ZAHORANSKY EDGE Offers New Possibilities for Efficient Eco Conscious Toothbrush Manufacturing

The oral care sector is seeing a convergence of innovative brush design, cost-effective, environmentally friendly production methods, and the high demands on dental health. In order to meet all design, environmental, and cost-effectiveness requirements, ZAHORANSKY has introduced EDGE, a compact production technology that makes it possible to manufacture anchor-free monomaterial toothbrushes efficiently. Handles, heads, and filaments can all be made of the same kind of plastic thanks to the novel anchor-free production method that thermally attaches filament bundles to the brush head.

This not only allows for head designs that are up to 70 percent thinner, but also ensures a constant output of up to 30 brushes per minute – regardless of head geometry or number of filament bundles. The toothbrushes, which are made entirely from a single material and without anchor wire, are 100 percent recyclable and therefore particularly resource-efficient. “The innovation carousel in the highly competitive oral care market is spinning faster than ever. At the same time, manufacturers are under increasing cost pressure when introducing new products. In addition, recyclability and sustainability are becoming increasingly important to end consumers. We are delighted with the first joint projects and the positive customer feedback on EDGE. This confirms our solution expertise for hygienic, stylish, and environmentally friendly products,” says Kevin Eisemann, Head of Development at ZAHORANSKY.

The benefits for end users begin at the very end of the manufacturing chain: thanks to extremely delicate geometries, the EDGE achieves head thicknesses of only about 1.5 millimeters. The edge distances between the filament and the brush contour shrink to just 0.8 millimeters. This is ideal for better reaching the rear areas such as wisdom teeth and molars during daily dental care. In addition, the filament bundles are not pressed together with anchors, but thermally bonded. This prevents the formation of cavities in which saliva, water, or germs could collect, reducing the risk of contamination of the oral cavity, gums, and teeth by germs or mold.

New Design Freedom for Form and Function
From a design perspective, EDGE sets new standards: “Since pre-drilled holes are no longer required in the head, EDGE offers manufacturers great design freedom,” explains Eisemann. Bundles for interdental focus, large-area tufts for massage, and even complex mixed forms can be set in a single production step and then fused with a counter profile at the desired height. Another advantage for manufacturers: this variety of options can be produced more easily and cost-effectively on the EDGE, as magnetically fixed pattern parts are used instead of expensive mold bars for injection molding tools. Most design changes can therefore be made quickly, without tools, and without risk of mix-ups.

Faster Time to Market
To implement new designs quickly, precisely, and cost-effectively, ZAHORANSKY also supports manufacturers with its own rapid prototyping service. New product designs are reviewed at an early stage in collaboration with the customer. Findings, such as how new hole field geometries or profile heights affect haptics, cleaning performance, and brand image, are thus directly incorporated into the further development process and accelerate time to market.

Output That Pays Off
The EDGE also sets standards in terms of business efficiency. “Since the process feeds in all bundles simultaneously, the cycle time of up to 30 toothbrushes per minute remains constant, regardless of the complexity of the brush head,” explains Eisemann. At the same time, there are no costs for anchors or the purchase of multiple injection molding inserts. Thanks to its compact design, requiring only 11 square meters of space, the EDGE can be integrated into existing production environments. Installation and commissioning by the ZAHORANSKY service team on site can often be completed within one working day thanks to the machine’s extensive preconfiguration. During operation, the intuitive ZMI 4.0 control unit guides the operating personnel safely through all production and maintenance processes. In addition, the automatic feed mechanism for brush bodies and filaments means that only occasional human intervention is required for refilling. In times of skilled labor shortages, the EDGE not only provides a stable basis for calculable unit costs, but also makes the entry into anchorless monomaterial technology economically attractive and feasible for medium-sized manufacturers.

Standard-Compliant Manufacturing
The EDGE meets all international testing criteria for manual toothbrushes. Internal measurement series conducted by ZAHORANSKY also prove that the thermally bonded tufts of the EDGE can withstand much higher pull-out forces. It also passes the pendulum impact test for breakage resistance of ultra-thin heads, which is mandatory in Europe and the USA, despite a head thickness of only 1.5 millimeters, which is far below the industry standard of 4 to 5 millimeters. This exceptional stability forms the basis for worldwide approvals – from FDA registration in the USA to CE marking in the European Economic Area. “The EDGE therefore not only offers hygienic and economic advantages, but also provides our customers with the regulatory security to be able to sell their products in all relevant target markets,” says Eisemann.

www.zahoransky.com

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Syensqo Selects Fairmat as Partner for Carbon Fiber Waste Solution

Syensqo, a global leader in advanced performance materials, has announced a strategic collaboration with Fairmat, a pioneering French deeptech company specializing in recycling carbon fiber composites. This new agreement marks a significant step forward in the sustainable management of composite waste and reinforces both companies’ commitment to advancing the circular economy. Under the terms of the agreement, Fairmat will take responsibility for recycling Syensqo’s UK-based carbon fiber prepreg waste. Through its proprietary recycling process, Fairmat will transform this high-performance composite waste into valuable raw materials for a variety of demanding applications—including in the sports, energy, mobility, and electronics industries.

This partnership highlights the growing urgency and industrial commitment to finding scalable and efficient ways to manage end-of-life advanced materials. With the carbon fiber market continuing to expand, the challenge of managing manufacturing and post-industrial waste has become a pressing concern for industries reliant on lightweight, high-performance composites. Traditional disposal methods such as landfilling or incineration not only carry significant environmental drawbacks but also result in the loss of valuable materials. Fairmat offers a proven, innovative alternative by recovering and reprocessing composite waste into new engineered materials—preserving much of the mechanical performance and drastically reducing environmental impact.

Gabriel Molina, Sustainable Development Director at Syensqo Composite Materials, emphasized the strategic importance of this new initiative, stating, “This new collaboration contract adds to our other recycling agreements worldwide and is integral to our comprehensive strategy to advance on composite materials’ circularity.” Molina’s statement reflects Syensqo’s broader efforts to develop a global network of recycling partnerships and sustainable waste management streams, aiming to make its operations more circular across its business units. In the UK, where the company operates a number of advanced materials facilities, including those dedicated to aerospace and automotive prepregs, this collaboration offers a practical solution to one of the industry’s most difficult waste streams: thermoset carbon fiber composites.

The Fairmat partnership is part of a broader sustainability roadmap being rolled out in all Syensqo operations worldwide. The company is already taking steps to lower the carbon footprint of its manufacturing processes and is implementing more bio-based and mass-balanced materials. Its composite materials are already serving a central function in making mobility solutions more efficient—ranging from next-generation electric drives and hydrogen fuel cell technology to aircraft parts optimized for fuel efficiency and emissions reduction. Outside mobility, Syensqo is investing in renewable energy infrastructure, electronics, and sporting goods that depend on high-performance but sustainable material solutions.

Fairmat’s CEO and Founder, Benjamin Saada, expressed enthusiasm about the new partnership, noting the value that Syensqo’s materials bring to the recycling process. “We are proud to partner with Syensqo and help them achieve a sustainable outcome for their UK waste,” Saada said. “Thanks to our proprietary and proven technology we will extract precious value out of their materials to create new engineered materials for high-performance applications.” Fairmat’s approach is based on a proprietary mechanical recycling method that preserves the intrinsic properties of carbon fiber, allowing the company to develop new composite materials with exceptional strength-to-weight ratios and a dramatically lower environmental footprint compared to virgin carbon fiber.

This agreement is not a standalone effort for Syensqo. It exists as part of an emerging global recycling and sustainability strategy being rolled out by the company in Europe, the Americas, and Asia. Besides recycling alliances, Syensqo is also investing in novel resin systems from renewable feedstocks and is working diligently on enhancing the end-of-life recyclability of its product lines. These initiatives are part of Syensqo’s overall ESG ambitions and its drive to reach net-zero emissions throughout its value chain by 2050.

“We see in Fairmat a mature partner that offers a reliable and sustainable business model. We look forward to seeing where this new partnership takes us,” added Molina. His statement underscores the need for trusted and technically capable partners to enable real circularity in complex industrial supply chains. Unlike linear manufacturing systems, circular economy models depend on robust collaborations between material producers, recyclers, and end-users to close the loop and minimize waste across product lifecycles.

The collaboration also comes at a time when regulatory pressures on composite waste management are intensifying. The UK and European Union have introduced stricter guidelines on industrial waste disposal and are incentivizing businesses to adopt circular strategies. In this context, Syensqo’s proactive approach to recycling not only strengthens its environmental credentials but also positions it favorably in a market where regulatory compliance is becoming a key component of competitiveness.

Syensqo’s role as a technology enabler in the global shift toward sustainability is also gaining recognition. The company continues to support a broad ecosystem of innovation, ranging from lightweighting solutions for e-mobility to next-generation wind turbine components and consumer electronics. Through this new partnership with Fairmat, Syensqo adds another layer to its vision of creating a closed-loop model for composite materials—one where performance, profitability, and sustainability can coexist.

www.syensqo.com
www.fairmat.tech

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GIC Reveals Ecosystem to Unite Consumer and Chemical Sectors on Sustainability Objectives

In an effort to facilitate a future with net-zero and circular chemicals, the CEO-led Global Impact Coalition (GIC) is launching a new project to involve consumer-facing businesses as Value Chain Partners.
It has become evident that no one industry alone can address the growing pressure on businesses throughout the chemical value chain to achieve climate, circularity, and recyclability requirements. Deeper cooperation between chemical manufacturers and downstream consumer goods companies—who depend on the chemical sector for a wide range of product ingredients and packaging materials—will be necessary to make significant headway.

“Reducing what is known as scope 3 carbon emissions will require a deeper integration of business models and ultimately, greater collaboration along the material and product value chain,” said Charlie Tan, CEO of the Global Impact Coalition. “We are putting out a strong call to action for global consumer goods companies to co-build the next generation of supplier-enabled solutions, along with the chemical industry.”

GIC invites consumer goods leaders to join a structured engagement with chemical suppliers, from ideation to tangible projects, designed to co-develop commercially scalable projects that reduce emissions, increase circularity, and enable safer chemical use.

“Collaboration of chemical companies with downstream partners such as consumer goods companies is essential to scale sustainable products and build viable business cases,” said Lars Kissau, President at BASF and member of the GIC Executive Committee. “This is not about talk. It’s about co-creating real solutions with the companies that rely on the chemical industry in all their products.”

Unlike traditional industry groups focused on advocacy or roadmaps, GIC operates as an action-oriented platform that guides members through a four-stage process: from shared problem definition and ideation to project development and spin-out. Current GIC projects include joint efforts on developing 100% circular waste streams, sustainable biomass sourcing, and PFAS remediation and destruction.

The Value Chain Partner initiative gives consumer brands a unique opportunity to:

• Shape future-ready projects that directly reflect consumer goods business needs
• Pilot tangible solutions with chemical suppliers and scale what works
• Join a platform of global leaders working to accelerate progress on Scope 3 emissions reduction, circularity, and “no harm” innovation

Participation is open to global consumer goods companies committed to partnering with their chemical industry suppliers to accelerate emissions reductions and drive systemic change. Engagements include executive-level discussions, project working groups, and biannual ideation workshops.

https://globalimpactcoalition.com/

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