How Automotive Stillages Reduce Damage During Parts Transportation

A scratched panel, dented component or damaged assembly can quickly turn into extra cost, delays and rework.

Automotive stillages help reduce that risk by keeping parts secure, separated and stable while they are moved between factories, warehouses and production lines. Their rigid steel frames, dedicated supports, dunnage and stacking features help limit movement, prevent part-to-part contact and protect components during handling and transport.

In this guide, we’ll look at the main ways automotive stillages reduce damage and how features such as pallet feet can improve stability during transportation.

Why Automotive Parts Get Damaged During Transportation

Automotive parts can pass through several stages of handling before they reach the production line or final destination. Each movement creates a risk of damage, especially when parts are not properly secured or protected.

Common causes include:

1. Load shifting and movement: Parts can slide, move or knock against the stillage during braking, turning or sudden stops.
2. Vibration during transport: Continuous vibration can cause components to rub against supports, frames or each other.
3. Part-to-part contact: When components are stored too closely together, they can collide and cause dents, scratches or other damage.
4. Scratches, chips and surface damage: Painted, coated or finished parts are especially vulnerable to contact with hard surfaces.
5. Forklift and handling impacts: Poor forklift positioning or rough handling can damage both the stillage and the parts inside.
6. Unstable stacking: Incorrectly stacked or poorly designed stillages may shift, lean or become unstable during transport.

A well-planned automotive stillage design helps control these risks by keeping each component secure, supported and in the correct position throughout handling and transportation.

How Automotive Stillages Protect Parts During Transport

Automotive stillages are designed to hold components in a controlled position while they are being stored, handled and transported. This helps reduce unnecessary movement, contact and impact that can lead to damaged parts.

1. They Keep Parts Secure and Limit Movement

Rigid steel frames provide a strong structure around the load, while locating points and dedicated supports help keep each component in the correct position.

When the stillage is properly sized for the parts it carries, there is less room for components to slide or shift during acceleration, braking, turning or forklift handling. This helps reduce impacts against the frame and other parts.

2. They Separate Components to Prevent Part-to-Part Contact

Many automotive stillages use dividers, compartments or dedicated loading positions to keep individual components apart.

This separation is especially important for parts that can be scratched, dented or distorted when they come into contact with each other. Keeping each item in its own position reduces collisions during transport and helps components arrive in better condition.

3. Dunnage Protects Fragile and Finished Surfaces

Dunnage adds a softer protective layer between the automotive component and the steel stillage.

Materials such as rubber, polyurethane (PU), felt, padding and protective liners can be used around contact points to reduce rubbing, vibration and direct metal-to-part contact. This is particularly useful for painted body panels, glass, coated components and other finished surfaces where even minor scratches can lead to rework.

4. They Reduce Damage During Forklift Handling

Heavy duty automotive stillages are commonly designed with fork pockets or fork guides that provide clear and controlled lifting points for forklifts.

This makes the stillage easier to pick up and move without directly handling the components inside. Reducing unnecessary manual handling and providing consistent forklift access can help lower the risk of accidental impacts, dropped parts and damage during loading and unloading.

How Pallet Feet Improve Stillage Stability and Reduce Damage

Pallet feet play an important role in keeping automotive stillages stable during storage, handling and transport. When correctly designed, they provide a firm contact point between the stillage and the floor, helping distribute the load evenly and keep the frame level.

Well-fitted pallet feet can help:

1. Reduce rocking and unwanted movement: A stable base helps stop the stillage from moving or tilting when it is loaded, handled or transported.
2. Maintain consistent ground clearance: Pallet feet create space underneath the frame so forklifts can access and lift the stillage more safely and consistently.
3. Keep the stillage correctly positioned: A level and supported base helps maintain the intended position of the frame and the components inside.
4. Support secure stacking: When used with suitable stacking or nesting features, pallet feet can help stillages locate correctly when placed on top of each other.
5. Reduce component damage: Less movement and instability means the parts inside are less likely to shift, collide or come into contact with the stillage frame.

For manufacturers building or repairing automotive stillages, choosing pallet feet for automotive stillages means matching their size, shape and fit to the frame and stacking requirements.

Kirmell manufactures steel pallet feet in standard and bespoke sizes, giving stillage manufacturers options for different frame designs and applications.

Stable Stacking Helps Prevent Transport Damage

Load stability becomes especially important during automotive stillage storage and transport, particularly when stillages are stacked in multiple levels.. If one stillage is not correctly located on the one below, the stack can shift, lean or place uneven pressure on the load.

A good automotive stillage design should include stacking and locating points that help:

1. Prevent stillages from shifting: Secure locating points help keep each stillage in the correct position during movement and transport.
2. Keep loads level: A stable stack reduces leaning or tilting that could cause parts to move inside the stillage.
3. Avoid excess pressure on components below: Correct stacking transfers the load through the stillage frame rather than through the automotive parts being carried.
4. Reduce stillage-to-stillage movement: Less movement between stacked units lowers the risk of impacts, vibration and instability during transport.

Pallet feet and nesting plugs can both form part of a secure stacking system.

When designed to locate correctly with the stillage above or below, nesting plugs can help reduce movement during storage and transport by keeping stacked units aligned and limiting unwanted sideways movement.

Kirmell manufactures both steel pallet feet and nesting plugs in standard and bespoke sizes for different stillage and steel pallet designs. These components can help manufacturers create more consistent and stable stacking arrangements, reducing movement and the risk of damage during transport.

Bespoke Stillages Protect Parts More Effectively

Bespoke or custom automotive stillages are designed around the size, weight, shape and fragility of specific automotive parts. This gives components a more secure fit than generic containers and reduces unnecessary movement during transport.

Custom supports, locating points, dividers and protective dunnage can be added where needed to keep parts separated, correctly positioned and protected from impact or surface damage.

The same applies to the stillage base. Where standard sizes are not suitable, bespoke pallet feet can be manufactured to match the frame dimensions, load requirements and stacking design.

Heavy-duty pallet feet may be required for higher load demands and demanding applications. Kirmell manufactures both standard and bespoke steel pallet feet for stillage applications.

Suggestion:

If you’re unsure which pallet feet size or design is suitable for your stillage, contact Kirmell and our team can guide you through the available options.

The Cost of Poor Parts Protection

Poor protection during transport can create costs far beyond the damaged part itself. Even minor scratches, dents or surface marks can affect production and delivery.

Common costs include:

1. Rework and repainting: Damaged finishes may need repair before parts can be used.
2. Scrapped components: Parts with serious damage may have to be rejected completely.
3. Production delays: Missing or damaged components can slow assembly lines and disrupt schedules.
4. Replacement costs: New parts may need to be manufactured and transported at extra cost.
5. Quality issues: Repeated transport damage can affect consistency, customer satisfaction and overall quality standards.

Using well-designed automotive stillages helps reduce these risks by keeping parts secure and better protected throughout handling and transportation.

How to Reduce Automotive Parts Damage

Even with a well-designed stillage, regular checks and correct handling are important for keeping automotive parts protected, particularly with returnable stillages that go through repeated storage, handling and transport cycles.

1. Use the correct stillage: Make sure the stillage is suitable for the component’s size, weight and shape.
2. Inspect pallet feet and stacking points: Look for bending, wear or damage that could affect stability.
3. Replace damaged dunnage: Worn padding or liners may no longer protect parts properly.
4. Check welds and frame condition: Cracks, distortion or loose sections can reduce structural strength.
5. Avoid overloading: Stay within the stillage’s recommended load capacity.
6. Stack correctly: Ensure each stillage is properly located and stable before adding another.
7. Train forklift operators: Correct lifting and handling can reduce impacts and accidental damage.

FAQs

Conclusion

Reducing transport damage starts with keeping automotive parts secure and stable. Secure positioning means less movement, less movement improves stability, and greater stability reduces the risk of component damage.

Every part of the stillage contributes to this, including the frame, dunnage, stacking points and pallet feet.

For stillage manufacturers and repairers, Kirmell supplies UK-manufactured steel pallet feet in standard and bespoke sizes to suit different frame designs, stacking requirements and applications.