To what temperature is the tool holder heated during the heat-shrink process?

This depends on the holder's geometry, the clamping diameter, and the taper size. While some standard holders have a 4.5-degree taper, slim holders have a 3-degree taper. Depending on the type, different temperatures ranging from 150˚C to 350˚C are used when the holder is shrunked.

The fume extraction system reliably removes fumes from the operator's working area. The established and patented fume extraction system above the induction coil has been extended to include an integrated extraction system inside the coil housing. The fumes are therefore extracted directly where they are produced. The filter unit has a safe place in the under-table.

What types of cutting materials can be used in shrink-fit holders for the shrink-fit process?

Steel, HSS, carbide, heavy metals, metal powders, collet extensions.

What is the required tolerance for the shaft diameter of the cutting tool during usage with a shrink-fit tool holder?

The shank tolerance of the cutting tool must amount to h6 or h5.

Is it possible to monitor the lifetime of the tool holder and the number of shrink cycles it has undergone?

With the ZOLLER »powerShrink«, it is possible to monitor the tool holder’s heating cycles using a unique tool holder ID number—for example, via ZOLLER »idChip« technology. Each cycle is monitored and recorded in the »pilot« software.

What are the minimum and maximum heating times?

The heating time depends on the geometry of the tool holder and the clamping diameter. For small diameters, it takes 2 to 3 seconds; for large diameters, 5 to 7 seconds.

What are the minimum and maximum cooling times?

ZOLLER offers two types of cooling systems: a non-contact cooling system with air cooling and cooling adapters. Depending on the tool diameter, the cooling time with cooling adapters ranges from 60 to 120 seconds. With »Zstream« air cooling, the process is called “conditioning,” during which the entire tool holder is cooled from the projection to the flange. The conditioning time depends on the diameter of the tool holder and ranges from 3 to 5 minutes.

Is an air-conditioned room required to install the »powerShrink« device?

An air-conditioned room is not required. The device can be installed in a dust-free area in the machine shop.

How does (to) shrink work, and what kind of process takes place here?

The concept is simple. Each shrink-fit tool holder is manufactured with an inner diameter that is slightly smaller than the shaft diameter of the cutting tool. An induction heater is used to rapidly heat the nose of the tool holder in order to increase the inner diameter. At this point, the cutting tool can be used in the tool holder. The tool holder is then cooled, causing the diameter to shrink and applying force to the shaft of the cutting tool to hold it in exact position.

What is non-contact cooling and contact cooling?

When tool holders are shrunk without direct contact, the tool holder system is referred to as a contactless cooling system. This is achieved, for example, using cooling adapters or air cooling. When tool holders are cooled with a liquid after being heated, this process is called quenching. The tool holder’s lifetime is reduced, and it will rust if it continues to be used with liquids in direct contact with it. The coolant becomes contaminated after a short time and must be replaced; otherwise, it will break down, emit a strong odor, and contain harmful substances that are dangerous to human skin.

Is it possible to use the same shrink machine for standard diameters ranging from 3 to 32 mm and heavy-duty shrink holders for diameters greater than 32 mm?

Yes, it is possible with the ZOLLER »powerShrink 600«, which allows the 14 kVA induction coil and the 22 kVA induction coil to be quickly and simply exchanged using the quick-change interface.

Is it possible to adjust the total length of the tool after it has been shrunk with the »powerShrink« machine?

Yes, with the »eQset« and »liteSet« adjustment systems, it is possible to preset the total length of the tool on »the« »powerShrink«.

Air cooling »zStream«

With ZOLLER's air cooling »zStream« you obtain maximal flexibility and protection with the cooling of your shrink fit tool holder, independently of its contour or diameter. In addition, your shrink-clamping tools are cooled consistently and safely across their entire length – without the risk of being damaged. »zStream« is also ideally suited for cooling placed down tools.

Length adjustment »eQset«

The integrated length adjustment system is used to set the overall length or projection length and for tool replacement. The pneumatically activated quick adjustment and fine adjustment by handwheel enable fast, ergonomic and precise positioning of the probe head to the desired height.

Scan function incl. hand scanner

The »pilot« software scan function in combination with the hand scanner enables reliable selection of the appropriate shrink fit parameter by scanning the holder number on the shrink fit holder. Regardless of the manufacturer, all shrink fit toolholders with DataMatrix code (e.g. ZOLLER »idLabel«, ZOLLER »idChip«) are supported. In the »pilot« software, each heating process can be counted for each shrink fit chuck. In addition, a warning and wear limit can be stored in relation to the permitted heating processes.

Set-up table for »powerShrink 400«

As an alternative to installation on a workbench, the »powerShrink 300« and »powerShrink 400« can be positioned on a set-up table with ergonomically optimal working height. This provides a tidy place for the cooler and flue gas suction device. The table is optionally available with sturdy rollers and an ergonomic handle to allow variable positioning.

Configurations for »powerShrink 400 | 11«

There are 3 basic configurations for the induction coils to choose from: 1. combination of any 14 kVA induction coil with quick-change interface, changing the induction coil from one induction coil axis to the other depending on the shrink chuck length 2. combination of any 2 14 kVA induction coils without »shrinkbyLight« and without quick-change interface 3. combination of any 14 kVA induction coil with a 22 kVA induction coil with quick-change interface

With your »powerShrink«, you will receive a receiving pot as standard. Additional pots can be ordered for parallel heating and cooling. The work surface is perfectly matched to the receiving pot and ensures convenient and quiet movement.

The different mounting rings allow flexible changeover between different mounting interfaces. For all common tool holder types and sizes up to SK 50, HSK 100 and PSC 10.

Special cooling adapter

Cooling adapter for special shrink fit chuck shapes and sizes (e.g. also for D3 mm to D5 mm). Suitable for cooling bells D14 mm to D16 mm or D25 mm to D32 mm.

Storage board for mounting rings and special cooling adapters The storage board provides space for storing four mounting rings and six special cooling adapters size I or three special cooling adapters size I and size II. Tool trayFor storing socket tools at the shrinking workstation. The position of the tray can be freely selected by the operator. Shelf for cleaning brushesA shelf with all brush diameters is available for storing cleaning brushes, which can be attached to the device in any position using magnets. The brushes for cleaning the mounting hole of shrink fit chucks are also available from ZOLLER - for shaft diameters D3 mm to D32 mm, optionally made of brass or plastic. Split shielding discs with trayAn optional set of shielding discs (5 pieces) in a split design including the corresponding disc tray can be ordered for shrink-fitting offset tools.

Coil operating handle

For optimum user-friendliness, the operating handle, which is fitted on the left as standard, can be fitted on the right or on both sides. Each operating handle is equipped with two function buttons - for moving the coil and activating the heating process.

Shrinking device »toolEx«

»toolEx« helps you to remove tools from the shrink fit chuck that cannot be pulled out by hand or with pliers, such as broken tools. The set includes a holder and six ejector rods.

Length adjustment »liteSet«

Use »liteSet« to set the projection length of the tool to be shrunk. The maximum projection length is 150 mm. The set contains four clamping prisms for shank diameters D3 mm to D32 mm.

»powerShrink«

Name: »powerShrink«
Brand: Zoller

»actbyLight«

Shrink and unshrink tools in record time while saving energy and protecting the tooling: You get all these benefits with the »powerShrink« inductive shrinking system. With the »powerShrink« series of devices, you can boost the efficiency of your production.

»actbyLight« guides you safely through the shrinking process and includes the »shrinkbyLight« coil function, the LED control on the induction coil, and the »coolbyLight« LED user guidance on the cooling system.

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Using resources correctly and effectively is our motto. We leave nothing to chance; instead, we align our efforts to achieve 100% efficiency—unique, innovative, and simply phenomenal.

Christian Pfau, Head of Research and Development

We, the technology company ZOLLER, have focused our experience and expertise on this new product development, thereby setting another milestone and rounding out the ZOLLER product portfolio. Typical ZOLLER: Everything from a single source.

Christoph Zoller, Managing Director

The perfect combination of design, ergonomics, and technological intelligence. The ZOLLER solution with certified safety for resource-efficient application in your manufacturing operations.

Alexander Zoller, Managing Director

Efficient Assembly Line Production

Up to 30% Energy Savings

Long-Term and Sustainable Savings

With ZOLLER’s »powerShrink«, you save time, reduce your electricity costs, and extend the life of your shrink fit holders thanks to the perfect interplay of electronics, software, and mechanics, combined with a well-designed, reliable shrink process.

30% energy savings

30% energy savings

ZOLLER induction technology allows you to heat your shrink fit holders optimally. For you, this means: consistent heating across the entire clamping range and only for as long as necessary. This results in short heating and cooling times, short cycle times, reduced wear on the holders, and a longer lifetime.

A particular advantage of »powerShrink«—through which ZOLLER contributes to sustainable manufacturing practices—is the energy savings of up to 30% compared to the previous model. We’re especially proud of this. The heat and energy are delivered exactly where you need them to safely shrink and unshrink your tools.

ZOLLER Re-inventing the induction coil

Tool Heat Shrink Technology

A smart, well-designed highlight of »the« »powerShrink« is the ZOLLER induction coil. Two windings connected in parallel within the coil can be activated separately and controlled differently depending on the clamping diameter and length. This enables optimal energy transfer to the clamping area, accelerates the heating and cooling process, and protects your tool holders.

Coil with »varOct« shielding system Coil with shielding discs

When Art Hits the Mark

Inspired by modern architecture and optical kinematics, ZOLLER’s Research and Development department has created a masterpiece. The ZOLLER induction coil with the »varOct« shielding system ensures maximum efficiency and ergonomics in the shrink-wrapping process.

8 ferrite elements

Ingeniously conceived. Perfectly constructed. The eight variable elements of the »varOct« coil shielding glide smoothly past one another—a design masterpiece. ZOLLER’s unique approach delivers unbeatable design and efficiency.

Flexibility in the blink of an eye

With the ZOLLER induction coil with shielding discs, you’re choosing a simple, manual shrink-fitting process for applications with infrequent diameter changes or low variation.

Discs of different diameters ensure that the coil’s magnetic field is optimally aligned and shielded accordingly. The optionally available »shrinkbyLight« user guidance, consisting of a control LED for diameter monitoring and a status indicator for the windings, provides additional process reliability during the operation of your »powerShrink«.

»coolbyLight«

With »powerShrink« from ZOLLER, you can cool with maximum efficiency. The five cooling bells for standard-compliant shrink fit holders ranging from D6 mm to D32 mm ensure fast, consistent cooling thanks to their intelligent design and integrated contact cooling. Your shrink fit holders are protected, and their high concentricity is maintained.

Cooling bells Cooling bell guide ZOLLER »zStream«

Focused on comfort and safety

The right cooling bell for every requirement: Choose between the standard cooling bell or the cooling bell with »coolbyLight« user guidance for maximum safety for your operators. Both cooling bells are available with either free-moving or linear, mechanical guidance, depending on your preference.

Cooling Bell Guide

Simply hooked in or securely guided? Choose between two options for the cooling hood guide: the simple fixing mechanism or the linear guide for maximum comfort and safety.

The Unique Cooling Alternative

With the »zStream« air cooling by ZOLLER you get maximal flexibility and protection with the cooling of your tools and shrink fit tool holder, independently of their contour or diameter. Tool cutting edges are in absolutely no danger of being damaged. You require absolutely no accessories such as a cooling adapter. In addition, your shrink tools are cooled evenly along their entire length.

»»powerShrink« 200«

ZOLLER-Basic: A Compact Way to Start

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»»powerShrink« 300«

ZOLLER-Advanced for Safety in Routine Operations

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»»powerShrink« 400«

ZOLLER Premium for Complete Flexibility

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»»powerShrink« 600«

ZOLLER Professional for the Highest Level of Perfection

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»powerShrink 400 ❘ 11«

For standard lengths up to 460 mm and modular tools up to 1,100 mm.

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A new era has begun in shrink technology. To achieve this, we haven’t just redesigned the key components of shrink machines. We’ve introduced a new generation of machines that far surpasses all other solutions.

Significant energy savings, heating with nearly 100% efficiency, extremely fast cooling, and intuitive user guidance—shrinking and unshrinking with ZOLLER redefines an established process.

See for yourself the benefits of the ZOLLER Shrink Solution.

More about Tool Heat Shrink Technology