Defined cavities enable fast and precise picking processes, feeding technology, and handling systems to be implemented with the aid of workpiece carriers. Precision parts are thus optimally handled, processed, and assembled in batches.
Modular Part carriers, standardized with defined matrix. Customizable in less than three minutes.
Precise Placement in Gentle Plastic Clips, optimally positioned for grippers and automated handling systems.
Industrial automation thrives on standardization, process reliability, and high repeatability. Workpiece carriers from ZELL are designed to efficiently support automated processes—from feeding technology and robot-assisted machine loading to controlled material flow between production steps and handling systems, right through to intelligent warehouse logistics with Autostore systems.
Our workpiece carriers are modular in design – they fit perfectly into existing automation processes and can be combined with handling systems from leading robotics manufacturers:
✅ Automated loading and unloading of CNC machines
✅ Separation and handling by pick & place robots
✅ Automated feeding and removal at cleaning systems
✅ Picking and storage in Autostore systems
✅ Feeding technology with identification and transfer to subsequent processes
Manufacturers of precision parts and small parts with automated production processes can transport them as bulk goods in workpiece carriers or individually. Workpiece carriers with their unique storage matrix offer many advantages for automation and feeding technology.
Manufacturing companies usually start by transporting components in inexpensive KLT, VDA, or Euro containers. These are difficult to handle in precise pick-and-place processes. While an employee can easily remove a part, "reaching into the box" is a computationally intensive task for a robot. Thanks to ongoing innovation in cameras, sensors, and software, there are already effective solutions for separating components from a container. Nevertheless, each of these methods is slower than the clear feeding of individual components in a workpiece carrier.
Workpiece carriers enable the efficient handling of larger batches of parts. More complex automation processes require the complete separation of the parts in a next step. These are then usually handled directly in the production line or machine.
The high standardization of ZELL plastic components enables the cost-effective custom development of new clips/multiclips for the precise holding of precision parts. This is often necessary so that feeding technology, robot grippers, and machines know where parts are positioned.
Our workpiece carriers are standardized to the logistics dimensions 200x300, 400x600, 800x600, as well as Schäfer I and II dimensions, for which most machines and cleaning systems are designed.
Additional components such as labeling plates and tags supplement the identification options of the modular assembly. Other aids such as "removal aids" or special grippers simplify the handling of the entire carrier by the robotics.
If certain storage points are already available due to existing blisters into which reloading is required, it is usually necessary to develop analog Part carriers. The same applies to existing automation processes. If, for example, an industrial robot is already programmed in a certain way, it may be more advantageous to adapt the carrier to these conditions instead of reprogramming the automation.
In Particular, if certain external dimensions are required that cannot be configured with ZELL standard components, a "custom" stainless steel tray must be manufactured with the corresponding requirements. Here, the development costs are significantly lower (compared to plastic), but the material price for purchasing is correspondingly more expensive.
As a rule, all individual solutions are manufactured for manufacturers with adapted stainless steel trays and plastic receptacles in order to enable optimal processes.
Again and again, there are also individual requests from customers. For example, ZELL has already developed a suitable solution for the existing cleaning system. Individual trays can be inserted flexibly in height via integrated plate elements. This means that a wide range of Parts can be covered without the need for costly conversion work. The basket material is made of V2A, 1.4301 with electropolished surfaces. Cleaning baskets in this form are suitable for industries with very large components that vary in shape.
More about our cleaning baskets for large componentsMüller Präzision GmbH is one of the pioneers in automation for series production in the machining industry and operates numerous automated production cells for sophisticated precision components. To ensure stable material flows, high component quality, and cost-effective processes, the company relies on ZELL workpiece carriers.
The challenge was to transport workpieces reliably within automated machining and assembly processes, avoid damage, and at the same time implement a durable solution with minimal maintenance.
By using ZELL workpiece carriers, Müller Präzision was able to achieve reliable workpiece positioning and stable handling processes in the automation cells and also during component cleaning. The sustainability of the load carriers pays off particularly well in continuous operation: some of the carriers used have been in service for over 16 years and continue to support a trouble-free production process.
"We have been partnering with ZELL Systemtechnik GmbH since 2010. The load carriers are in continuous use!"
— Julian Plötz, Purchasing Müller Präzision GmbH
Result:
Müller Präzision benefits from reduced operating costs, high process stability, and a sustainable solution for automated workpiece transport. The long-standing partnership with ZELL underscores the reliability of the systems used and their contribution to efficient, scalable series production.
Improved safety
Standardized cleaning baskets have safety features such as handles, locking mechanisms and ergonomic designs. These features facilitate safe handling, transport and loading/unloading of Parts, both in automated processes and manually. In addition, standardized baskets undergo extensive testing to ensure compliance with relevant safety standards and minimize the risk of accidents or injuries during the cleaning process.
Cost savings
Standardized cleaning baskets offer cost advantages compared to individual solutions. Because of their standardized design, they can be produced in larger quantities in stock. This usually results in lower unit costs and offers a more favorable alternative, especially for customers with large production runs.
Clear identification of all Parts to be washed
Cleaning baskets from ZELL can optionally be ordered with identification holders. RFID chips can be attached to these or bar or QR codes can be lasered in. These enable the unique identification of Parts during the entire cleaning process in real time and thus contribute directly to quality management.
Sustainable maintenance options
In addition, the standardized design of modular cleaning baskets simplifies maintenance and repair procedures, as individual spare Parts or components are readily available and interchangeable. This also makes ZELL's baskets a sustainable alternative to existing basket systems.
Marking the Part carriers is essential for automated handling. For this purpose, we primarily offer labeling options with barcodes or QR codes, which can be lasered directly onto the tray or an optional labeling element.
RF-ID/auto-ID tags can also be used for real-time detection. Customers often already have automation Partners who can integrate these systems holistically. Together with Partners such as TURCK, we also take on the project planning for this.
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