Modular container inlays for OEMs

ZELL supplies HDPE carrier systems as a better alternative to thermoforming trays and foam inlays

In series production and the logistics chain, the same question arises for every component: How does it reach the customer safely, sorted by type, and efficiently – without rejects, repackaging, or excessive packaging costs?

Many companies resort to disposable deep-drawn trays or expensive foam inlays. Others use elaborate PA or stainless steel carriers, which were actually designed for in-house processes and automation – which is overkill when it comes purely to external transport.

ZELL currently supplies modular inlay systems made of HDPE that hit exactly this sweet spot:
✅ Inexpensive, ✅ stackable, ✅ reusable and ✅ precisely adapted to the component.

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The Status Quo – why many systems are not ideal

❌ Deep-drawn trays are inexpensive, but inflexible: A new tool is required for each variant. This costs several thousand euros and slows down time-to-market.

❌ Foam solutions are variable, but space-consuming: They often do not utilize the container volume well and wear out quickly with multiple uses.

❌ PA/stainless steel carriers are robust, but expensive: They are usually over-dimensioned for the requirements of a simple container inlay for shipping.

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The ZELL solution: Modular inlays made of HDPE

ZELL combines the advantages of existing systems in a new HDPE inlay concept, specially developed for external transport of goods:

✅ Modular principle – one cavity, no solid tool

Instead of designing complete deep-drawing molds, ZELL only develops the cavity for the new component. This reduces:

• Development costs
• Lead time
• Risk of variant change

✅ More content – better use of materials

Thanks to the clever arrangement and nest geometry, the existing container can be utilized much better than with foam or standard trays.

✅ HDPE as a material – ideal for KLT inlays

• Food-safe, recyclable, chemical-resistant
• Lightweight and cost-effective to manufacture
• Robust solution for repeated use – without overengineering

✅ Integration into existing container logistics

The inlays are compatible with KLT, Eurobox, GLT & reusable packaging systems – stackable, washable, identifiable.

With the modular inlay solutions from ZELL, a leading automobile manufacturer was able to increase the utilization per load carrier by up to 50 % - with the same container format. Instead of being packed loosely or in bulky foam inlays as before, the components are now transported compactly and with precise positioning in the ZELL system. This not only saves loading volume, but also significantly reduces transport costs: One truck with ZELL carriers theoretically replaces up to two trucks with conventional packaging.

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Advantages for OEMs and system suppliers

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With the new HDPE inlay concept, ZELL is launching a smart packaging solution at OEM level that is significantly more economical than classic trays, while being developed with the modular DNA of ZELL Part Carrier Systems.

Get in contact now and learn more about development, tooling & individualization.

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