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The production of modern lithium-ion cells requires maximum process reliability, high technical cleanliness and consistent automation. Whether round cells (e.g. 2170 or 4680) or prismatic cell formats - the ZELL part carriers offer exactly the standards required in industrial cell production.
As one of the first partners of Tesla and Panasonic, ZELL developed part carriers for the Gigafactory, which are still used today for the cleaning and handling of battery sleeves.
ZELL systems are established in:
A real innovation in cell manufacturing is the concept developed by ZELL for active water cooling directly in the workpiece carrier.
This solution is used in the formation process of prismatic battery cells, where high temperature stability and precise temperature control are crucial.
Advantages:
🌊 Temperature control directly in the carrier – without separate cooling devices
♻️ Reusable & low-maintenance
🔧 Ideal for lines with high cell density & parallel aging
⚙️ Seamless integration into automated processes
This innovation offers manufacturers a previously unique opportunity to combine cooling and handling functionality without having to resort to external cooling trays or metallic carriers.
➡️ Technical details on resistance, particle-free and ESD properties can be found in the material data sheets in the download area.
ZELL Part Carriers are:
✅ Stackable & compatible with standard logistics sizes (e. g. KLT, Euroboxes)
✅ Suitable for robot handling with ABB, KUKA, Fanuc, Epson, etc.
✅ Traceable through DMC, laser marking or RFID
✅ Ideally suited for automated palletizing, pick & place, and Autostore systems
✅ Modular design – also adaptable for variable cell geometries
Since 2008, ZELL has been a reliable partner for precise carrier systems in sensitive production areas. Long-term industrial partners include customers such as: Bosch, Trumpf, BorgWarner, SFS, etc.
✔ Safe handling for round cells & prismatic cells
✔ ESD-safe, easy to clean, temperature-stable
✔ Water cooling for forming processes can be integrated
✔ Stackable, automatable, modularly adaptable
✔ Production-ready & proven for many years at OEMs and integrators
Contact us now and work with ZELL to make your cell production more efficient, temperature-stable and automation-capable - with workpiece-integrated cooling and maximum flexibility.
Depending on the application, we recommend starting with our "Factory" workpiece carriers, as these can be configured both as inserts for Euro containers and as standalone functional carriers. More demanding applications are better suited to our reinforced "Carrier" or "Stainless Steel" carriers.
Yes, all carriers are washable. Samples can be provided for specific critical process parameters.
Yes, all workpiece carriers are compatible with automation systems, form a defined matrix, and can therefore be configured for robotic use. Components are arranged in such a way that grippers can be positioned accordingly. Because the carriers are designed to be cleanable, they are slightly heavier; therefore, their weight and center of gravity must be taken into account when handling the entire carrier.
Our plastic carriers operate reliably over extended periods at temperatures of approximately 60–70°C, and in some cases even at significantly higher temperatures during short cycles. Our stainless steel carriers—particularly the GRID carriers—can be used in furnaces at temperatures up to 1,200°C. For additional specifications, please refer to our material data sheets.
Yes, all plastic components can be manufactured with an antistatic additive. See also the data sheet in the Downloads section.
Yes, ZELL can custom-manufacture component holders, as well as entire workpiece carriers or inlays for containers, as a single injection-molded component. We typically start by reviewing the more than 1,300 available variants using our ZELL configurator; if no satisfactory solution is found there, customers can work with our engineering team to develop a “new clip.” These can be tested in 3D and as prototypes before the corresponding injection mold is manufactured.
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