Flexible and Precise Quality Begins in the Mind Turkish Customers Hosted in Todtnau

CUSTOMER FOCUS 10 TRADE FAIRS 14 SHORT NEWS 15

Everything for the Household – In-House Exhibition Oral Care Z.LION: Next Generation of YELMEN Plastics Turkey in Japan Brush Production Dental Care in Japan Upcoming Trade Fairs 2017

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Picture gallery Video Link Information 4 GROUP News

The New Factory in Spain is Completed! GROUP News 5

Our factory in the Spanish city of Logroño in the province of La Rioja has been completely redesigned. After a full year of construction, the opening ceremony was recently held for the 4,000 m2 factory. This brings all six ZAHORANSKY factories up to the standard of state of the art technology, forming a coordinated and powerful production network.

ZAHORANSKY began production in Logroño 43 years Household Machines ago. We re-built the factory for around 2.5 million euros in response to the increased demand for machines to manu- Made in Logroño facture household and technical brushes. “We're not just investing in brick and mortar, we are also investing in pro- The Z.PARD and Z.LION series and the Z.WASP and viding our employees with expertise and training on site,” Z.HORNET are manufactured in Logroño. There is now sig- says Robert Dous, Head of Sales. The number of employ- nificantly more space to do so. The expansion doubled the ees will be doubling in the medium term to 80. floor space to 4,000m2. The new assembly hall offers room for component assembly, machine assembly, testing areas, Black Forest Quality and incoming and outgoing goods storage. With an open span of 30m and a 8.5m hook height, it offers outstanding is Everywhere versatility.

Once again, ZAHORANSKY has made a pioneering invest- Long-Time Employees ment in infrastructure, underscoring our commitment to producing the Black Forest Quality our customers expect Travel to Opening at every location. The new factory in southern India began operations just three years ago. Logroño is the next mile- There was a unique gesture in honor of the opening: Five stone. long-time employees with over 50 years at our company were invited to the ceremony. Besides Ulrich Zahoransky and Gerhard Steinebrunner, our two Chairmen, representatives of the political and economic worlds in Logroño and the province of La Rioja also took part.

Black Forest Quality at Home Worldwide

1 Headquarters in the Black Forest 10 Plants in 7 Countries

1 Family-run Company 750 Employees Worldwide

1 Mission 100 % Responsibility

1 Quality pledge from the Black Forest 4,000 happy customers worldwide 6 About Us

Ideas Make the Difference

Product Development

Idea Development Design & Feasibility Studies

Prototyping & Produktion

Of course, a good idea isn’t always easy to implement. It often needs to be researched, worked through, developed and refined. Custom-tailored R&D service at ZAHORANSKY does just that: From idea to finished product.

We support our customers in developing products and our customers to develop new or changed blister packag- applications, procedures and methods. The in-house coming designs, including samples. We use our experience in petence offered by our experts starts with design and fea- designing mascara brushes, developing pilot tools, or com- sibility studies, and extends to prototyping and producing pleting feasibility studies for specialist brushes in industrial samples for market research as well as optimizing prod- applications. ucts and processes, through to production tests on spe- cialized machinery – all supported by the most up-to-date We would be happy to inform you about how you can ben- measurement technology available. During toothbrush efit from our knowledge and expertise. development, we focus on improving the topography of the handle design, the rounding or the tufting. We work with 7 Editorial About Us 7

> Numerous Turkish customers accepted our invitation to Todtnau

> Exciting go-kart race in Umkirch

> The winners of the go-kart race received a prize > Great excitement at the presentation of Z.PARD

Turkish Customers Hosted in Todtnau

We had important visitors at the end of October. A group of interest for our Turkish customers. A framework program visitors from Turkey, one of our key regions, visited us in the was set up for Saturday. It included a roller-coaster ride on Black Forest at our main plant in Todtnau for a few days. All Todtnau's local mountain, a glass-blowing demonstration, of our Turkish-speaking colleagues from sales and service and an excursion to the go-kart track with exciting races. were on site during their visit. Our visitors also got a taste of good Baden cooking during relaxed dinners at well-known restaurants in the region. Welcome Our customers enjoyed a pleasant and informative stay in the Black Forest. The event was a complete success for HOŞ GELDİNİZ ZAHORANSKY, and we’re already looking forward to wel- coming our next visitors. “It was a perfectly organized Around 20 customers from leading companies paid us a event with enlightening insights into the company,” con- visit. They got to see more than just our company. Guests cluded the excited visitors. were treated to a company presentation and factory tour. On the technical side, the focus of the presentation on Fri- day was on our Z.PARD 6225. This machine is of particular 8 About Us

> Technician Training on the Machines

Because Quality Begins in the Mind

Quality is one of the core promises we make to our customers. It is a promise fulfilled by our employees. That’s why ZAHORANSKY makes targeted and long-term investments in providing high-quality advanced training to our employees.

In view of our growing project volume and ever more com- plex tasks, nothing is as important as a well-trained employee. That’s why ten ZAHORANSKY employees spent six months back at school alongside their regular employ- > In-House Vendor Training ment, to deepen their knowledge on challenging project management topics. The company now has ten project managers certified in accordance with IPMA standards.

The training and continued education of all We see this as a reasonable investment in the efficiency employees is a key building block in and safety of our customer projects at all ZAHORANSKY locations worldwide. ZAHORANSKY’s VSQ initiative. However, we are not only training our own employees through our VSQ quality initiative. Numerous external technicians and machine operators are trained by ZAHORAN- SKY on our products according to the newest quality standards and in accordance with the relevant application. This commitment has a long-term effect on all processes, continuously increasing product quality. Short News / About Us 9

The Tiger Is Flexing Its Jaws

Overview of Highlights Material savings in manufacturing end products Brushes with up to 40°-bundle position possible Highest tufting speeds of up to 600 UpM Additional unit to increase product variety Optionally available and upgradeable

A new version of the Z.TIGER recently became available on the market. It provides a new filling tool for anchor filaments using servo-controlled tool jaws. This allows for sig- nificant material savings during production of the final products. The anchor plates are fed continuously, even at high bundle positions and high tufting speeds. In addition, handle thicknesses of less than six millimeters can now be tufted. This makes it especially well suited for a large number of household and cosmetic products.

The Z.TIGER is the universal, fully automated, five-axis > With (left) and without (right) movable tool jaws drilling and tufting machine for producing household products such as toilet or dish washing brushes and hand The new technical development increases the diversity of brushes or street sweepers. It offers a modern and efficient products that can be produced on the Z.TIGER. The mov- concept with the versatility needed to react precisely to able, servo-controlled tool jaws are an optional feature customer requirements. available with new machines. Machines that have already been delivered can be upgraded as needed.

The New Man in Packaging Moritz Seger is the new Product Manager at ZAHORANSKY

He is young, and a recent addition to our team: Moritz Seger, 24, started at ZAHORANSKY as a Product Manager for packaging machines. It was a challenging task for the industrial engineer who had already worked as a distribution engineer for Turkey and eastern Europe, among other areas, after his graduat- ing from DHBW Lörrach. “The duties of a Product Manager are extremely var- ied,” says Moritz Seger. “You are partially responsible for the success of a product and are involved in all the decisions related to that product.” The exciting thing about the job is that it allows the employee to network and collaborate with experts from almost every department – from development to manufacturing and assembly to sales and marketing. “Communication skills and team spirit are, therefore, just as important as a major interest in technology in my case.”

During his leisure time, Moritz Seger is a passionate musician. He plays saxo- phone and is the conductor and youth instructor in an orchestra. “Actually, there's never a day when I don’t make music” he says. 10 Customer Focus

Everything for the Household!

The success story of Yelmen Plastics goes back almost 50 years. This manufacturer of household goods from Turkey has grown steadily during this period. We spoke with dris Yelmen – he and his brother lyas Yelmen are the two Managing Directors of the company.

CONTACT: Mr. Yelmen, you decided to pur- CONTACT: What advantages are you chase a Z.LION 6325 MT from ZAHORANSKY. currently enjoying, thanks to your use of What was your reason for doing so? the Z.LION? What have your initial experi- dris Yelmen: We researched different ences been? products in advance, of course, and learned Yelmen: The machine's equipment, production that machines by ZAHORANSKY are faster capacity, and operations completely conform and more powerful. This made our decision to the expectations we have for our production. much easier. Because of this, we’re very satisfied with the machine. It was the right decision! CONTACT: What were your primary requirements for a new brush production machine, CONTACT: You have been using technology and did ZAHORANSKY fulfill these? by ZAHORANSKY for many years. Yelmen: A high degree of automation and Why is that? How did this business great flexibility were especially important to relationship begin? us. ZAHORANSKY fulfills these criteria, offers a Yelmen: ZAHORANSKY is the foremost broad product portfolio, and is able to offer us specialist in this industry. The experience products and solutions that meet our expecta- ZAHORANSKY has to offer, and the fact that tions within a short period of time. ZAHORANSKY has proven itself on the global market, are two reasons for our decision. We CONTACT: How would you rate your collabo- visited ZAHORANSKY's exhibition booth at ration with ZAHORANSKY, from technical the PLASTEURASIA fair in Istanbul in 2013. advising to putting machinery into operation We were received very warmly by Mr. Salih on site? Balkan at the booth during our visit, and he Yelmen: Since our decision to purchase a provided excellent consultation and support. ZAHORANSKY machine, we have always been This visit and this meeting were the start of provided with the best possible support from our business relationship with ZAHORANSKY. sales and from the technicians. This confirmed our decision, and we’re very happy about what we’ve seen. 11 Editorial CustomerKundenfokus Focus 11

.LION Z.LION 6325 MT

CONTACT: What do you consider the most The support we receive from ZAHORANSKY is important advantages that using ZAHO very satisfying to us as a customer. RANSKY machines and systems provide? Yelmen: Producing products on a ZAHO CONTACT: Why did you decide to invest in RANSKY machine is something special. new machine technology? For us it is a little like an art form, like painting Yelmen: We want to secure our position on the on a canvas. We are proud to produce our market. To do so, we need to be able to always products on ZAHORANSKY machines. But deliver products to our customers quickly and of course, the performance features I spoke on time. We are able to do so, thanks to about earlier also won us over. ZAHORANSKY.

CONTACT: How would you rate the service CONTACT: Mr. Yelmen, thank you very much you receive from ZAHORANSKY? for the interview. Yelmen: Service from ZAHORANSKY is always focused on satisfying the customer, and if machines require servicing, the company always works to bring them back into production as quickly as possible without any down- time. ZAHORANSKY always does everything they can to get machines running again as soon as possible.

Yelmen Plastics was founded by Mehmet Yelmen 1968 founded in 1968. He began production that year at Vefa Istanbul, Turkey main headquarters Street 48 in Istanbul, in the well-known Alkan Han business district. The company took over Arbi 5,000 m2 production area Plastics in 2008. The takeover of Arbi helped Yelmen Plastics grow even more quickly than in approx. 80 employees previous years. The takeover also significantly Colanders, spice jars, whisks, tiered expanded the company's product portfolio. serving dishes, citrus presses, vege- table graters, soap dispensers, hand towel rails, household brushes and pastry brushes products 12 GROUP News

> The new Z.PACK guide system

The New Z.PACK: Flexible and Precise

Mobility and precision aren’t a contradiction. The new The Principle is Ingeniously Simple Z.PACK proves it. Thanks to an improved guidance system, the stations can now be adjusted on the guide rails even Full-length guide rails were installed on both sides along more precisely than ever before in just a few steps. the entire chain length of the system. Guide carriages were installed on these rails, on which the stations sit. Since the This change is a response to the needs of our customers guide rails run the entire length of the system, the individu- who have to complete frequent format changes but don't al stations can be moved the entire distance without being want to be subjected to long retooling or standstill times. subject to a grid system.

n Highest technical machine availability of up to 98 % in accordance with DIN 8743 n Short fitting times (approx. 30 min.) and simple station setup using rapid tool-free exchange systems n Servo motor-driven transport chains provide the highest precision in foil positioning n Manual or automatic feeding n Excellent accessibility through large safety doors with wide aperture angles Z.PACK 5 n Remote maintenance over the Internet n Standard tool compatibility on all Z.PACK machines About Us 13

1 to 75—How Zongye Zhang Ended up at ZAHORANSKY

Zongye Zhang has been responsible for Far East sales His Bags Are Always Packed at ZAHORANSKY for two years. “I am responsible not only for China itself, but also for Hong Kong,Taiwan Zongye Zhang travels about 40 days out of the year. “I've and Macao, as well as for parts of Southeast Asia.” His always got my bags packed, and I'm ready to travel or fly field of activity encompasses supporting existing cus- to China,” he says. This flexibility is no trouble for the young tomers, acquiring new customers, and providing mar- father. He loves both cultures, and enjoys spending time ket analysis. Zongye Zhang's move to Germany was both here and in China almost like winning a lottery ticket – he had to prove himself before finding his way to the Black Forest.

At first, Zongye Zhang came to the Harz region. This is where he studied mechanical engineering at the TU “Fly to China? Clausthal-Zellerfeld in southern Lower Saxony. Four seats at the university were awarded to Chinese students through No problem!” a partner program. Three hundred students applied for the seats. That means 75 people applied for each seat. Zongye > Zongye Zhang Zhang was one of the four who were chosen. After studying in the Harz region, he worked in sales for a foundry supply company.

At Home in the Black Forest

He came to ZAHORANSKY in the beginning of 2014. “I felt very comfortable here,” says the 34 year-old engineer, who lives with his family in Freiburg. It’s not unusual for us to have a Chinese employee at ZAHORANSKY in the Black Forest. China is one of the most important countries in brush production. Due to its large population, it is also the world’s biggest market for such products. After all, everyone in China has to have a toothbrush. That makes it all the more important for us to have an employee here who has an understanding of both cultures. This makes it easier for Zongye Zhang to support existing customers and acquire new ones. “We have the best machines in the world, and we want to grow our market share over the next few years,” he says. To do this, he serves as a contact person not only for customers, but also for numerous representatives and service employees as well as colleagues on site. Zongye Zhang is more or less the man building a bridge between the Black Forest and the Far East. Zongye Zhang does retain his Chinese citizenship, but he's come to feel at home in the Black Forest. His wife is also from China. How- ever, he met her in Germany. They married five years ago, and the couple has two young daughters. 14 Trade fairs

In-House Exhibition Oral Care at ZAHORANSKY in Japan

115 representatives from more than 40 companies came to the ZAHORANSKY in-house exhibition in the Japanese city of Kobe. The goal of the event was to get new and existing customers excited about Black Forest Quality. It was a true success: All of the exhibited machines – there were a total of eight machines and components from the Oral Care area – were sold during the event. A great success for our team on site!

Japanese customers primarily demand toothbrushes with smaller heads and smaller filament bundles. This is a unique challenge for machine manufacturers, who primarily supply high-speed machines with tapered filaments for the Japa- nese market. In addition, the tufting quality must also be extraordinarily good. ZAHORANSKY machines fulfill this requirement. The exhibition was housed in 1,600 m2 of space at the Kobe Fashion Mart, where Z.ORCA, Z.SHARK, Z.SAILFIN, and Z.SWORD were on display.

Dental Care in Japan

Prevention is better than a cure – it’s a simple formula that also applies to oral health. According to a report by the World Health Organization, tooth decay is the most wide- spread disease in the world. It is well known that Japanese citizens are spending more and more money on dental and oral care. Ever stricter beauty ideals mean the topic of dental hygiene is becoming more and more important. Besides the right products, to get gleaming white teeth you need the right brushing techniques. In Japan, for example, each tooth is brushed individually for optimal results. The market is growing quickly, and offers major potential for investment in high-quality toothbrushes and interdental production machines.

Imprint

Publisher: ZAHORANSKY Concept, layout and realization: ZAHORANSKY AG Automation & Molds GmbH srp. Werbeagentur GmbH Anton-Zahoransky-Strasse 1 Bebelstrasse 11a Kaiser-Joseph-Strasse 274 79674 Todtnau-Geschwend 79108 Freiburg, Germany 79098 Freiburg Germany Phone: +49 761 7675-0 Germany Phone: +49 7671 997-0 Phone: +49 761 45263-0 ZAHORANSKY AG srp.de Editorial staff: (Systems Technology) Robert Dous Hanferstrasse 21 Phone: +49 7671 997-447 79108 Freiburg, Germany [email protected] Phone: +49 761 88509-0 zahoransky.com

Trade fairs / Short News 15

Next Generation of Brush Production

High level of trimming and flagging quality with consistent performance Superior trimming and flagging quality compared to similar systems Only one machine operator required Output of fully-finished brushes Inexpensive fully-automated solution for common household brushes

Our Z.LION is the fully automated solution for producing is unmatched in the market, giving our customers a clear brushes and brooms. This five-axis machine makes a great advantage. In addition to high quality and excellent perfor- impression with its high availability and an outstanding mance, the machine offers a newly designed safety con- price-performance ratio. The Z.LION can produce up to six cept for improved ergonomic handling and safety. brushes a minute or 360 per hour, making it 30 % more powerful than comparable machines from other manufac- Unbeatable performance and price. And all with an avail- turers. And it does so with outstanding quality. ability of over 90 % – that’s Z.LION.

With its 70 to 100 mm stroke, the Z.LION is suitable for producing brooms and brushes with lengths up to 400 mm. In doing so, the Z.LION achieves a much denser and more even bristle pattern than comparable machines from other manufacturers. The quality of the trimming and slitting unit

Trade Fair Dates

Plastvision Cosmopack Chinaplas January 19 – 23, 2017 March 16 – 19, 2017 May 16—19, 2017 Mumbai, India Bologna, Italy Guangzhou, China

Interplastica Moscow Plástico Brazil Plastpol January 24 – 27, 2017 March 20— 24, 2017 May 23— 26, 2017 Moscow, Russia São Paolo, Brazil Kielce, Poland

Pharmapack Paris ABMA

February 01 – 02, 2017 March 22 – 25, 2017 Paris, France Orlando / Florida, USA 3D-TuftingTM Technology: The Fill, Feed and Fuse Solution

Highest performance Best tuft retention Most tuft density

Passion and Perfection in Molds, Machinery and Automation. Black Forest Quality by ZAHORANSKY

zahoransky.com PICTURE GALLERY > to the article The New Factory in Spain is Completed! PICTURE GALLERY > to the article The New Factory in Spain is Completed! PICTURE GALLERY > to the article The New Factory in Spain is Completed! PICTURE GALLERY > to the article The New Factory in Spain is Completed! PICTURE GALLERY > to the article The New Factory in Spain is Completed! PICTURE GALLERY > to the article The New Factory in Spain is Completed! PICTURE GALLERY > to the article The New Factory in Spain is Completed! PICTURE GALLERY > to the article The New Factory in Spain is Completed! PICTURE GALLERY > to the article The New Factory in Spain is Completed! PICTURE GALLERY > to the article Turkish Customers Hosted in Todtnau PICTURE GALLERY > to the article Turkish Customers Hosted in Todtnau PICTURE GALLERY > to the article Turkish Customers Hosted in Todtnau PICTURE GALLERY > to the article Turkish Customers Hosted in Todtnau PICTURE GALLERY > to the article Turkish Customers Hosted in Todtnau PICTURE GALLERY > to the article Turkish Customers Hosted in Todtnau