More structure in the system: Part carrier for AutoStore® and chaotic storage
How modular carrier systems improve picking accuracy, component protection and automation in the warehouse
Modern warehouse solutions such as AutoStore®, Kardex or SSI Schäfer are based on chaotic storage – they optimize storage density and speed. But inside the containers, the opposite often occurs: Unstructured component placement, manual sorting and damage-prone components.
With modular workpiece carriers, structure and automation potential are created directly in the storage bins – without compromising protection or efficiency.
❌ Typical problems in warehousing reality
- Scratches, impacts, micro-defects due to loose storage
- Time-consuming manual singulation during picking
- Inefficient transfer to production or assembly
- Defective traceability per component
- Scaling efficiency losses in JIT/JIS processes
✅ Advantages in warehouse logistics with ZELL carriers
- Reduced repacking processes and material loss.
- Faster gripping & access times in the warehouse
- Clear assignment during order picking
- Stable position during transport and robotic transfer
- RFID/DMC-ready – ideal for MES/ERP systems
ZELL solution: Structured part carriers in standard containers
ZELL Part Carriers are developed for the internal dimensions of Euro containers (e.g., 600 × 400 mm) or comparable storage systems. This allows you to remain flexible in the storage process while gaining control in component handling:
More order & overview
- Positionally accurate placement per cavity
- No slipping, no overlapping
- Protection of sensitive geometries (e.g. optics, contact surfaces, O-rings)
- ESD-compatible if required
Automatable Picking
- Grippable storage – robot or camera-compatible (Pick-and-Place directly in the container)
- Ideal for automated line replenishment processes
- No re-warehousing required between storage and production
Systematic warehouse logistics
- Multi-layer carrier structure for maximum container utilization
- Position recognition via laser engraving, DMC, or color identification
- Expandable with intermediate layers or defined removal aids
Logistical Added Value in the Overall Process
A storage container with ZELL carriers can be used directly in the production line – without media discontinuity.
This creates a continuous material flow from goods receipt to finished product – with clear positioning and reusability.
Practical application examples
🔧 Storage for turned parts: Stainless steel carriers structure 20–40 variants per tray – camera records position, picking fully automated
🔬 Sensor manufacturing: Components with sensitive connectors are stored in an ESD-safe manner in AutoStore containers with ZELL trays – ready for immediate use in the production area.
📦 Shipping logistics: The same carrier goes from the warehouse via production to packaging – saves over 30% of internal transport costs
Your Benefits as a Logistics or Warehouse Manager
📦 Order Picking
Component-accurate, automatable, error-free – ideal for robot removal, pick-and-place, and variant handling without repackaging.
🛡️ Protection
No contact between parts, no friction, no impacts – rejects due to bearing defects are significantly reduced.
🔁 Reuse
Durable carriers made of stainless steel or PA6-GF30 – robust, easy to clean and reusable over many cycles.
🧠 Traceability
Position marking via engraving, DMC, or RFID – for seamless traceability in the MES/ERP system.
🤝 Integration
Precisely fitting for AutoStore®, SSI Schäfer, Kardex, etc. – ideal for continuous intralogistics without media breaks.
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