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CHAOTICALLY ORGANIZED PARTS ARE DESTROYING YOUR QUALITY & PRODUCTIVITY!

Do you need a customized tray for your automation line? Enable automation in production and logistics. If you think you are already enabled, think twice!

A customer tried to switch from manual production to a fully automatic assembly. And as it is, we had to straighten out the process.

Every manufacturing process involves different steps, like grinding, milling, turning, etc. Important to know is that between each machining step, a part needs to be moved from one machine to another. Sometimes even between different companies. In this specific example, my customer had to work with three suppliers: a robotic company, a precision grinding company, and an industrial cleaning company. Therefore, we had to devise a solution to move our parts between machinery efficiently. Bulk bins weren’t an option since surfaces shall not touch each other, especially during washing. Different tray options for each machine caused severe challenges later in production since my customer had to keep up with raw materials and ensure enough trays were available. Having for each machine a customized tray, would cause very low operation efficiency because an operator had to put parts in a different tray for each machine.

My customer wanted a tray solution that he could use across the board. A tray to feed a robotic machine that the robot grabs parts continuously from a programmed spot. A cost-effective tray that can be used for machining, washing, storing, and on transportation systems like conveyor belts and automated guided vehicles (AGV). And that was the moment when my customer found the ZELL Factory System.

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REDUCING TRAY VARIATION WHILE ENABELING AUTOMATION, WAREHOUSING & LOGISTICS

ZELL Group has developed a superb product that solves all problems. ZELL created a stackable standardized system that can fit on any conveyor. It is compatible with our feeding system for your automated machining and assembly machines due to standardized sizes. A customizable clip design keeps your product perfectly in place. If you choose not to use a customized clip, ZELL offers many standardized clips for the best retention. All trays fit perfectly in a basket that keeps your parts secure during washing and transportation - an excellent solution made in Germany.

HOW ZELL GROUP HELPED US SOLVE OUR PROBLEMS

ZELL looked at the overall process and goals that must be achieved and helped select the right Multiclip and the proper tray size. Since parts washing was required, ZELL selected the best-fitting basket. 

Process symbol

1

ANALYZE PROCESS

We want to understand your process and what you would like to achieve. Based on that information, we can best evaluate how our product portfolio can address your needs. Our goal is that you have one carrier throughout your manufacturing process, including warehouse and shipping operations - One parts carrier for everything. 

Tailor 3D Multiclip

2

SELECT MULTICLIP

We have many clips available. Our portfolio has over 700 standardized clips, and we most certainly find a few options to keep your part well captured on our trays. If you want the perfect fitting clip, you would like to go with a customized Multiclip. A clip developed around your part geometry. 100 % matching your part design. 

Tailor 3D Tray

3

SELECT TRAY SIZE

When our customers have decided on the clip, a standardized or customized clip, we select our standardized components. The tray size depends primarily on how many parts you want to process in a specific time and the weight limit on a fully loaded tray. We cover five different standardized sizes to address your needs.

Tailor 3D Basket

4

SELECT BASKET SIZE

The basket size depends on the tray size. We offer two defined heights of 200 mm and 300 mm. How many trays fit in each basket depends on the height of each tray. Our baskets fit most industrial cleaners and are the perfect choice for automated cleaning and for ultrasonic cleaning. Put ZELL Factory System baskets on an automated guided vehicle (AGV), send it to the warehouse and stack our baskets on top of each other and send it to your customer. 

Tailor 3D Accessories

5

SELECT ACCESSORIES

Even though our standardized solutions address many requirements, we still offer additional parts. We offer labeling plates to identify trays individually for our trays and baskets. You can add a QR code or any other information. Additionally, we offer many adaptors, removal tools, and assembly devices if you need to replace single components. 

PROTECT YOUR PARTS WITH CUSTOMIZABLE CLIPS

ZELL develops for your parts a customized multiclip that perfectly matches your product's shape. Each multiclip creates a pocket where your parts are seated, protected, and cannot touch other parts. Any surface damage, like scratches and dents, cannot occur. We have an easy process to develop your multiclip: Send us your part in a step-format, and our engineering team will develop your customized clip. If you want multiple parts on a clip, no problem either. We can use multiple clips to find the perfect solution. Your part, or workpiece as we call it internally, gets the maximum protection during transportation and washing.

Tailor 3D Customizable Clips

CUSTOMIZE POCKETS ON STANDARDIZED MULTICLIPS

The size of your part defines the number of pockets per multiclip. The general rule is that the smaller your part is, the more parts can fit in a multiclip. The size of the multiclips is standardized. No worries. If your part or workpiece is bigger than one multiclip, we can use multiple multiclips per part. Multiclips are made of high-quality Polyamide and are dimensionally stable and suitable for all common solvents used in the industrial washing equipment.

Tailor 3D Standardized Multiclips

FIVE STANDARD TRAY SIZES ENABLE YOUR AUTOMATION PROCESS

Every multiclip has the exact dimensions, so all multiclips fit perfectly in all tray sizes. This way, ZELL reduces any hassle when matching multiclips with five different tray sizes. The number of multiclips defines the size of the tray. Most likely, you have a certain number of parts you would like to process at a specific time, which also influences the tray size. 

Standard sizes and defined geometries are essential for robots and logistic systems to perform well in operations. 

Tailor 3D Tray

THE PEFECT TRAY ASSEMBLY

Every tray assembly consists of a tray plate, handles, spacers, and optionally a marking plate.

Two ergonomic handles ensure safe handling and stackability. All parts are made in high-quality Polyamide to ensure lightweight and durability. The tray assembly is customizable in height, depending on your product height. ZELL offers spacer heights in 5mm (1/4 inch) increments. 

Marking plates are a great option to ensure clear identification of the tray assembly and what part belongs in it. Your quality team will love it. 

Besides all these benefits, every single component can be easily disassembled, replaced, or recycled.

Tailor 3D Tray Assembly

ZELL BASKETS KEEP YOUR TRAYS AND PRODUCTS SAFE

For each tray size, ZELL offers a matching basket in two heights: 200 mm (= 7 111/127 inches) and 300 mm (= 11 103/127 inches).

The two stainless steel frames ensure rigidity and define the size. Keep in mind that only the two stainless steel wire frames are different. All other components of the basket are standardized. So for any basket you purchase, the polymer part is the same. Your purchasing/warehousing team will love it. Lower variation leads to more clarity and less confusion.  

ZELL offers accessories like removal tools, adapters, and basket labeling plates for laser marking. 

Tailor 3D Tray Sizes

WHY CHOOSE OUR CARRIER SYSTEMS

ENABLING AUTOMATION

ZELL Factory System is the best solution if you want to increase your level of automation in your production area. ZELL Factory trays are standardized and ensure your product will always be delivered to your robots in the same way. Same size, same orientation, same location. ZELL trays can replace your expensively customized trays with a very cost-effective solution.

Visualization of a Cobot with a ZELL part carrier
Visualization of a ZELL Factory system during cleaning

PARTS CLEANING

ZELL Factory System is designed to work with all commonly used cleaning solvents and all water-based solutions. Changing your machined parts into a new tray after the final machining process is unnecessary. ZELL Factory system is perfectly designed to be used on conveyors and fit in all standard industrial washers. Parts are kept secure and can even swivel 360°. All trays, multi clips, and lids are designed to allow the highest level of surface penetration for best cleaning results. 

LOGISTICS

ZELL Factory System was built for a rough environment. We use high-quality polymers in combination with stainless steel to provide the highest rigidity to protect your machined goods in your operations. Our product is well thought through and was built with a focus on safety and protection in harsh environments. Stackability and a well-designed clamping mechanism ensure that your parts will not touch the floor when even baskets get tipped over. A well-designed system allows you to run the basket directly on your conveying belts in your plant. We even provide our carriers with electrostatic discharge (ESD) approved material if you have special electrical requirements.

Visualization of ZELL Factory System stacked on a Euro pallet
Different sizes and parts of ZELL Factory System

WAREHOUSING

ZELL Factory System protects your parts or workpieces in your operations and keeps them safe and organized in your warehouse. Why should you unpack your goods between the ZELL Factory System into boxes when your customer might use them directly from the ZELL baskets? Save your time for better activities and get more efficient using the ZELL Factory System!

Logo of Tailor3D

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CONTACT

320 Gold Ave. SW, Ste. 620 PMB 2582
Albuquerque, NM, 87102
USA

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ABOUT

Tailor3D focuses on additive manufacturing and automation solutions in combination with augmented and virtual reality. We believe that manufacturing will change significantly in the following years, and it is essential to create everything digitally until you need an actual product. Customized solutions supported by advanced development technologies to lower costs and make the best fitting product! We are Tailor3D!

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