Systematic component transportation:
How modular workpiece carriers make your production and intralogistics more efficient, safer and more automated
In modern manufacturing plants, component transportation is not just a logistical issue - it is a key factor for cycle time, process reliability and component quality. Where components are manually reloaded, transported in bulk goods boxes or passed on in an unorganized manner, losses occur due to damage, mix-ups and unnecessary handling costs.
For production and logistics managers, this means:
🔻 Rejects increase,
🔻 Rework piles up,
🔻 and material flows become opaque.
The solution: Modular workpiece carriers from ZELL - developed for end-to-end use from goods receipt to dispatch.
❌ The reality without a system carrier
- No defined component position - robots & machines require readjustment
- High repackaging and separation costs
- Inadequate component securing - rejects and rework increase
- No end-to-end traceability in ERP / MES
- Media breaks between storage, processing, cleaning and assembly
The result: scaling efficiency losses per cycle - per shift - per line.
✅ Transport in modular workpiece carriers
- Uniform carrier for the entire process chain - no repackaging necessary
- Can be automated: Compatible with lines, carousels, AGVs, robot cells
- Protection & stability: clips hold components securely and gently in place
- Stackable & washable - robust for industrial series production
- Traceability through DMC, QR, engraving or RFID per item
- MES/ERP-ready - each process step can be assigned to a component
Advantages in intralogistics - crucial for logistics managers
A standardized workpiece carrier becomes the logistical bracket for your processes:
🔁 Free from media discontinuity
No moving between storage, processing, washing, assembly - one continuous carrier for all steps.
📦 Storage & return transport
Suitable for shelving systems, storage containers and AutoStore® boxes - ideal for integration into existing systems.
Optimized for transport
Stackable, AGV-compatible, barcodeable - ideal for internal plant transportation and external logistics.
🧠 Real-time data
RFID and DMC integration for traceable load units in the MES or ERP system.
⚙️ Can be automated
Direct transfer to palletizer, cobot, robot or conveyor belt - less handling, more process reliability.
Production management perspective
For the production manager, the use of modular workpiece carriers brings benefits:
- Fewer rejects thanks to safe, component-specific handling
- Higher cycle times, as pick-and-place and feed processes can work precisely
- Flexibility when changing variants thanks to interchangeable holders (no new carriers required)
- Plannable process chains, as the position, status and location of each component are clear
Practical example from series production
An automotive supplier uses modular stainless steel beams from ZELL across five stations:
- Manual loading (individual positions)
- Feeding by conveyor belt to CNC cell (DMG MORI, Hermle)
- Robot removal for cleaning
- Feedback via AGV to the test cell
- Direct placement of end packaging (blister) from carrier
The result: less repackaging, less personnel required for transportation, almost complete component tracking.
A modular workpiece carrier from ZELL is more than just a means of transportation:
It is a component protector, an information carrier and an automation module - throughout your entire production process.
Fewer handling steps. More transparency. Less waste.
Exactly what a modern production and logistics organization needs.
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