Competitors Technologies

Comparison of workpiece carrier systems:
Why modular solutions from the ZELL Group offer decisive advantages

In modern manufacturing environments, workpiece carrier systems play a key role in determining efficiency, component protection and automation capability. However, not all technologies meet the increasing requirements for traceability, variant management and process integration. Compared to conventional systems such as foam inlays, thermoformed tra ys and wire cleaning baskets, the modular workpiece carrier systems from the ZELL Group(www.zell-group.com) offer significant advantages.
‍

‍

Foam inlays - inexpensive but limited

Advantages:

• Low entry costs
• Good cushioning during transportation
• Customizable for small quantities

Disadvantages:

• Not suitable for cleaning - absorb cleaning media, unsuitable for ultra-fine cleaning
• Limited service life - mechanically sensitive, wear out with frequent use
• Not suitable for automation - no defined component position, unsuitable for robotics
• No traceability - items cannot be coded, no RFID/DMC possible
• Volume disadvantage - foam layers with thick walls reduce the usable volume of KLTs/containers

Conclusion: Suitable for prototyping or one-off transports - but inefficient in automated series processes.

‍

Thermoformed trays - often underestimated, rarely economical

Advantages:

• Low weight, easy to handle
• Individually moldable (for large quantities)
• Suitable for disposable or shipping packaging

Disadvantages:

• High tool costs for modifications - each tray requires a new complete tool
• Hardly modular - no individual components can be changed
• Dimensional stability suffers at higher temperatures or aggressive media
• Not scalable - variant changeover = new development, high time-to-market
• Limited automation - difficult control for pick-and-place, as positioning varies

Conclusion: Useful for constant quantities and geometries - but quickly costly for flexible production.

‍

Wire cleaning baskets - robust, but not process-safe

Advantages:

• Open structure for cleaning & drying
• Heat-resistant - suitable for autoclaves and washing systems
• Stable, durable, stackable

Disadvantages:

• No defined positioning - components move freely → Risk of scratches, collisions
• Not process-capable with automation - no clear gripping points for robots
• High insertion effort - no clip recording or coding
• No protection for sensitive surfaces - not suitable for precise functional surfaces

Conclusion: Ideal for simple cleaning runs - not suitable for reliable series production or automated lines.

‍

The modular ZELL solution: one system for all processes

The workpiece carrier systems from the ZELL Group combine the advantages of all systems - without their weaknesses.

Typical advantages:

• Modular & scalable - holder, clip, material interchangeable with the same carrier
• Standard formats - Compatible with KLT, Euro containers, racks, palletizers
• Robotics-ready - pick-and-place, AGV & camera systems can be easily integrated
• Tracking - RFID, DMC, engraving directly on the item or carrier plate
• Suitable for cleaning - stainless steel & PA6-GF30 for ultrasound, aqueous media, autoclaves
• Sustainable - reusable, washable, durable

ZELL systems are successfully used by manufacturers such as Müller Präzision, NTK, SFS, medical technology companies, automotive OEMs and defense suppliers - worldwide, series-tested, modular.

‍

Future-proof processes require modular workpiece carriers

In a production environment that balances robotics, cleaning, logistics and variant handling on a daily basis, there is no alternative to modular carrier systems. The systems from the ZELL Group ensure reproducible quality, short changeover times and digital traceability - with an economical and future-proof platform approach.

‍

Request a CAD example or test carrier now.

‍