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Information on the cooperation between KOCH Pac-Systeme GmbH and ZAHORANSKY AG

Since November 2022, KOCH Pac-Systeme GmbH and ZAHORANSKY AG have been working closely together in the blister packaging field on technology and sales issues. This new cooperation focuses on providing sustainable, environmentally-friendly packaging solutions in the personal care sector. Specifically, this means that the KOCH model series KDT and KBS will be integrated into the ZAHORANSKY portfolio, while the ZAHORANSKY Z.PACK 4 | 5 machines will be distributed by KOCH.

How did the relationship between KOCH and ZAHORANSKY come about?

The KOCH and ZAHORANSKY companies have known and respected each other and their individual solutions for a long time. Through joint projects in the past, the two companies realized that they could be the perfect compliment to each other.

As part of the cooperation, ZAHORANSKY will phase out the production of blister packaging machines significantly. What led to this decision?

ZAHORANSKY will focus on its core competencies in the future, namely machines and equipment for the production of all types of brushes, as well as injection molding and injection molding-related automation, with a focus on personal care and medical technology. The market for plastic packaging has changed, and this form of packaging has become the target for criticism. As a result, sales of such packaging machines are declining, at least in industrialized countries. However, as there is still demand for competitively priced smaller blister packaging machines, ZAHORANSKY will continue to keep these in its portfolio.

What were the reasons why in-house developments to expand the respective portfolios were not an option?

Both KOCH and ZAHORANSKY would have had to invest too much time and money for this.

Who can prospective/new customers contact in the future and what are the subsequent processes?

As part of this partnership, the sales teams of both companies have been trained in their respective packaging machines. Prospective and new customers can therefore contact either KOCH or ZAHORANSKY. A joint decision will then be made on how to proceed.

The general contact addresses for both companies are and

Who should existing customers contact?

Here too, existing customers can continue to contact their established contacts at both companies. KOCH and ZAHORANSKY are in constant contact with each other. Together, they will determine the best course of action for each customer individually – of course with the customer’s wishes taking priority.

In which ways do the machine portfolios of KOCH and ZAHORANSKY complement each other?

With the cardboard single-material blister machines from KOCH, ZAHORANSKY can fill a gap in its portfolio, while the Z.PACK 4 | 5 machines from ZAHORANSKY do the same for KOCH.

Why will the ZAHORANSKY machines Z.PACK 6, Z.PACK 8, and Z.PACK 11 be discontinued?

The market development has clearly shown ZAHORANSKY that the demand for these machines that would justify the expense for further development no longer exists. Further requirements can be covered by ZAHORANSKY with the KOCH machine portfolio. Spare parts and service for these machines will continue to be available.

What is special about the Z.PACK 4 and Z.PACK 5 machines from ZAHORANSKY?

These machines are compact and easy to operate, affordable to purchase and maintain, and perform their work reliably. They complement KOCH’s portfolio of plastic blisters in the investment-friendly, lower performance range. Thanks to the established technology, rounded packaging corners can also be produced.

What distinguishes the machines from KOCH and ZAHORANSKY?

The KOCH KDT model series at a glance: The KDT turntable machine is particularly suitable for the cost-effective packaging of consumer goods in small to medium sized quantities. The standard version includes a turntable with four sealing tools and a sealing unit for thermal sealing. As a GMP-compliant turntable machine, the compact KDT medplus® system can also be used for sensitive products in the healthcare sector.

The KOCH KBS model series at a glance: When you need maximum flexibility in terms of material, format, and batch size, KBS is the model series of choice.

The sealing pallets of the KBS-PT blister machine can be changed in no time. When switching formats, only the individual format parts need to be changed, not the complete set.

The KBS-PL blister machine with linear pallet transport are particularly efficient at packing long runs of the same or similar products. The KBS-PL and KBS-PT can also be equipped with the environmentally friendly cyclePac® single-material packaging that is 100% reusable.

Maximum flexibility is the trump card with the KBS-KF: It can continuously package a wide variety of products as hard blisters and soft blisters at high capacity.

The ZAHORANSKY Z.PACK 4 | 5 packaging machines at a glance: The Z.PACK 4 | 5 packaging machines are suitable for all standard full blisters. Thanks to their modular design, companies can enjoy a particularly high degree of flexibility in blister design, such as labeling on the front, perforation, embossing, printing, and more. Semi and fully-automatic options for product infeed ensure high machine performance and efficiency. In addition, the touch-free infeed reduces the error rate and machine downtime. Planned changeover times can also be significantly shortened thanks to the integrated ERCO (Ergonomic Rapid Change Over) functions. The cutting tools score points for durability and are also compatible with all Z.PACK machines. The Z.PACK 4 | 5 can be used in a wide variety of applications, from stand-alone machine to integration into fully automated packaging lines. PVC, PET, or PLA film can be used as forming materials while cardboard, “Tyvek”, aluminum, PET, and PVC film can be used as cover materials.

How will service and support be organized in the future in terms of spare parts supply, maintenance, and warranty?

All service and support services will be provided by the respective manufacturer. Customers will not see any change in their familiar service contacts – just as in sales. Customers may contact either KOCH or ZAHORANSKY. Both companies are in constant contact with each other and will take the appropriate steps that are best for the customer. This will have no impact on costs.

Who should customers contact in the future if they are interested in a complete toothbrush production system including injection mold, production machine, and packaging machine?

As the customer in such a case will be dealing to a large extent with the ZAHORANSKY team, ZAHORANSKY will incorporate the appropriate packaging machine and act as the general contractor – unless the customer requests otherwise.

How is communication handled at the system engineering level, especially with regard to the interfaces, different controllers, and operating panels of the KOCH and ZAHORANSKY machines?

As manufacturers of customized machines, both KOCH and ZAHORANSKY have many years of experience in offering and implementing interfaces for machines and components from other manufacturers. The basic structures of the controller are not changed and interface management with established technology is guaranteed. In this way, even long-time users will be able to work with the control system they are familiar with in the future.

What effects does the cooperation have on the pricing of the machines, commercial conditions, and delivery times?

There will be no changes to the existing terms and conditions. Both KOCH and ZAHORANSKY will be even closer to customers through this cooperation. Delivery times will also not be affected by the cooperation.

How does the cooperation benefit customers directly? Can a machine be ordered from both KOCH and ZAHORANSKY?

The main advantage for customers is that they can use their established channels, yet at the same time have the expertise of both specialists at their disposal. For more complex systems with machines from both partners, the complexity of the process can be reduced by using a general contractor scheme (“one-stop shopping”). This also makes it possible to implement customer wishes in an even more customized manner. They will always get the best solution, tailored to their needs.

What priority does sustainability have at KOCH and ZAHORANSKY, and what specific solutions are offered in this area?

Sustainability has a high priority at ZAHORANSKY. In the area of recyclable single-material products, the company is involved across the board: examples include wooden toothbrushes, toothbrushes made of degradable injection-molded materials, and the elimination of metal anchors in toothbrushes or cardboard single-material blisters.

At KOCH, too, the topic of sustainability is actively implemented with the highest priority in the development and manufacture of machine solutions. Herewith, both companies now have machines in their portfolio that offer both plastic blisters and carton mono-material packaging such as cyclePac®, cycleBox® and cycleForm®. The importance of the topic of sustainability at KOCH is demonstrated, among other things, by the Eco-Vadis and UN Global Compact eco-labels, which evaluate the company holistically.

The background behind the cooperation: market trends and legal requirements

The issues of sustainability and avoiding plastic waste play a crucial role for an increasing number of end customers, and are increasingly influencing their purchasing decisions. A representative Statista Global Consumer Survey on “Sustainable Consumption 2021” reinforces this explicitly: According to the survey, “one in two consumers say they have changed or adapted their consumption behavior for reasons of sustainability.”

Additional pressure is coming from official channels: The submission of the European Corporate Sustainability Reporting Directive (CSRD) is mandatory as of January 1, 2024, for companies with 250 employees or more and a turnover of over €40 million. The new Packaging Act (VerpackG) has already been in force in this country July 1, 2022. This includes a registration requirement for all packaging manufacturers and regulates the return and disposal of materials.

This benefits manufacturing companies in particular, as they remain open to all options and not only produce sustainable products, but also extend their environmental commitment to the packaging materials. After all, one thing is clear: demand will increase in the coming years. KOCH and ZAHORANSKY have responded accordingly and are preparing themselves.