More structure in the system: workpiece carriers for AutoStore® and chaotic storage systems
How modular carrier systems improve picking accuracy, component protection and automation in the warehouse
Modern storage solutions such as AutoStore®, Kardex or SSI Schaefer are based on chaotic storage - they optimize storage density and speed. However, the opposite often occurs inside the containers: unstructured component storage, manual sorting and damage-prone components.
Modular workpiece carriers create structure and automation potential directly in the storage containers - without compromising on protection or efficiency.
❌ Typical problems in the warehouse reality
- Scratches, knocks, micro-defects due to loose storage
- Time-consuming manual separation during order picking
- Inefficient transfer to production or assembly
- Poor traceability per component
- Scaling efficiency losses in JIT/JIS processes
✅ Advantages in warehouse logistics with ZELL carriers
- Fewer repackaging processes and material loss
- Faster picking & access times in the warehouse
- Clear assignment during order picking
- Stable position during transportation and robot transfer
- RFID/DMC-ready - ideal for MES/ERP systems
ZELL solution: Structured workpiece carriers in a standard container
ZELL carriers were developed for the internal dimensions of Euro containers (e.g. 600 × 400 mm) or comparable storage systems. You remain flexible in the storage process - but gain control in component handling:
More order & overview
- Position-accurate deposit per cavity
- No slipping, no overlapping
- Protection of sensitive geometries (e.g. optics, contact surfaces, O-rings)
- ESD-compatible if required
Automated order picking
- Tangible storage - robot or camera-capable (pick-and-place directly in the container)
- Ideal for automated line replenishment processes
- No transfer between warehouse and production necessary
Warehouse logistics with a system
- Multi-layer support structure for maximum container utilization
- Position detection by laser engraving, DMC or color coding
- Expandable with intermediate layers or defined removal aids
Logistical added value in the overall process
A storage container with a ZELL carrier can be used directly in the production line - without media discontinuity.
This creates a continuous material flow from incoming goods to finished product - with clear positioning and reusability.
Application examples from practice
🔧 Warehouse for turned parts: Stainless steel carriers structure 20-40 variants per tray - camera records position, fully automatic picking
🔬 Sensor production: Components with sensitive connectors are stored ESD-safe in AutoStore containers with ZELL Tray - can be used directly in the production area
📦 S hipping logistics: one and the same carrier goes from the warehouse to production to packaging - saves over 30% internal transport costs
Your benefits as a logistics or warehouse manager
📦 Order picking
Accurate, automatable, error-free - ideal for robot removal, pick-and-place and variant handling without repacking processes.
🛡️ Protection
No contact between components, no friction, no impacts - rejects due to bearing faults are significantly reduced.
🔁 Reuse
Durable carriers made of stainless steel or PA6-GF30 - robust, cleanable and reusable over many cycles.
🧠 Traceability
Position marking by engraving, DMC or RFID - for seamless traceability in the MES/ERP system.
🤝 Integration
A perfect fit for AutoStore®, SSI Schäfer, Kardex and others - ideal for end-to-end intralogistics without media discontinuity.
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