To meet the customer’s specific requirements, WALTHER’s experts developed a flexible large load carrier on castors, tailored to the customer’s returns-handling processes. A sturdy, foldable sleeve with two access openings sits between the pallet and the lid. For return transport of the empty load carriers, the sleeve folds down, reducing the unit’s overall volume by 65 per cent. The pallet, sleeve and lid are firmly held together by a lockable return sleeve, keeping the components aligned and slip-resistant during return transport.
To ensure long-term load capacity, the pallet is also steel-reinforced, reliably preventing deflection under high loads.
Free-spinning castors when stacked
The integrated castors of the pallet unit play a special role. The four swivel castors make warehouse transport much easier and, alongside handling with industrial trucks, also allow for convenient manual manoeuvring. To ensure the empty units can still be stacked without difficulty, the WALTHER team developed a dedicated technical solution.
Project Manager André Hecker at WALTHER Faltbox Group explains: “When stacked, the castors can spin freely, so their orientation doesn’t matter when positioning the units. Special stacking elements between the lid and the pallet secure the units and hold them firmly in position.”
From design to series delivery in under four months
One particular challenge for the WALTHER specialist was the short time-to-market: from product design to series deliveries, less than four months were available. In that time, the team developed not only the products themselves, but also the complete tooling for the pallet, lid and the separate stacking element.
We owe the successful adherence to this tight schedule to the strong collaboration between our project management, production, assembly and external partners. Everyone involved played their part with great commitment in delivering this project successfully. Our sincere thanks go to everyone.”
