From contract manufacturers for contract manufacturers - ZELL® workpiece carriers & cleaning baskets from practical use

ZELL is not only a manufacturer, but also a contract manufacturer: At ZELL Surface Technology, tens of thousands of parts are automatically cleaned, sorted, transported and stored every day - using exactly the workpiece carriers and cleaning baskets that are also available to customers.

The ZELL® system is therefore not a laboratory product, but has been a proven production tool in our own series production from day one. It was developed because no system available on the market met the requirements for flexibility, surface protection and automation – especially with changing components, tight cycles and high demands.

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1. Flexibility that counts in manufacturing

• Component change in less than 2 minutes thanks to the clip system
• Ideal for small to medium series with changing geometries
• Less effort when scheduling external or follow-up orders

➡️ No carrier rework or new purchase necessary – just change the clip, the line continues to run.

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2. Cleaning & Handling in one system

• Part carriers are directly suitable for cleaning – no need to repack
• Optimized for spray and ultrasonic systems (e.g. LPW, BvL, Mafac)
• Also available in ESD-safe or rinsing medium-resistant versions (e.g., for galvanized parts).

➡️ Parts remain in the carrier – from deburring to packaging. No additional logistics effort.

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3. Efficiency: What contract manufacturers really need

• Trays from  20 €, reusable hundreds of times
• Replaces disposable packaging & special holders
• Saves setup time, handling time and scrap due to incorrect gripping

➡️ Typical ROI: less than 3 months – especially for high-frequency orders with changing customers.

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4. Traceability & order structure under control

• RFID & Barcodes enable automatic tracking
• Batch handling directly on the tray – without manual repackaging
• Relieves ERP & QS processes in series production

➡️ Particularly advantageous for IATF / ISO-certified processes and customer-side traceability requirements.

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5. Sustainability as a side effect

• No disposable packaging, no filling material
• Separable by plastic/stainless steel – fully recyclable
• Reduced cleaning agent and water consumption due to open, optimized carrier geometries

➡️ In addition to lower process costs, the ecological footprint is also reduced.

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ZELL develops, tests and optimizes its workpiece carriers and cleaning baskets in its own contract manufacturing operations – under real conditions, with real customer orders. The result: a well-thought-out, field-tested system that offers clear advantages, especially for contract manufacturers with changing components, tight margins and high quality standards.

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