Maintenance of aviation wear parts: Efficient MRO processes with cleaning baskets and part carriers from ZELL

The maintenance of aviation components requires maximum process reliability, complete traceability, and reliable protection of high-quality components – from the engine to the cabin hydraulics. Especially in the maintenance and cleaning of wear parts, structured part carriers and cleaning baskets determine efficiency, quality, and compliance.

ZELL offers modular carrier systems that are specifically designed to meet the requirements of aviation MRO (Maintenance, Repair, Overhaul) – compatible with applicable standards and automatable maintenance processes.

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🧩 ZELL Part Carriers & Cleaning Baskets: Technically Sophisticated for MRO Practices

✅ Suitable for all common MRO process steps:

• Parts cleaning: Ultrasonic, spray chamber, steam, solvent baths
• Visual and mechanical inspection: Visual inspection, dimensional inspection, functional testing
• Preservation & Coating: Passivation, PVD/CVD, protective varnishes

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✅ Typical design features:

• Chemical & temperature-resistant materials (e.g. stainless steel 1.4301, PA6GB30)
• Positive and non-positive mountings with component protection (clamping profiles, soft inlays, compartments)
• Handle and stacking edges designed according to ergonomic specifications
• Optional integration of RFID, DMC, engraving, or barcode for seamless traceability
• Resistant to >500 cleaning cycles – validated in real aviation MRO processes

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🔍 Typical application examples from the aviation industry

🔧 Example 1: Engine maintenance (CFM56, LEAP, PW1000G)

• Cleaning of turbine blades & static components
• Individual recordings in the cleaning basket prevent edge contact
• DMC marking with unique traceability per component

🔧 Example 2: Landing gear MRO (e.g. A320/B737 Brake Assembly)

• Part carriers with module-specific clamping for valves and pistons
• Integration into leak testing stations and manual visual inspection stations

🔧 Example 3: Hydraulic component repair

• Sorting baskets with foam-padded compartments for seals, springs, bushings
• Prevention of mixing by segmented cleaning units
• 25 % faster component allocation during reassembly

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📈 Economic advantages for technical management and purchasing

The part carrier and cleaning basket systems from ZELL are designed for long-term use and high process reliability – and thus offer clear economic advantages for the operation of certified MRO organizations.

Thanks to the high reusability of the carrier systems – sometimes over 500 documented cleaning and process cycles – consumption costs can be significantly reduced. Unlike disposable carriers or improvised holding solutions, ZELL systems offer sustainable investment protection, as all components are designed for resistance to typical cleaning chemicals, temperature loads and mechanical stress.

In addition, the modular carriers ensure a significant reduction in setup and sorting times, especially for complex components or maintenance with a wide range of variants. In practice, the time to ready-to-use parts inspection or assembly can be reduced, which has a direct impact on the throughput time and productivity of the maintenance areas.

Quality also benefits measurably: Thanks to positive-locking holders, precisely fitting receptacles, and defined protection against contact and storage effects, transport damage, mix-ups, and cleaning defects are significantly minimized – with proven reductions in reject rates of over 90%.

Last but not least, ZELL systems are fully compatible with existing systems, conveyor technologies and automated testing solutions. Tracking requirements – for example, using RFID, DMC or serial engraving – can also be directly integrated into the carrier structure, thus fulfilling current standards for traceability and auditability (e.g. according to EASA Part 145, FAA or internal OEM specifications).

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🧠 Why ZELL? – Modular. Customized. Aerospace-proven.

For over 30 years, ZELL has been developing modular clamping and carrier systems for industries with the highest quality requirements. In the aviation industry, we supply solutions for OEMs, Tier 1 suppliers and certified MRO companies worldwide. All systems are developed in close cooperation with users – CAD-supported, process-specific and, on request, with simulation and documented validation.

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✅ In conclusion: Clear processes. Clean parts. Economical operation.

Cleaning baskets and workpiece carriers are not just accessories – they are an integral part of efficient, safe and auditable MRO processes. With the ZELL carrier systems you create the basis for reduced costs, assured quality and complete traceability – whether in the ultrasonic bath, in the test bench or in warehouse logistics.

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