What actually is a Part carrier?

Every manufacturing company faces the challenge of controlling the material flow for the product being manufactured across all departments. This logistical challenge can be optimally solved with an intelligent part carrier (small load carrier). Ideally, the process from raw part to finished product is then covered with a single part carrier system. This allows production, component cleaning, storage, and logistics to be continuously automated.

Why precision manufacturers use workpiece carriers ...

Müller manufactures at two different locations in Cham and therefore requires part carriers for the safe transport (intralogistics) of the precision parts, as well as for the protection of the "high finish" surfaces. In production itself, the components are separated, washed and fed to the various automated handling systems/robotics on the ZELL part carriers. Andreas Domani (team leader for heat treatment and technical cleanliness) explains individual production processes in detail and describes the importance of the part carrier systems.
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No automation without Part carriers

Especially in the age of Industry 4.0, production processes are being consistently automated. Consistent production conditions are required so that all robots and automation components can optimally control, remove and process the component and then transfer it to the next production step. These are realized, among other things, by Part carriers. The unique structure of the carrier defines a matrix on which each position can be precisely controlled.

Production steps that would be unthinkable or very difficult to automate with a box full of bulk goods (picking from the box) are easy to implement with a Part carrier that is filled only once. Part carriers are usually moved, stored (buffered) or reloaded on a conveyor belt or Part conveyor along the production line. ZELL Systemtechnik is currently focusing on the production of Part carriers, baskets and other components for the transportation and cleaning of components.

How is a Part carrier constructed?

Each Part carrier consists of two main components:

Part holder(or clip or Multiclip, plastic basket for bulk material)
Carrier (referred to in English as carrier or tray, on which the clips or plastic baskets can be mounted)

Part carriers are equipped with handles for optimal handling by machines or production employees. Spacers or the handles themselves guarantee the stackability of several Part carriers on top of each other.

Minimize waste and protect surfaces

Every customer is interested in maximum product quality. Especially after the surface treatment of a workpiece, it is important to protect it optimally. Production companies that work with small manufacturing tolerances are particularly challenged to guarantee maximum manufacturing quality here. The components can therefore no longer be transported as bulk material, as damage or abrasion cannot be avoided, especially with metal parts. A part carrier is required! The special plastic holder, whether clip, multiclip or plastic basket, guarantees gentle transport.

Within production, workpiece carriers can not only structure the entire material flow, but they also serve above all to protect the components by clearly fixing them in place.

The perfect Part fixture for every component

Each Part holder is adapted so that the component to be transported can be optimally protected. For example, if the component is ring-shaped, it can be accommodated with an adapted cylindrical clip. ZELL customers benefit from a portfolio with more than 700+ standard clips and Multiclips in a wide variety of designs. These are manufactured with injection molding machines from high-quality polyamide plastic and mounted on the carrier in large numbers. With a Multiclip that combines 9-36 individual clips, ZELL has been able to significantly reduce assembly time while increasing capacity on the same Part carrier.

Each clip, depending on size and shape, must now be mounted on the carrier. ZELL has established different processes here:

The clip is screwed to the carrier from below (This process is becoming less and less common, as the small screws can come loose from the plastic after some time in intensive production processes.)
The clip is screwed in (Currently the most common method, as in addition to easy assembly, it also ensures a high degree of flexibility on the carrier surface)
The Multiclip snaps into place (This innovation has further reduced assembly effort)

The mounting method generally depends on the procurement of the carrier. For example, clips on our GRID and GRID Plus Part carriers are screwed to the cross points of the metal grid, on our trays with molded punchings they are screwed in, and the Multiclips on our latest plastic carriers are merely snapped into place.

In any case, the result is a Part carrier capable of holding a corresponding capacity of components, depending on the number of Part holders. This makes Part carriers suitable not only for transport, but also for storage and logistics of high-quality Parts.

More about our clips/multiclips

Part carrier as assembly

Generally, every manufacturer wants to offer its customers an individual solution that is perfectly matched to its component. However, a traditionally manufactured Part carrier becomes problematic when the production process changes, a new component is transported or a new project is planned. Since stainless steel Part carriers are often welded or bolted together, they can only be adapted to a limited extent.

The solution for the future is therefore modular, standardized Part carrier assemblies. Here, for example, the height can be easily adjusted by means of spacers. In addition, an assembly can always be easily mounted and dismounted (see video). Every customer can thus adapt his Part carrier system as desired.

ZELL recognized this early on and patented new products together with international customers. Today, the group of companies is the leading manufacturer of this new type of Part carrier.

More about our ZELL® Factory System

Why do I need cleaning baskets?

Normally, with a suitable Part holder (clip) for the respective component, the transport process within the company is secured. However, a suitable carrier on which the respective clip can be mounted is more than useful. So is the suitable basket, especially if it is suitable for cleaning Parts.

Here, depending on the size of the basket, several work carriers can be used and stacked(see height determination). The basket is closed with an end cover. This usually has a safety mechanism to fix the individual Part carriers.

In addition to stainless steel baskets, plastic baskets are often used for gentle component cleaning. These are in turn inserted into suitable carriers, which are manufactured in such a way that they can accommodate all corresponding standard plastic baskets. All baskets are designed in such a way that the Parts can be optimally rinsed.

From the beginning, ZELL has designed all products of the ZELL Factory System to be compatible with each other, especially for the respective standard size. This not only ensures a certain flexibility in the composition of the overall system, but ultimately also the basic safety of the components to be transported.

This is Particularly important in cleaning processes. Within the cleaning lines, the baskets are gripped and swiveled for optimum cleaning. A coordinated Part carrier system thus avoids unnecessary re-charching processes.

More about our cleaning baskets

What materials are Part carriers made of?

As already mentioned, polyamide plastics are ideal for the production of individual Part holders. The carrier can also be made of dimensionally stable polyamide. Heat treatments in ovens, in Particular, require a Part carrier made only of high-quality stainless steel (see GRID system) that retains its shape even at temperatures of up to 1,200 degrees Celsius. The weight of the components or the automation process itself also play a decisive role. ZELL has therefore repeatedly produced special industry solutions in the past, which are individually adapted to the Part to be transported.

ZELL Systemtechnik has decided to voluntarily obtain ISO:9001 certification in order to assure customers of maximum production quality.

Are Part carriers sustainable?

In fact, a Part holder that is individually adapted to a specific component is not sustainable at first glance. If a customer process changes or the production of a new, differently shaped component is necessary, the Part carrier can simply be dismantled and the clips used recycled .

The Part carrier itself can be used over and over again and only needs to be replaced if it is resized for a new machine, for example. Even in this case, however, it can be recycled. At ZELL, we have recognized that the greatest potential for sustainable use of our products lies in easy disassembly of the installed components.

For this reason, and to ensure even greater flexibility of the Part carrier assembly, we have made the strategic decision to manufacture our Part carriers only according to the modular principle . This is easier to assemble and disassemble.

All components can thus be completely separated and recycled. With the interchangeable round frames of our latest baskets, ZELL also guarantees the flexible adaptation and sustainability of the entire basket kit, as it can thus be changed in area. The same applies to our latest Part carriers, which can be adjusted in height depending on the number of spacer sleeves used.

Why standardize instead of customize?

As a manufacturer, our long-term goal is to develop Part carriers with and for our customers that offer them the greatest added value. With our standardized products we are today able to cover the majority of all customer requirements. A consistent standard of modular products guarantees an attractive price management, quality and fast availability of our portfolio.

In contrast, the number of 700+standard clips seems to contradict standardization. As already mentioned, each Part fixture has to be adapted to the respective component. This aspect has its justification, nevertheless our business experience confirms that many components are similar and already developed clips, often represent the required solution.

If a customer requirement exceeds the possibilities of our standard components by far, a new development of the suitable Part fixture is also conceivable.

One thing is certain, the limits of our current Part holders only define further innovations from ZELL. "We have ideas for better solutions!"

Receive solution proposals for your component

We will be happy to generate 5 images of the Part carrier system that specifically fits your component. All we need is a CAD file of your Part. As a ZELL customer, you will be credited the one-time expense of 500,- USD for this with a subsequent order*.