KLT by WALTHER: Watch out - car inside!

Car production depends on precise delivery of parts controlled by highly complex logistics systems. Our KLT have been developed to meet these high demands. Optimum design and ease of use ensure flawless transports, our small load carriers make the job easier.

1. Flexible integration of a folding box

1. Flexible integration of a folding box

1. Flexible integration of a folding box

Products ordered by the customer do not always fit readily into the container dimensions adjusted to logistic processes. This is precisely what happened to an automotive supplier: the 500 mm long rear lights requested by the client were too long for the ISO module dimensions used. Upright, they jutted out beyond the 320 mm high foldable KLT. Disposable cardboards were no option, just like the introduction of a separate container for the rear lights.
The solution was to develop a new collar for the 600 x 400 mm large foldable KLT which had already been circulating in large quantities. Internal dimensions could thus be increased to 510 mm. A combination of folding boxes and collars can now transport 12 rear lights and be reduced to just 30% of its full volume for return shipment.

2. New oversize mega pack also for KLT transport

2. New oversize mega pack also for KLT transport

2. New oversize mega pack also for KLT transport

A typical situation with an automotive supplier: due to modifications and extensions of working processes, the habit of dealing with a whole variety of transport packaging had crept in through the years. Various materials, different dimensions, and dubious packaging quality had an increasingly negative impact on the company’s work flow.
Since the new reusable packaging was to be employed with different suppliers, a transport of VDA KLT and of large parts on a single base pallet had to be achieved.
The new, nine-foot pallet is reinforced and therefore very stiff, measuring 1225 x 825 mm and carrying up to 500 kg in high-bay warehouses with a dynamic load of 1,000 kg. Its oversize is relatively slight and thus unproblematic during transports, allowing to stack VDA KLT containers which are employed in all applications of the automotive industry.
In addition, an antiskid attachment ring made of sturdy polypropylene twin-wall sheet can be placed in the edge region of the pallet for goods that are not packaged in KLT. The result is a mega pack transport container such as for fuel tanks, cable sets, rubber and plastic parts, or steerings.
During shipping, two mega packs can be stacked on top of one another, thus filling the internal height of a truck completely.

3. Mega pack ESD - electrically conductive mega packs for the transport of electronic components

3. Mega pack ESD - electrically conductive mega packs for the transport of electronic components

3. Mega pack ESD - electrically conductive mega packs for the transport of electronic components

WALTHER Faltsysteme GmbH now offer a complete range of large and small foldable ESD containers. These containers can move electronic components safely, preventing electrostatic charging. This property is achieved by the use of special plastic mixtures.
Using these packages, customers of the automotive industry can be sure that during shipping, sensitive circuits and semiconductors get no electric shocks causing malfunctions or costly product recalls. The new, extremely robust and tough foldable ESD pallet containers are available in the basic dimensions of 800 x 600, 1,200 x 800 and 1,200 x 1,000 mm. For return shipment, they shrink to only one fifth of their normal size. Flaps on the top ring facilitate loading and unloading of the pallet box. To bring optimal packing volume and cargo space utilization into accordance, the adapter ring can be tailored to the client's desired usable height.

4. Pallet containers for robots

WALTHER pallet containers
WALTHER plastic pallets

4. Pallet containers for robots

A customer from the automobile supply field had already tried plenty of pallet plastic boxes. None of them met the requirements imposed by the already highly automated range of brake components: reusable containers with the dimensions 1200 x 800 mm and a height of 940 mm, secure stacking of existing workpiece carriers on a high bay storable pallet, strapping of the trays for transport security and additional donning of a protective ring, and finally the automated filling and removal of brake parts by robots from all four sides.
WALTHER Faltsysteme offered a suitable solution, employing a standard pallet from the Mega-Pack system. The mega pack Hybox palette with the basic dimensions 1,200 x 800 mm fitted the work piece carriers, even leaving space for the stacking of a protective ring made of PP twin-wall sheets.
To fix the workpiece carrier exactly in its place for robot loading and unloading as well, a specially adapted pallet deck with stacking strips was developed. Also, strapping grooves have been inserted at appropriate locations of the pallet in a way that strapping of the workpiece carrier will not obstruct the additional donning of the protective ring.
The possible payload of up to 900 kg in high-racks finally made the Hybox palette winner of this project.
Today, Hyboxes are driven to the automatic loading and unloading stations, the robots do their jobs securing the sensitive goods with protective rings and sturdy covers. After filling, the entire unit is strapped and can be shipped. With these new transport boxes, our customer reaches very high circulation rates, has optimized the process costs of loading and unloading and is delighted as no transport damages occur. When Hyboxes are sent back without trays, 10 to 12 units can be returned to one storage space.

5. Efficient loading of sea freight containers with reusable pallet boxes

5. Efficient loading of sea freight containers with reusable pallet boxes

5. Efficient loading of sea freight containers with reusable pallet boxes

With the standard basic dimensions 1,200 x 800 mm or 1,200 x 1,000 mm, a freight container cannot be optimally filled. To make our customers respond flexibly to this challenge, we have developed an entire system of container mega packs that make optimum use of sea freight containers, depending on the desired inner dimension of the available base.
Thus, even parts having more than 2 meters in length are transported in a mega pack. With a container base utilization of up to 98%, every inch of space is exhausted – no more wasted space in container logistics. The mega pack volume reduction of up to 80% exists for the sea freight containers, as well as for any other item of this product family. Thus, the empties of 5 containers can be recycled in one single freight container. Of course, you may also choose the height of the pallet box here. According to the selected container (e.g. Highcube), the top ring may be adjusted in height so that up to 3 layers may be transported.

6. ESD foldable boxes against electrical shocks

6. ESD foldable boxes against electrical shocks

6. ESD foldable boxes against electrical shocks

Automotive suppliers set high quality standards and expect great logistic efficiency. In the area of automotive electronics, foldable boxes made of conductive material have been doing a great job for many years. In this case, our customer was the first electronics supplier in the automotive industry to use folding boxes for global plant-to-plant logistics.
These boxes are made of a special polypropylene in two basic sizes and different heights with a precisely defined resistance coefficient. They have been designed for the transport of sensitive electronic components. A volume reduction of up to 80% ensures low cost of empties recycling and their long lives make them very economical. Electric shocks caused by electro-static discharge and the associated destruction of the transported components are strictly excluded.

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