How to Choose the Right Wire Basket

How to Choose the
Right Basket?
Drew Greenblatt
President
Marlin Steel Wire Products
How To Choose the Right
Wire Basket

Table of Contents:
Part I. Typical Basket Applications………………………….4-18
Material Handling Applications………………………5-9
High Temperature Applications………….………10-11
Cleaning Applications…………..…………………...12-17
Part II. Custom Basket Options……………………….……18-46
Wire or Sheet Metal……………….......…………...19-23
Material of the Basket………………………….......24-25
Dividers……………………………………………………..26-30
Lids……………………………………………………………28-31
Handles………….………………………………………….31-32
© Marlin Steel - Quality Engineered Quick
"How To Choose The Right Wire Basket?"
2

Table of Contents:
Basket Tags for Kitted Parts………………………….34-35
Stacking Designs…………………………………….…...36-42
Hoist Baskets………………………………………………….…43
Coatings…………………………………………………….…44-45
Part III. How to Create the Right Basket for the Job..46-69
The Questionnaire……………………………………….47-49
Productivity Considerations………………………….50-54
Choosing the Right Basket……………………………54-69
3

Typical Basket Applications
-Material Handling Applications
-High Temperature Applications
-Cleaning Applications
Part I.
4

Bulk Material Handling
Features Typically Include:
• Durable 30+ years
• Repurposed later
• Parts may touch each other
• Part contact satisfactory
• Parts scratching not a concern
• Can be manufactured with a
wide variety of custom
coatings which correspond to
environmental conditions
5

Bulk Material Handling
The dimensions of the parts that your
basket will be holding give our
engineers the ability to design a
basket that will fit your machine like a
glove.
Too much space, and a part could
rattle around excessively, creating a
risk of damage to that part. Too little
space, and the part will not fit in the
first place. Naturally, the tolerance for
extra space in a materials handling
basket will differ based on the
individual parts and washing process
involved.
6

Baskets that hold cylinders
With wire “pegs,” hollow
cylinders can be held securely
in place so that they do not fall
out of the basket or impact
one another during a wash
cycle.
7

Baskets – Confirm all parts
are where they should be
• Baskets can be custom
manufactured to hold
several different parts at
once.
• When using such baskets, it
is important to ensure that
all slots/holders have the
right parts in them.
8

Stacking Conveyor
Material Handling Basket
• When designing a basket for
conveyor belts, it is
important to know the
characteristics of the belt
(solid, segmented, roller-
type, etc.).
• Adjust base of basket based
on type of conveyor system.
9

Heat Treat Baskets
• Below 1600 Degrees
Fahrenheit
– Stainless Steel 304
or 316
• High temps 1600
Fahrenheit
– Stainless Steel Grade
330
– Inconel
10

“These baskets will run through a hot water washer with no soap.
Water temp = 210 degrees F / Air Blow Dry temp= 140 degrees F /
Wash cycle duration = 9 minutes”
11

Washing Systems & Baskets
With grade 304 SS and grade
316 SS, our washing baskets
are corrosion-resistant.
They’re an ideal basket to hold
your delicate equipment and
parts when being ran through
washing processes.
12

“Baskets will be used to transport our
components to our coater and then run
through a washing process.”
13

Ultrasonic Cleaning Racks
Baskets need to have an open
design to allow cleaning medium to
reach parts easily and drain away
after washing.
Basket needs to be able to endure
ultrasonic vibration and cavitation
for thousands of uses.
Dimensions of basket need to meet
exacting specifications for both the
machine and the parts to be held.
14

Disk Basket
These baskets are designed to hold
round, flat metal objects without
obstructing the wash process.
The baskets feature two handles that
can be built in an A-frame design to
stick above the basket, usually so they
“nest” in a stack. Other times, steel
wire by sheet metal can form “drop
handles” that can fold up or down.
15

“The baskets should be as open
as possible to allow for more
effective washing and drying of
the parts.”
16

Articulate Parts to
Maximize Washing Basket
The basket must be sturdy
enough to withstand the
agitation, cleaning agents and
temperatures of a wash
process, while keeping parts
from being scratched during
loading and unloading.
The design must also maximize
flow to remove the most
particulates and debris
possible.
17

Custom Basket Options
-Wire or Sheet Metal -Stacking Designs
-Material of the Basket -Pins
-Dividers, Lids, Handles -Hooks Coatings
-Basket Tags for Kitted Parts
Part II.
18

Common Basket Materials
• Mild Plain Steel 1008 or 1010
– Cheap
– Rusts
• Stainless Steel Grade 304
– Inhibits Rust
– Pharmaceutical
– Harsh Environment
– Heat Treat Application
19

When Are Wire Mesh Baskets Best?
• Rounded surface of the wire
provides no flat spot for
liquids to settle.
• Open Area – uniform heating
and cooling of parts.
• Fast drainage.
• Effective in ultrasonic cleaning.
– Four openings per linear
inch
– 0.063” wire diameter is
standard
• Pressure agitation.
20

“The open area of a wire mesh product can
range anywhere from 20 to 80 percent of the
surface area of the mesh basket.”
21

When are Perforated Sheet Metal
Baskets best?
• Lower cost.
• Will not dry as efficiently
as wire.
• Resistant to abusive
environments.
• Higher structural integrity
due to fewer points of
contact versus wire mesh.
22

Sheet Metal & Wire –
Mixed Media Solution
• Combine benefits of
sheet metal and wire
forms.
• Sheet metal provides
tensile strength/load
capacity, wires provide
ease of access/custom
shaping to better hold
parts.
• Often used in basket
designs to ensure best
design flexibility.
23

Downside to Plastic Bins?
Steel is better than plastic for a
number of reasons:
-More temperature resistant
-More corrosion resistant
-More versatile
-Cleaner
-Greater protection against fire
-More sustainable
-Less expensive long-term
-Less expensive to make
-Less water absorption
24

Plastic Bins
• Chipping – Plastic goes in engine, it can ruin
transmission
• Collect Dust
• Opaque – hard to see how many parts are
inside
• Chips of plastic can fall in parts
• Inhibits Sprinkler Operation - Fire Marshal,
Insurance Companies prefer non flammable
porous handling devices
25

Individual Parts Holding
• Individual parts holding - divided
baskets.
• Keep groups of parts that go through
similar processes separated.
• They are easily identifiable.
• Precision Orientation.
• Eliminates damage to parts from
handling or part to part contact.
• Can be used for multiple types of
parts at once, assuming all part types
fit in dividers.
26

Automotive Component Basket
• Parts need to be held
securely in place so that
they do not bounce around
and become scratched.
• Designs for these baskets
can vary wildly based on
part dimensions and
finishing processes.
27

Baskets with Lids and Dividers
28

Divider Basket with Lid and Lock
Left to sit loose in a basket, parts that
are not properly constrained will
bounce and roll around, hitting each
other and potentially causing damage.
These baskets, with welded basket
dividers, are generally sturdier and
lower the likelihood of losing basket
parts. It also eliminates the possibility
of using the wrong dividers with the
wrong baskets, which may happen
with a basket with removable dividers.
29

30

Bulk Basket with Handles
& Locking Lid
Baskets with lids are especially
useful for washing/finishing
processes where the parts in
the basket need to be rotated to
get the best results.
A lid will secure your parts so
that they do not become lost or
damaged.
After we have the dimensions of
your basket down, we design
your basket using precision
computer software.
31

“The handles of the basket are part
of the stacking mechanism. The
handles, which feature a
precision-bent hook design, can be
flipped into or out of the basket.”
Baskets with Handles
32

Cylinder Baskets for Parts Shaking
33

Basket Holding Precision
Parts from Inside
34

Basket Tags for Kitted Parts
• Help organize parts by
batch.
• Keep multiple baskets with
similar designs separate to
ensure that right basket is
used for the job.
• Keep parts from going to
the wrong finishing/wash
process.
35

Stacking Baskets Holding Delicate Parts
“These baskets take up minimal space when
not in use, but are able to be stacked
without putting pressure on the contents
when in use.”
36

Stacking Gear Baskets
Different clients will have different
priorities. During the initial design
phase, Marlin Steel’s engineers ask
clients to rate these key
characteristics of the final product in
importance:
• Functionality
• Appearance
• Cost
• Delivery
Generally, for stacking gear baskets,
clients rank functionality as high
priority over appearance.
37

Mobile Baskets?
Locking & Swiveling Casters
• Heavy-gauge wire for high
weight tolerance.
• Caster wheels for ease of
manual transport.
• Lid keeps parts and
materials from falling out in
case of basket upset to
minimize lost time from
accidents.
38

“Stacking baskets are a great solution for
protecting delicate machined parts from
scratching. This protection will save you from
rework and additional inspections.”
39

Stacking Basket to Hold Canisters
With Handles
• Needs to hold many
objects at once.
• Large handles for ease
of manual handling.
• Stacks to conserve
space on the factory
floor.
40

“As you can see here, Marlin Steel stacking
baskets for holding delicate parts will stack with
existing baskets. This way, you can have the option
of using them singularly or together.”
41

“The baskets will be stacked on
top of one another, therefore the
baskets above become the top of
the basket below. These will be
robot loaded and palletized so
they will need to have nesting
features similar to our baskets
now.”
42

Hoist Baskets with Knock Down Sides
• Designed to be lifted with a
mechanical hoist.
• Needs to have high weight
tolerance.
• Knock-down sides enable
easy access to basket
contents once set down.
43

Best Basket Coating for
Your Application?
44

Basket Coatings
Impact Design…Example
• Problem:
Bridges and bubbling can occur in corners.
Solution:
Coat internal components separate from
the basket and then rivet them in place as
opposed to welding.
45

How to Create the Right Basket for the Job
-The Questionnaire -Robotics
-Productivity Considerations -Choosing the Right Basket
Part III.
46

Better Engineering leads to 33%
throughput improvement and 60%
handling reduction
The perfect custom metal form
you’re looking for come from our
talented staff. Over 20% are
degreed mechanical engineers,
which means they have the tools,
training and experience needed
to help design your next project.
47

Basket Questionnaire
• Mechanical
Engineers Probe &
Understand:
–Fit
–Form
–Function
48

Goal: Cradle to Grave Processing
• Keep parts in same basket from start of
process to end of process.
• Less time handling parts from one area to the
next.
• Parts can be processed in the baskets.
49

Productivity Considerations:
Tight Tolerance Handling Racks
The tolerance of the handling rack
you need is critical to know.
Our steel has great tensile strength
and is durable; made to stand the test
of time.
Computer modeling and virtual
testing helps ensure final product will
hold the desired shape during heavy
use.
50

Part Numbering of Baskets
Marlin Steel uses part numbering
for baskets to keep track of the
different part sets quickly and
easily. This makes the parts quick
to identify how many sets of a
parts load are on the floor for
assembly.
Instead of simply placing a
temporary label on a basket, you
can have plates with custom-cut
numbers integrated with the
baskets. Numbering baskets in this
way is much more durable than
using a barcode.
51

Unique Machined Parts Basket
The automated manufacturing
robots enable Marlin Steel to
complete custom machined
parts baskets with both
precision and speed.
Because of this, it is possible to
build a custom parts cleaning
basket for unusually-designed
parts.
52

Jar or Bottle Baskets
Jar and bottle baskets pose many
design considerations. Every time such
a basket order is made, Marlin’s
engineers consider not only the
dimensions of the machinery of the
client, the processes the basket will be
used for, and the dimensions of the
bottles or jars to be held, but the
materials such contents will be made
of.
53

Gripping Delicate Parts
• Delicate parts need to be held
securely so that they do not
bounce around or fall out.
• Scratches can ruin the
functionality of delicate
objects.
• Wire forms allow for parts to
be held securely so that they
do not move.
54

Other Basket Attributes?
Design Features?
• Lid?
• Dividers?
• Hinges?
• Locking
• Wall Mounting?
• Mobile?
• Hoist Friendly?
• Conveyor Friendly?
Best Way to Store Baskets?
• Stacking?
• Nesting?
• Stacking & Nesting?
55

Ways to Weld Baskets
• Resistance
– Heat + force + time (60
cycles)
• Mig
– Add solder, generates
spatter – more clean
up
• Tig
– Add solder
• Medium Frequency
– Heat + force + time (2
cycles)
56

Robotic Interaction
• Presenting a manufactured
part to a machine.
• Robotic arm can pick the
part from its nesting spot,
perform a series of
operations and then return
it to the original position.
• Develop correct tolerances
to interact effectively in
repeatable machine
57

Benefits of Medium Frequency
Welding for Precision Baskets
• Reduces Scratching on
Parts
– less cycle time and
creates less heat.
• Tighter tolerances
– Less warping and
distortion
– Flatter parts
• Robotics/Automated
machinery – Small Room
for error
– interacting with
baskets.
58

Laser Cut Elements
Improve Safety for Precision Parts
• Platforms to Hold Parts
Precisely.
• Delicate Zones of Parts
Safe.
• Grip Parts so they are
constrained in Washers.
• Customized Orientations
for Water Jets.
• Dividers.
• Hinges.
• Latches.
59

Laser Cutting +/-0.004” tolerance
Our laser cutting machines use the
intense, and tightly-focused, heat
generated by a laser to quickly make
cuts in sheet metal. The laser will
repeat these cuts over and over,
hundreds of times per hour. Once the
machine is programmed with the right
cutting patterns, it makes the cuts on
its own.
All risk of human error is eliminated by
automating the laser cutting process.
Marlin Steel can effectively create the
perfect parts that will fit together
every time.
60

Precision Part Holding with
Laser Cut Sheet Metal
• Laser-tight tolerances
allow cut sheet metal to
hold parts precisely.
• Laser cutting can be run
at peak speed for hours
on end.
• Leaves smooth cuts in
metal plates.
61

Precision 4 axis bending – for
improved part and divider layouts
Marlin Steel’s 4th axis offers us
with a greater range of motion
and reduces changes in the
tooling operation, which helps
ensure the tightest tolerances.
62

Louvers for air flow and beads for
stands – holding delicate parts
63

Punch: roll threading, perforations
and louvers in line
• CNC punch machine can quickly
and efficiently punch holes into
sheet metal, and bend it into
specific shapes.
• The TruPunch 2020 can perform
the following:
• Cluster punching.
• Tool rotation.
• Square tool nibbling.
• Extruding and tapping.
• Wheel forming, deburring,
and offset.
• Multi-bend of sheet metal.
64

Basket Decision Matrix
Holding
Weight
Durability Flexibility
Lead Time
Tolerance Chemical
Temperature
Cost
65

Mounting Baskets –
How will it adhere to a wall or
machine?
• Can design mounted
baskets to hang from
hooks in a wall, or from
integrated plate with
screws or nails.
• Mounting baskets often
used for bicycles and
offices.
66

Baskets to Hold Discs for
Robotic Loading
In this design, the parts
needed to be held in
precise positions to allow
an automated machine to
retrieve parts without
damage.
Using manufacturing
robots allows these
baskets to be made to the
incredibly tight tolerances
needed to ensure that
robotic loaders can work at
maximum efficiency.
67

Baskets that Kit Delicate Parts
• Baskets that hold
multiple types of parts
that go through the
same wash/finishing
process help to
streamline final
assembly by putting all
of the needed parts
together.
• Parts are protected by
being kept separate.
68

Basket Packaging –
every detail must be executed well
• Packing materials need to be
sufficient to keep baskets
from being damaged.
• Box/crate must be easy to
open at destination without
risking damage to contents.
• Proper shipping labels must
be on box to facilitate ease
of transition at checkpoints.
69

Repeatable Clear Process
• Team enjoys step by step methodology
• Craves consistency
• Visual Cues
• Easier to Innovate with Repeatable Quality
• ISO 9001: 2008
70

Thank You!
Drew Greenblatt
Marlin Steel Wire Products
www.marlinwire.com
Dgreenblatt@MarlinSteel.com
410.644.7456
71

How to Choose the Right Wire Basket

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