ZAHORANSKY Unveils Next-Generation Z.TUCAN for High-Speed Nail Polish Brush Production
New platform combines servo-driven automation, optical inspection, and flexible machine configuration for cosmetic brush manufacturers.
The cosmetic brush manufacturing sector continues to evolve as manufacturers seek greater production flexibility, improved quality assurance, and faster changeovers. Addressing these demands, ZAHORANSKY has introduced the latest generation of its Z.TUCAN machine, designed for the fully automated production of nail polish brushes.
Capable of manufacturing up to 300 brushes per minute, the upgraded system combines modern drive technology, intelligent machine control, and optional optical inspection while maintaining the configuration flexibility that has made the Z.TUCAN platform a preferred solution for cosmetic brush manufacturers worldwide.
Built for Diverse Nail Polish Brush Production
The new-generation Z.TUCAN has been engineered to manufacture a wide variety of nail polish brush designs. Manufacturers can produce short, long, round, oval, and speciality cosmetic brushes, as well as selected medical brush applications, using different filament lengths and configurations.
The machine utilizes ZAHORANSKY’s proven loop technology, securing filament bundles inside the brush body using fine wire. For applications requiring greater brush density, an optional double-hole configuration enables two filament tufts to be inserted into adjacent elongated holes, allowing manufacturers to produce fuller brush designs.
Finished nail polish brush components produced using the ZAHORANSKY Z.TUCAN automated manufacturing platform.
Servo Drive Simplifies Machine Setup
One of the most significant upgrades is the introduction of a servo-driven main drive for the tufting axis.
Unlike previous generations, the servo system allows operators to reposition the tufting axis electronically, making machine setup and product changeovers considerably faster and easier. The improvement reduces adjustment time while increasing production flexibility for manufacturers producing multiple brush variants.
According to Andreas Ehmann, Product Manager Personal Care at ZAHORANSKY,
“The strength of the Z.TUCAN lies in its adaptability. With the new generation, we have made machine setup and changeovers easier than ever while raising process reliability to a new level through increased automation.”
Andreas Ehmann
Product Manager Personal Care, ZAHORANSKY
ZMI 4.0 Brings Smarter Machine Control
The latest machine is also equipped with ZAHORANSKY’s ZMI 4.0 control platform.
An enlarged operator display provides real-time monitoring of machine functions and production parameters. Mounted on an ergonomic swivel arm, the interface can easily be positioned for comfortable operation from different working positions around the machine.
The machine also adopts ZAHORANSKY’s updated dark and light grey industrial design, reflecting the company’s latest equipment generation.
Optional Camera Inspection Improves Quality Control
To further strengthen process reliability, ZAHORANSKY now offers an integrated camera inspection system as an optional feature.
The system continuously verifies the presence and correct positioning of filament tufts during production, helping manufacturers detect potential defects before downstream processing.
This inspection module is currently available for the short-chain machine configuration, which performs tufting and trimming operations. Manufacturers requiring additional finishing processes can opt for the long-chain configuration, which incorporates grinding stations for end rounding and other finishing operations.
Expanding into a Complete Production Line
Beyond brush manufacturing itself, the Z.TUCAN can be configured as a complete production solution through several optional modules.
A coating and drying system applies a specialized stabilizing coating to the filament bundle, preventing individual filaments from spreading while the brush is inserted into narrow nail polish bottles. Once exposed to nail polish, the coating dissolves during normal product use.
Manufacturers can also integrate an automated counting and sorting module that groups finished brushes into predefined quantities before transferring them to collection containers, simplifying downstream packaging and logistics.
Supporting Flexible Cosmetic Brush Manufacturing
With the latest Z.TUCAN generation, ZAHORANSKY continues to focus on improving production flexibility while reducing setup complexity and increasing process automation.
By combining high production speeds with intelligent controls, modular configurations, and optional inspection technology, the company aims to provide cosmetic brush manufacturers with a scalable solution capable of supporting both standard production and specialized brush applications.
About ZAHORANSKY
Founded more than 120 years ago, ZAHORANSKY is a family-owned technology company specializing in machinery, automation, and mold manufacturing for the brush industry, medical technology, and related sectors. Headquartered in Germany, the company employs approximately 690 people across facilities in Germany, Spain, China, India, Japan, Brazil, and the United States, providing turnkey manufacturing solutions to customers worldwide.
Today, the company supplies machinery and complete production solutions to leading manufacturers across the oral care, cosmetic, household, industrial brush, and medical technology sectors worldwide.
Editorial Note
This article has been prepared and edited by the editorial team of Brushes, Hairs & Fibres using information and images provided by ZAHORANSKY AG through its official media relations team.
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