The efficient use of loading space is becoming increasingly important in view of the growing volume of lorry traffic on German roads. Igus has therefore developed the new readychain eco-rack. The transport and assembly rack for pre-fitted energy chains consists of strong multiplex panels made of birch wood. In contrast to classic metal racks, it can be dismantled without tools. During return transport, it saves up to 88 per cent of the original transport volume, reducing CO2 consumption and transport costs. The eco-rack is now available for customers of the readychain service. 

They have become a common sight on German motorways: lorry convoys that jam up the right-hand lane for several kilometres. According to the Federal Environment Agency, around 231 million lorry journeys were made in 2024, with a total distance of over 21 billion kilometres and a transported freight weighing 2.78 billion tonnes. The Ministry of Transport forecasts that there could be a further increase of 54 per cent by 2051. Congestion, noise and CO2 emissions will grow correspondingly. In view of these figures, it is important for every company to consider the transport space of lorries as a valuable resource, to make optimum use of it and reduce deliveries. Igus has therefore developed the readychain eco-rack, a new type of transport rack for returnable packaging that can be used to reduce volume and costs when transporting pre-fitted energy chains by lorry.

The readychain eco-rack is based on multiplex blanks consisting of several thin layers of birch wood - a robust and dimensionally stable material. These blanks can be assembled as individual modules on a modified Euro pallet without tools. Combined with sheet metal elements that remain in the customer's application, this results in a customised transport rack that positions the energy chain according to the geometry of the machine in such a way that a connection is possible without laborious lifting. After assembly at the customer's premises, igus can dismantle the eco-rack in a few simple steps without tools and transport it back in the lorry for the next use. The system saves space: "When we deliver an eco-rack, we need around 1.5m³ for a customer's system. After dismantling, only 0.17m³ are required. This reduces the volume by around 88 per cent compared to a conventional metal frame. The eco-rack is also lighter and can be dismantled, unlike the heavy, welded metal rack," explained Markus Hüffel, Product Manager readycable & readychain at igus. As a side effect, the lorry uses up less fuel due to the low weight.

The eco-rack is another building block with which igus is making the readychain service more sustainable as customers receive energy chains that are ready for connection. All cables from the in-house chainflex range are already laid and fitted with plug connections, and sensors for predictive maintenance are already installed. This not only reduces assembly time by up to 75%, but also minimises preparation time. "Customers no longer have to combine numerous components from different manufacturers, but can get everything from a single source with just one part number," said Hüffel. The system also relieves transport logistics. "As all required parts are delivered in one package, the number of individual transports is significantly reduced, which results in less traffic."

The readychain service is now available at 13 locations around the world. Every week, 400 harnessed energy chain systems leave the readychain factory in Cologne. Thanks to a high degree of automation in production, igus can offer customised harnessing economically with no minimum order quantity.