Custom plastic pallets
for PowerCo battery cell production
- Customers
- Case studies
- Plastic pallets for PowerCo battery cell production
Executive summary
PowerCo needed a pallet solution for battery cell production that could operate in clean and dry rooms while remaining compatible with the established VW pallet standard. Working from the existing 1200 × 1000 mm footprint and foot contour, Utz Group developed two custom plastic pallet variants for automated handling: a transport pallet and a cleanroom pallet.
The result provides PowerCo with a plastic alternative to stainless steel for transporting mechanical parts and reusable packaging within battery cell production. The pallet concept has also been selected for further PowerCo production locations, including Valencia.
The client
PowerCo SE is a wholly owned subsidiary of the Volkswagen Group, headquartered in Salzgitter, Germany, specializing in the development and production of battery cells for electric vehicles. The company is developing an international production network spanning Salzgitter, Valencia in Spain and St. Thomas in Canada.
The challenge
Battery cell production places specific requirements on the load carriers entering clean and dry rooms. PowerCo was looking for a pallet made from an appropriate material that could be cleaned effectively while remaining suitable for automatic handling.
At the same time, the new solution had to fit into an established logistics environment. The dimensions and foot contour therefore needed to be compatible with the existing 1200 × 1000 mm VW steel pallet.
Cleanability was another central requirement. Closed edges and flat, smooth surfaces were important to reduce areas where dirt or dust could accumulate and to make the pallet easier to clean.
Choosing plastic also offers PowerCo a more cost-efficient alternative to stainless steel while retaining the required pallet geometry.
The solution
Utz developed two plastic pallets with the same external dimensions and foot contour as the established VW steel pallet.
The transport pallet has a closed deck and was designed for a required load capacity of 1,000 kg. The initial design uses five steel profiles for reinforcement.
The cleanroom pallet has a 560 × 360 mm opening in the center of the deck and a required load capacity of 500 kg. This variant does not require steel reinforcement.
Both pallets have smooth surfaces to facilitate cleaning and reduce areas where dust or dirt can be collected. Their upper sections are welded, while the surrounding edges are sealed to avoid cracks or gaps through which dirt or water could enter.
The pallets are used to transport trays, small load carriers, and other packaging materials containing mechanical parts required in PowerCo's battery cell production. They are handled automatically within the production cells.
Development, testing and adaptation
The project progressed from concept development through toolmaking and sampling to a series of practical tests.
Testing included load tests, washing tests, and compatibility tests. During the sample phase, cleanability proved to be an important development point. The sealing around the pallet edges was adapted to prevent water from entering the pallet during cleaning.
Following these modifications and tests, the pallets were integrated into PowerCo's production process.
Further testing is currently assessing whether the steel reinforcement used in the transport pallet may no longer be necessary.
The result
A pallet concept for further PowerCo locations
The new plastic pallets support PowerCo's battery cell production while providing a more cost-efficient alternative to stainless steel. Their compatibility with the established VW pallet dimensions also allows the new solution to fit the required handling environment.
The concept is not limited to one production location. According to PowerCo, the pallet will also be used at its Valencia plant and establish a standard for further PowerCo battery cell production locations.
Utz and PowerCo are also working on a 1000 × 600 mm half-pallet designed to be compatible with the existing 1200 × 1000 mm plastic and steel pallet system.
“I am very proud that we developed and implemented a new plastics pallet based on classic VW pallet dimensions but allowing Clean and Dry room handling and cleaning. By implementing the new pallet, the standard for all further battery cell production locations for PowerCo was done. E.g. for Valencia plant this pallet will be the one and only pallet for PowerCo.”
Moritz Drabon, Logistics and Packaging planning for Battery Cell Production
Need a load carrier designed around your production process?
When standard packaging does not meet specific handling, cleaning or automation requirements, Utz can develop customer-specific reusable logistics solutions around the application.
Request consultationAutomotive and manufacturing case studies
Optimized logistics at MAN
MAN enhanced warehouse efficiency with Magazino's SOTO robots. Explore their logistics automation success and learn how robotics can optimize your operations.
Read case study
Optimizing material flow at Handtmann
By integrating 30,000 Utz EUROTEC containers into a new automated Dematic Multishuttle system, the company significantly accelerated its internal material flow.
Read case study
Lithium-ion battery packaging
Discover how Utz developed an innovative packaging solution for lithium-ion batteries, enhancing safety, handling, and transportation for a leading electromobility manufacturer.
Read case study
Production optimization for vinyl records
Utz Group designed and produced 45,000 custom vinyl record containers for GZ Media, Europe’s largest vinyl record manufacturer.
Read case study
SICK optimizes production logistics with Utz
How Utz and KNAPP helped SICK streamline manufacturing operations with durable, automation-ready EUROTEC bins over a 20-year partnership.
Read case study
Plastic pallets for battery cells
PowerCo needed a pallet solution for battery cell production that could operate in clean and dry rooms while remaining compatible with the established VW pallet standard.
Read case study