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Nested transport trays are the quiet workhorse of interplant logistics. When a supplier ships empty trays back to fill again, every millimetre of stack height matters: a tray family that nests to one third of its loaded height can cut return freight by more than half across a year. Our vacuum formed tray programme is built around exactly this problem.
Wall geometry engineered for nesting
Each tray is deep-drawn from PP or HDPE sheet with a tapered side wall, so loaded trays stack firmly while empty trays nest into a compact block. Corner ribs are drawn into the tool rather than added afterwards, which keeps the stack aligned even after hundreds of round trips. Molded-in stacking lugs separate each tray in a column, so parts are never crushed by the tray above.
Cavities matched to your part family
We develop the cavity layout around the components you actually move, from die-cast housings to glass subassemblies. CAD files or a physical sample are enough to start; the first prototype tool is usually cut within ten working days, and design revisions are cut into the existing mould instead of restarted, which protects both your schedule and your budget.
Standard platform sizes
SN 1210: 1200 x 1000 x 145 mm outer, nesting height 55 mm, 6 cavities, payload 60 kg.
SN 1210-L: 1200 x 1000 x 210 mm outer, nesting height 75 mm, 4 deep cavities, payload 80 kg.
SN 865: 860 x 650 x 120 mm outer, nesting height 45 mm, 8 cavities, payload 35 kg.
SN 604: 600 x 400 x 95 mm outer, nesting height 38 mm, 4 cavities, payload 20 kg.
Materials for the shop floor
Virgin PP offers the best nesting memory and strong resistance to cutting fluids; HDPE adds low-temperature toughness for unheated yards; conductive grades are available for sensor and electronics parts. All resins are virgin material, and REACH and ROHS declarations can be issued with each production batch.
Pooling across plants
Because the tray footprint follows standard pallet modules, stacked columns can be palletised, stretch-wrapped and moved with a standard forklift. Customers running multi-plant flows standardise on one tray design across the network, which simplifies cleaning, inspection and replacement over the life of the programme.
Send us your part drawings and annual volumes, and our engineering team will return a cavity proposal with nesting height, material recommendation and tooling cost within three working days.
