What Are Automotive Stillages? Types, Uses & Benefits
Moving heavy, awkward or high-value automotive parts safely is not as simple as placing them on a standard pallet. That is where automotive stillages come in.
Automotive stillages are strong, reusable steel structures designed to store, protect and transport vehicle components such as engines, gearboxes, body panels, and windscreens. They are widely used across automotive manufacturing, warehousing and supply chains where safe handling, stackability and efficient use of space are important.
In this guide, we’ll explain the main types of automotive stillages, where they are used, their key components and the benefits they offer.
What Are Automotive Stillages?
Automotive stillages are strong, reusable steel frames used to store, protect and move vehicle parts during manufacturing and transport. They are commonly used for components such as engines, gearboxes, body panels, bumpers, exhaust systems and windscreens.
Unlike standard pallets, which mainly provide a flat base for carrying goods, automotive stillage design can be adapted around the shape, weight and handling needs of specific components. They may include features such as dunnage, fork guides, pallet feet and stacking points to keep parts secure and make handling easier.
Across the automotive supply chain, stillages are used to move components between suppliers, warehouses and vehicle assembly plants. They can also support line-side storage, where parts need to be presented safely and efficiently for production.
Common Types of Automotive Stillages
Automotive stillages come in different designs depending on the size, weight, shape and protection needs of the parts they carry. Some are built for heavy components such as engines and gearboxes, while others are designed to protect more delicate parts like windscreens, bumpers and interior assemblies.
Stillages by Automotive Component
Custom Automotive stillages are often designed around the specific part they need to carry. Different components require different levels of support, protection and positioning, which is why stillage designs can vary widely across the automotive industry.
1. Windscreen and glass stillages
Windscreen and glass stillages are designed to carry fragile automotive glazing safely. They often use cushioned contact points and secure supports to reduce movement, vibration and the risk of breakage during storage or transport.
2. Bumper stillages
Bumper stillages are shaped around the size and profile of front and rear bumpers. They help keep finished surfaces separated and supported, reducing the risk of scratches, dents or unwanted movement.
3. Exhaust stillages
Exhaust stillages are built for long, irregular exhaust systems and related components. Their supports help keep each part in position while allowing efficient handling, storage and transport.
4. Fuel tank stillages
Fuel tank stillages use locating points and supports to hold fuel tanks securely. This helps prevent movement during lifting and transport while keeping the components organised within the stillage.
5. Instrument panel stillages
Instrument panel stillages are used for dashboards and other interior assemblies that can be sensitive to scratches or cosmetic damage. Shaped or padded supports help protect finished surfaces and keep each component correctly positioned.
6. Engine and gearbox stillages
Engine and gearbox stillages are examples of heavy duty automotive stillages, designed for powertrain components that require strong structural support. They typically use robust frames and secure locating points to keep engines or gearboxes stable during handling and transport.
7. Tyre and wheel stillages
Tyre and wheel stillages provide an organised automotive stillage storage solution for tyres, wheels and complete wheel assemblies. Their open and accessible design can make loading, unloading and warehouse handling more efficient.
Stillages by Construction
Automotive stillages can also vary by construction. Mesh stillages provide containment while keeping the load visible, sheet-sided stillages offer greater enclosure and protection, and open-frame or post-pallet stillages provide easier access for larger or irregular parts.
Many designs are also stackable or collapsible. Stackable stillages help make better use of warehouse space, while collapsible returnable stillages can reduce the space needed when empty units are stored or transported back to suppliers.
What Are Automotive Stillages Used For?
Automotive stillages are used to move, store and protect vehicle parts throughout the automotive supply chain. Returnable stillages are particularly useful for repeated handling between suppliers, warehouses and assembly plants.
- Transport between suppliers and OEMs: Stillages help move automotive parts safely from component manufacturers and Tier suppliers to vehicle manufacturers, while keeping parts organised and reducing movement during transport.
- Line-side handling: At assembly plants, stillages can deliver parts directly to the production line in a controlled and accessible way, helping operators handle components more efficiently.
- Warehousing: Stackable stillages make better use of vertical storage space and help keep automotive components organised before they are needed for production.
- Component protection: Dunnage, supports and locating points can be designed around specific parts to reduce scratches, impact damage and unwanted movement during storage and handling. These features also explain how Automotive Stillages reduce damage during parts transportation.
- Returnable packaging loops: Because steel stillages are durable and reusable, they can be returned to suppliers after unloading and used again across repeated transport cycles. In stackable systems, nesting plugs can help reduce movement and damage during storage and transport.
Key Components of an Automotive Stillage
An automotive stillage is made up of several components that work together to support the load, protect vehicle parts and allow safe handling.
The exact automotive stillage design varies depending on the components being carried, but most stillages include some of the following parts:
- Steel frame: Forms the main structure of the stillage and provides the strength needed to carry and contain the load.
- Dunnage and supports: Hold automotive parts in the correct position and help prevent movement, scratching or impact damage.
- Fork guides: Provide defined entry points for forklift forks, making the stillage easier and safer to lift and move.
- Identification plates: Display information such as part numbers, load details, ownership or tracking information.
- Pallet or stillage feet: Form part of the base, helping support the stillage, create ground clearance and, in some designs, contribute to the stacking system.
- Nesting or stacking components: Help locate one stillage correctly on top of another and reduce unwanted movement when units are stacked. Nesting plugs are one common way of creating this locating point.
What Makes an Automotive Stillage Reliable?
A reliable automotive stillage depends on more than just a strong steel frame. Its feet, stacking points, joints and retaining hardware must all work together to maintain load stability through repeated lifting, transport, stacking and loading cycles.
Pallet Feet: Supporting the Stillage Base
Pallet feet for automotive stillages are an important part of the stillage base. They help support the load, create clearance underneath the frame and, depending on the design, can work with nesting or stacking components to locate stillages securely when stacked.
Understanding the difference between pallet feet and nesting plugs is useful when specifying a stackable stillage system.
Because pallet feet are positioned close to the ground, they can also be exposed to repeated impacts, heavy loads and demanding handling conditions, making the correct foot specification particularly important for heavy duty automotive stillages. Bent, damaged or incorrectly sized feet may affect how evenly the stillage sits or how accurately it locates with another unit.
For both new stillage production and replacement work, it is important to choose pallet feet that match the frame dimensions and stacking arrangement.
Kirmell manufactures standard and bespoke steel pallet feet for stillages, including components made to specific dimensions where an off-the-shelf size does not suit the application.
Kirmell also supplies related stillage hardware such as nesting plugs, hinges, gate brackets, shoot bolts and identification plaand identification plates, supporting manufacturers with components for stacking, access, load retention and identification.
Benefits of Automotive Stillages
Automotive stillages help improve the way vehicle parts are stored, moved and handled across the supply chain. Their reusable and stackable design offers several practical benefits:
- Component protection: Helps reduce damage during handling and transport.
- Easier handling: Supports safer movement with forklifts and other equipment.
- Better space use: Stackable designs maximise warehouse storage.
- Consistent stacking: Helps units locate securely when stacked.
- Reusable transport: Suitable for repeated use across supply chains.
- Line-side efficiency: Keeps parts organised and accessible for production.
What to Consider When Choosing an Automotive Stillage
The right automotive stillage should suit the part being carried, the handling method and the way it will be stored or returned through the supply chain. or unusual part shapes, weights or handling requirements, custom automotive stillages may be required.
If the stillage requires new or replacement feet, checking the key pallet foot dimensions before ordering can help ensure they match the frame and stacking arrangement.
Considering these factors early in the automotive stillage design process can help improve component protection, handling efficiency and compatibility across the automotive supply chain.
Trusted by the UK Motor Industry Since 1985
Kirmell has been manufacturing in the Midlands since 1985, supplying pallet feet and other pressed steel components for automotive stillages and material-handling applications.
Over the years, Kirmell has supplied products to major automotive manufacturers including Ford, Vauxhall, Nissan and Toyota. Our UK manufacturing capability allows us to support both standard requirements and bespoke components made to specific dimensions or drawings.
For stillage manufacturers and automotive businesses, this means access to reliable UK-made components backed by decades of manufacturing experience.
FAQs About Automotive Stillages
An automotive stillage is a reusable steel frame used to store, protect and transport vehicle parts safely.
They are used for moving and storing parts between suppliers, warehouses and vehicle assembly plants.
Common types include stillages for engines, gearboxes, bumpers, windscreens, tyres, body panels and other automotive components.
Stackable stillages help save warehouse and transport space by allowing units to be stored safely on top of each other.
Pallet feet support the stillage base, provide clearance and can help with stable stacking. Kirmell manufactures steel pallet feet for stillage and pallet applications.
Yes. Kirmell can manufacture bespoke pallet feet and nesting plugs to suit specific frame dimensions, existing designs and stacking requirements. Contact us to discuss your requirements or send over your dimensions or drawings for a quote.
Conclusion
Automotive stillages play an important role in protecting, storing and moving vehicle parts throughout the supply chain. The right design can improve handling, stacking, component protection and the efficient use of warehouse space.
For manufacturers that need reliable stillage components, Kirmell supplies UK-made pallet feet, nesting plugs and bespoke pressed steel parts for a range of stillage applications. If you need a standard size or a component made to specific dimensions, contact Kirmell for a quote.
