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.
Feature
Foam inlay
Thermoforming carrier
Wire basket
ZELL system
Component fixation
Loose, not dimensionally stable
Medium, no resilience
Not defined
Form-fit & tension-free
Automation-capable
No
Limited
No
Yes, pick & place optimized
Suitable for cleaning
Not suitable
Limited
Very good
Validatable & flushable
Variant change
New cut
Completely new tool required
Manually reload
Change clip only
Traceability (DMC/RFID)
Not possible
External only
Not per component
Can be integrated per position
Transport compatibility
KLT possible
KLT / one-way
Universal use
Standard formats (KLT, Euro)
Sustainability / Reusable
Disposable
Disposable
Yes
Yes, durable & stackable
Economic efficiency for variants
Only for small series
Expensive if changed
Inexpensive, but inflexible
Modular & scalable
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.
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.