Component separation instead of bulk goods

More efficiency, component protection and automation in industrial production

In many production plants, components are still transported through production as bulk goods in KLT boxes or transport crates. This procedure seems simple - but it generates high costs, quality risks and hinders automation.

The alternative: the structured separation of components with workpiece carrier systems - reliable, automated and traceable.

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❌ Why bulk goods are increasingly becoming a problem

Cause loose components in boxes:

• Surface damage due to impact or friction
• unpredictable position that robots or pick-and-place systems cannot grip securely
• manual sorting effort, which costs time and opens up sources of error
• Lack of traceability, as there is no defined position
• Inefficient logistics because repacking is necessary

For modern production - especially in the precision parts, medical and electronics sectors - this is no longer economically viable or sustainable in terms of quality.

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✅ Separation with workpiece carriers: structure creates stability

ZELL workpiece carrier systems ensure that every component can be safely picked up, moved and retrieved in a defined position - from the raw part to the final packaging.

Your advantages at a glance:

• Avoidance of component damage thanks to form-fitting, tension-free holders (clips/multiclips)
• Can be fed by robots, machines and testing systems - ideal for automated processes
• Position-safe handling - each position in the carrier can be clearly addressed
• Reduced repackaging effort - one carrier passes through production, cleaning, testing and logistics
• RFID and DMC-capable - perfect basis for traceability and material flow control

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Application in practice - automated separation with recharging

More and more customers are using ZELL carriers in combination with "handle from the box" systems:
Parts are separated once from bulk material by robotics - then reloaded into a modular ZELL workpiece carrier, in which they pass through the entire subsequent process.

This allows:

✔️ Standardized transfer to CNC machines (e.g. DMG Mori, Hermle, EMAG, Grob)

✔️ Direct robotic removal for processing, testing or packaging‍

✔️ Traceable, repeatable test positions

✔️ Durable, cleanable carrier systems in a reusable cycle

The carriers thus become the uniform interface between production, quality and logistics.

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For whom is isolation particularly valuable?

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Separation is not an additional expense - but a central means of process optimization.
With ZELL workpiece carriers, you create a uniform, automatable and traceable basis for your production. This increases quality, reduces costs - and makes your production fit for Industry 4.0.

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