The Westinghouse electro-mechanical power meter assembly pallet requirement was to carry six full sets of components, including delicate rotors and gear subassemblies along with heavy transformers on a conveyer belt. The intricate cut out detailing is achieved by robotically trimming the thermoformed insert.

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While proceeding down the conveyor, this pallet insert supports an IBM computer monitor in all the positions required during assembly. Starting out screen face down, as parts are added the position is changed to upright, the base is added and the unit is tested.

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Purolator manufactures automotive OEM fuel filters which are specified to have no scratch as deep as 0.001 inches on the inlet or outlet nipples. Returnable dunnage thermoformed from HDPE protects either the cap component or the body component as the parts travel from the metal forming fabricator to the metal finishing operations and then to the assembly plant. The trays securely stack for travel in boxes or on conveyors, and interlock bottom to bottom for conveying stacks of assemblies.