Onfab future-proofs production with Zünd Digital Cutting System

• Significantly reduced material waste through intelligent nesting—cutting waste down to just 10–15%.
• Increased production efficiency with nesting time reduced from 45 minutes to just one minute.
• Future-proof cutting capabilities for both flexible and rigid materials, including pharma-grade polyurethane.
• Enhanced product quality and consistency thanks to the precision of Swiss-engineered cutting technology.
• Stronger sustainability and competitiveness through digital transformation and reduced environmental footprint.

Founded in 2004 and now part of Savillex in the USA, Onfab has established itself as a specialist in the design, manufacture and installation of flexible containment solutions within many pharmaceutical manufacturing processes. The company is especially renowned for its flexible containment isolator/glove bag systems used in environments handling high potent powders. With manufacturing facilities in the UK, Spain and the USA, Onfab serves many of the world’s leading pharmaceutical and biopharmaceutical companies, as well as contract manufacturing organizations around the globe.

In early 2023, the company began looking for ways to future-proof its manufacturing process, reduce material waste and diversify the types of materials it could work with. Recognizing the need for a high-performance, versatile cutting system, Onfab explored various solutions and quickly identified Zünd as the ideal partner. “Our ability to handle new and existing flexible and rigid materials in our manufacturing process needed future-proofing,” Mark explained. “We wanted a solution that could handle various material types, whilst reduce our environmental impact and support our expansion for new products and markets.”

After reviewing Zünd’s offerings through online research and product demonstrations, Onfab decided to invest in both the Zünd digital cutting system and Zünd’s PreCut Center (ZPC) software for a fully integrated solution. “What stood out to us was the precision of the Swiss-made system, its ability to cut both rigid panels and flexible sheeting—including food/pharma-grade polyurethane—and the intelligent nesting software that dramatically reduces both setup time and material waste,” said Mark. “The 24/7 service and support from Zünd was also a key factor in our decision.”

Onfab took delivery of their Zünd G3 XL-3200 in April 2025, and the impact was immediate. Reducing material waste was a top priority and Zünd’s advanced nesting capabilities delivered exactly that. The company saw material wastage reduced to 10-15% across the month, in both environmental impact and cost savings. Equally transformative was the implementation of the latest PreCut Center software. Dan, Onfab’s lead operator, noted that what once took 45 minutes to nest now takes just one minute, streamlining production and freeing up valuable operator time.

Reflecting on the investment, Mark said, “With Zünd’s digital cutting solution at the heart of our production strategy, Onfab is not only enhancing quality and efficiency but also reducing its environmental footprint in measurable ways. By investing in Zünd’s high-end cutting technology and intelligent software, we’ve modernized our operations, minimized waste and strengthened our ability to compete in a global market. What began as a search for a better cutter evolved into a full strategic transformation, driven by quality, efficiency, and sustainability.