VDAKLT包装标准_en

Disclaimer of warrantyVDA Recommendations may be used freely by anyone. Users are responsible for the correct application of the recommendations from case to case.The Recommendations take into account the state of the art prevailing at the time of the respective issue. Use of a VDA Recommendations does not absolve anyone of responsibility for their own actions. In so far all users act at their own risk. Liability of the VDA and those involved in the VDA Recommendations is ruled out.Anyone noticing inaccuracies when using VDA Recommendations or the possibility of incorrect interpretation is requested to notify VDA of this promptly so that any defects or shortcomings can be eliminated.Change historyThe following changes have been made in the present edition relative to the ninth edition of VDA Recommendation 4500:2.1 Terms and abbreviations∙Note indicating that identical covers in colour RAL 5005 are used for R and RL-KLT.2.2.1 System description∙Note indicating that KLT from tools of VDA Universal-KLT manufactured in a different colour may not be marked with a VDA registration number.2.3.1 System elements∙Position of the imprints was specified more precisely.6.4.1.1 Drop test for VDA Universal-KLT∙Drop sequence was specified more precisely.6.4.1.5 Drop test for VDA loading unit cover plates∙Temperature was unified to -20 °C.6.4.3 Base sagging test∙Table has been removed because all KLT are uniformly tested with 20 kg bulk.Contents1Introduction and objective (5)2System structure (6)2.1Terms and abbreviations (6)2.2VDA KLT system depictions, nominal dimensions, measures and weights (7)2.2.1System description (7)2.2.2VDA R-KLT system (8)2.2.3VDA RL-KLT system (10)2.2.4Special features of VDA R-KLT, RL-KLT 3215 and RL-KLT 3147 (300 x 200) (11)2.2.5VDA F-KLT system (12)2.2.6Other system elements (12)2.3Identification and marking (13)2.3.1System elements (13)2.3.2Goods carried (14)2.4Special KLTs (15)2.5Changes (15)3Materials (15)4Modular structure (16)4.1Height grid (16)4.2VDA R-KLT interlocking layers on 1200 x 1000 carrier pallets (16)4.3VDA R-KLT column stacking on 1200 x 1000 and 1200 x 800 carrier pallets (18)5VDA approval procedure (19)5.1Testing institutes (19)5.2SLC manufacturers (19)5.3Quality standards of the VDA approval procedure (20)5.4Measures in the event of quality defects (20)6Quality conditions and tests (21)6.1Quality conditions (21)6.2Test conditions (21)6.3Tests (21)6.3.1Inspection of external appearance (21)6.3.2Inspection of colour (21)6.3.3Dimensional inspection (21)6.3.4Inspection of markings and identifiers (22)6.3.5Weight check of VDA KLT system elements (22)6.4Application-specific tests (22)6.4.1Drop tests (22)6.4.1.1Drop tests for VDA Universal KLTs – temperature: (+23 ± 2) °C (22)6.4.1.2Drop tests for VDA Universal KLTs – temperature: (+50 ± 2) °C (23)6.4.1.3Drop tests for VDA Universal KLTs – temperature: (-20 ± 2) °C (23)6.4.1.4Drop tests for VDA loading unit cover plates – temperature: (+23 ± 2) °C (23)6.4.1.5Drop tests for VDA loading unit cover plates – temperature: (-20 ± 2) °C (24)6.4.2Crush pressure tests for VDA Universal KLTs (except VDA F-KLT) (24)6.4.3Base sagging test for VDA Universal KLTs (25)6.4.4Changes (26)6.5Ongoing quality assurance (26)7Handling and securing loading units (26)7.1Manual handling (26)7.2Mechanized handling (27)7.3Securing loading units (27)8Use and maintenance (27)8.1Damage features (27)8.2Ensuring the functionality of the user pool with the VDA KLT system (27)9Fire protection (28)10Notes on the Annex (28)1 Introduction and objectiveTo optimize the logistics chain in the automotive manufacturing and supply industry, VDA CoC Packaging has developed a standardized plastic small load carrier system for bulk and placeable goods suitable for automatic or manual handling (known as KLT, the abbreviation of the German name KleinLadungsTräger) that is coordinated in modular fashion with the Euro modulus 1200 x 800 and the ISO modulus 1200 x 1000 and represents a universally usable, poolable system.This achieves the following objectives:∙Resource conservation and waste avoidance by eliminating disposable packaging, exterior and interior packaging∙Rationalization of transport, storage and conveyor technology by using standardized design features∙Humanization of work through ergonomic design of KLTs∙Self-securing combination of containers by form-fitting interlocked stacking (R-KLT), making it possible to avoid loading unit securing means such as stretch wrapping, shrink wrapping and strapping∙Suitability for automatic filling and emptying (smooth, non-tapered interior walls)∙Quality assurance of the cargo∙Reduction of storage and provision areas in the supplier industry by means of a user pool ∙Increased flexibility in supplying empties∙Specification of the same system features for KLTs intended for special uses∙Assurance of constant KLT quality among all KLT manufacturers through a defined approval procedure with approval numbers∙Cross-manufacturer compatibility∙Ensuring material recycling of damaged system elements by requiring KLT manufacturers to take back KLTs2 System structure2.1 Terms and abbreviationsAbbreviationsKLT (KleinLadungsTräger / small load carriers): open containers (with footprint up to600 x 400 in accordance with VDA 4500 and EN 1399) for receiving bulk goods and placeable materialsVDA R– KLT (Redesign): adaptation or system extension to meet the requirementsof new supply chains.Features: Single-walled KLT design, rigid, filling weight up to 20 kg, composite baseVDA RL– KLT (Redesign Light): adaptation or system extension to meet the requirementsof new supply chains.Features: Single-walled KLT design, rigid, filling weight up to 20 kg, smooth baseVDA F– KLT (Folding KLT): adaptation or system extension to meet the requirementsof new supply chains.Features: Folding, single-walled, filling weight up to 20 kg, composite baseVDA C– KLT (Classic): special KLTFeatures: Double-walled KLT design, rigid, filling weight up to 50 kg, composite base(All KLT types are classified by specific VDA type numbers in this Recommendation)Further termsVDA Universal KLTsVDA R-KLT, VDA RL-KLT and VDA F-KLT with:∙function areas separate from the useful area∙material properties suitable for general-purpose use (in accordance with this Recommendation)∙specified type numbersVDA Special KLTsContainers developed on the basis of the Universal KLT for special applications, for example with:∙functions or function elements extending into the useful area (e.g. bored holes in the base for mechanical lifting out of inserts)∙special material properties∙the C-KLTCarrier palletRigid, low-profile horizontal platform that can be handled with forklifts, lift trucks, or other suitable equipment and that serves as a basis for combining goods and loads for stacking, storage, handling or transport.Loading unit (LU) / Trade unitA load consisting of objects or packages combined using auxiliary means so that it can be handled, transported, stacked and stored as a unit (e.g. a carrier pallet, several KLTs and a cover plate).Loading unit cover plate (A 1208 / A 1208-1 and A 1210)A system element with a safeguarding and protective function that closes the top of the loading unit with a level surface that distributes the weight of overlying loads in a stack.KLT lids (D65, D45, D35)R-KLT and RL-KLT system elements with virtually neutral height for protection of the cargo. Note: Identical KLT covers (D65, D45, D35) are used in colour RAL 5005 for R and RL-KLT. Securing plate (SP 1208)Neutral-height system elements for securing R-KLT or F-KLT loading units on standardized wooden pallets (1200 x 800 or 1200 x 1000). Securing plates cannot be used with RL loading units.2.2 VDA KLT system depictions, nominal dimensions, measures and weights2.2.1 System descriptionThe VDA KLT system consists of VDA Universal KLTs on carrier pallets with ISO modulus 1200 x 1000 and a VDA A 1210 loading unit cover plate, or on carrier pallets with Euro modulus 1200 x 800 and a VDA A 1208 loading unit cover plate.A separate functional check is recommended if non-system package units are used.The VDA Universal KLTs are marked with a permanently visible type number on the two long sides. Carrying handles and label frames are separated. Exceptions: R-KLT and RL-KLT with height 147.5 mm, for which the label frame on the end face is integrated in the carrying handle.KLT produced from the tools of the VDA Universal KLT in a colour other than the one assigned in sections 2.2.2 to 2.2.6 may not be marked with a VDA approval number in accordance with 2.3.1.2.2.2 VDA R-KLT systemAuxiliarymiddle handleMain handleLabel frameLower function area System composite base for 600 x 400 and 400 x 300 with stacking feet and stacking grooves for centring and securingThe VDA R-KLT system has a composite base as a special feature. The stacking feet distributed over the container base ensure a safe, non-tipping standing position and engage with the R-KLT below at the stacking edge when stacked offset, thus securing the R-KLTs with each other in interlocking form.The base ribs and the stacking feet ensure the functional safety of the filled containers in storage, transport and conveyor equipment (see Section 4.2).If ISO modulus 600 x 400 is selected, the composite base allows a self-securing stack to be formed on 1200 x 1000 ISO pallets by stacking the R-KLTs crosswise (see Section 4.2).Stacking grooveStacking footLid (sealable)2.2.3 VDA RL-KLT systemLower functional space Smooth base with drainage holes (except RL-KLT 3147)Drainage holes (except RL-KLT 3147)Label frameMain handleLabel frameLower stacking edge2.2.4 Special features of VDA R-KLT, RL-KLT 3215 and RL-KLT 3147 (300 x 200)VDA R-KLT 3215 and VDA RL-KLT 3147 are structurally identical. Both KLTs have smooth bottoms and no drainage holes, and they differ only in their colour. This means that only one certification is necessary for each mould and manufacturer.D39Lid D35Lid (sealable)Side face function area End face function area2.2.5 VDA F-KLT system2.2.6 Other system elements* A 1208-1 is derived from A 1208 and is stack compatible with A 1208Lower stacking edge Upper stacking edge for centring and interlocking Main handleVDA loading unit cover plate 1208-12.3 Identification and marking 2.3.1 System elementsThe following data is stamped on VDA-R-KLT and VDA-RL-KLT during manufacturing:¹ BQF: Procurement Source Approval (BezugsQuellenFreigabe) issued by VDA Logistics Department. This relates to the release, publication and procurement of information on system elements approved, recommended and certified in accordance with VDA 4500 or other standards.The following data is stamped on the VDA KLT lid during manufacturing:2.3.2 Goods carriedIn supplier transport and to a large extent in internal transport, the goods carried should be identified by VDA goods tags in accordance with Recommendation VDA 4902 (latest version).two pieces of adhesive tape or adhesive dots (items 1 and 2 in the example figure). Tape strips measuring 30 x 15 mm or adhesive dots with a diameter of 19 mm are recommended. The adhesive tape or dots may not conceal important information (see item 3 in the example figure). The size and position of the label frame are also suitable for automatic voucher reading.321XNo product tags with additional adhesives or self-adhesive product tags may be applied. Any use of such tags degrades quality by making unambiguous identification and automatic scanning more difficult. They also make recycling more difficult and incur additional costs for sorting, cleaning and removing adhesive residues.2.4 Special KLTsSpecial KLTs are containers made with tooling certified by VDA. They must be identified by a colour that is clearly distinguishable from RAL 5003 and 5005 and an approval number. They are not subject to VDA inspection conditions or VDA monitoring (VDA CoC Packaging). These special KLTs may not bear the VDA logo.C-KLTs are also classified as special KLTs, but due to the historical development of the VDA KLT system elements they do have approval numbers and a specified colour (RAL 5012). KLTs that are manufactured according to this VDA Recommendation with regard to design, standard RAL colour and approval number and additionally have ownership marking or other labelling are also classified as special KLTs and may not be placed in the user pool. These KLT do not comply with the basic objective of VDA CoC Packaging (see Section 1) and are thus not desirable, as confusion with the VDA Universal KLTs is inevitable if the colour is the same.2.5 ChangesProposals for modifications to VDA KLT system elements and VDA Recommendation 4500 should be submitted to VDA CoC Packaging for processing and approval.3 MaterialsCertified KLT manufacturers pledge to use only polypropylene copolymers for all VDA KLT system elements in order to maintain consistent quality. The use of foamed plastics is prohibited.Certified KLT manufacturers pledge to take back and recycle damaged VDA KLT load carriers. It is also possible for users to pass the containers on to other recycling loops. A prerequisite for returning containers is that they are free from foreign objects (such as metallic elements, self-adhesive labels, etc.) and are delivered in clean, oil-free condition so that they are suitable for recycling.This recommendation does not cover test conditions for raw materials. However, the finished VDA KLTs must fulfil the quality and test requirements set out in this Recommendation.The colour tolerances in delivered condition are checked by colour measurements. See the Annex for details.All plastics must be UV stabilized. See the Annex for details.KLTs must be able to withstand washing processes and cleaning agents. See the Annex for details.The material properties of electrostatically dissipative VDA KLTs are governed by VDA Recommendation 4504.4 Modular structure4.1 Height gridThe following requirements were taken into account in setting the KLT heights:∙Uniform insertion depth 15 mm∙Same layer height when different KLT heights are stacked together∙Compliance with standard 1200 x 1000 x 1000 dimensions for loading units on standard pallets with 150 mm pallet height and loading unit cover plate height of approximately40 mm, resulting in 810 mm useful height.Consequently the VDA KLT system has the followingtwo height grids:147.5 mm280 mm(Only the 147.5 mm height grid is intended for the 300 x 200 base modulus.)4.2 VDA R-KLT interlocking layers on 1200 x 1000 carrier palletsThe VDA R-KLT self-securing interlocking system is useful for internal and external transport operations with several layers stacked on a carrier pallet with ISO modulus 1200 x 1000 (except the smooth-bottom 3215 model). In line with DEKRA assessments AG70/2008-18567 dated 14 May 2008 und 28645/2012/1811793960 dated 18 Jan. 2012 (see Annex), VDA recommends securing the loading unit cover plate. Examples of variable stack formation are shown on the following pages.Due to their design, F-KLTs do not have rigid long sides when uprighted, so they have a smaller allowable top load than the other VDA-KLT types. For safety reasons (monitoring and compliance with allowable top load), interlocked stacking of F-KLTs in uprighted condition is not recommended .Layers per VDA R-KLT height for a standard 1200 x 1000 x 1000 mm loading unit: R-KLT Height [mm]Stack height less pallet and securing plate3215147.5 6 layers (810 mm)4315147.5 6 layers (810 mm)6415147.5 6 layers (810 mm)4329280 3 layers (810 mm)6429280 3 layers (810 mm)Modulus 600 x 400 Only R-KLT 600 x 400 and 400 x 300 can be stacked interlocked. 600 x 400 modulus combined with 400 x 300 modulusR-KLT 6429 and 4329Interlocked stacking is possible only with 600 x 400 on top of 400 x 300 (not the other way round).The coordinated height grid of VDA R-KLTs allows mixed stacking with layers of the same height or a stack height of 810 mm on standard loading units with various combinations.4.3 VDA R-KLT column stacking on 1200 x 1000 and 1200 x 800 carrier palletsIf the Euro 1200 x 800 modulus is used, VDA R-KLTs can only be stacked in columns. Due to their smooth bases, the VDA RL-KLT and VDA R-KLT 3215 can generally only be used for column stacking with both footprints.Column stacking of RL-KLTs, e.g. with a low-profile Euro pallet and an A1208-1 loading unit cover plate5 VDA approval procedureThe admission procedure secures the high quality standard of the VDA KLT system elements from different manufacturers and their certification by independent test institutions.The VDA Logistics Department is responsible for organizing and monitoring the procedure.5.1 Testing institutesThe VDA KLT system elements are tested by impartial testing institutes. Authorized representatives of VDA CoC Packaging (automotive manufacturers, automotive suppliers and the Logistics Department of the VDA office) verify the testing capabilities and impartiality of testing institutes.The following procedure is used to certify a testing institute:-Submission of a written application by the testing institute to the Logistics Department of VDA, including a presentation of the options for testing and documentation using photos and brief descriptions, as well as an explanation of why the testing institute can be regarded as impartial.-Verification by an authorized agent of VDA CoC Packaging with the aid of a standardized checklist. The applicant bears the cost of this.-Approval of the testing institute by resolution of VDA CoC Packaging.-Periodic verification at least every 5 years by an authorized agent of VDA CoC Packaging.A current list of authorized testing institutes and the checklist are contained in the Annex.5.2 SLC manufacturersApplicationA written application for approval for manufacturing and selling VDA KLT system elements and retrieving the current drawings is submitted to the VDA office. See Annex for current address.The mould numbers must be listed in this application.Tooling productionThe necessary tooling is the property of the KLT manufacturer.Production of VDA KLT system elements (first specimen)The VDA KLT system elements must be manufactured in accordance with this VDA Recommendation.Drawings with inspection dimensions are submitted to VDA and the authorized testing institutes. Modifications to drawings and tolerances require the prior written consent of VDA CoC Packaging. Each certified manufacturer is obliged to supply VDA KLT system elements only in the given dimensions and tolerances.Submission to an authorized testing instituteThe KLT manufacturer makes a sufficient number of VDA KLT system elements available to an authorized testing institute for testing according to Section 6 of this Recommendation, issues a testing order, and assumes responsibility for the cost of testing.A list of authorized testing institutes is included in the annex of this Recommendation.Test report generationThe selected testing institute generates a test report according to the test regulations of this Recommendation. The test report is sent to the KLT manufacturer and to the Logistics Department of the VDA office.Issue of an approval number by the Logistics Department of the VDA officeAfter the VDA office receives the test report(s) with confirmation of successful completion of testing according to VDA 4500, the VDA office issues a sequential approval number for each VDA KLT mould in accordance with the available list of approval numbers for VDA KLTs, usually within four weeks.The approval process must be carried out anew for each subsequent mould and a new approval number must be requested.The VDA office notifies the applicant company in writing of approval as a VDA KLT manufacturer or the inclusion of additional authorized products.KLT manufacturers marks the VDA approval numbers on their moulds. The approval numbers are listed on the VDA Procurement Source Approval list.To ensure quality assurance and the operability of the system, only products marked with a VDA approval number and the VDA logo may be used by system users.Annual report of production figuresVDA KLT manufacturers must on their own initiative advise the Logistics Department of the VDA office of the annual production figures for VDA KLTs manufactured in accordance with VDA Recommendation 4500, along with the corresponding VDA approval numbers, no later than 31 January of the following year.5.3 Quality standards of the VDA approval procedureThe VDA KLT manufacturers are fundamentally responsible for ensuring consistent quality. Certification in accordance with ISO\\ 9001 or a quality management system published by VDA must be proven at the time of submission of the application for approval.5.4 Measures in the event of quality defectsIf VDA CoC Packaging ascertains defects in quality assurance or non-compliance with the processes specified in this Recommendation, the manufacturer concerned is obligated to remedy the defect and furnish evidence of this by means of an 8D report within 10 working days.If the manufacturer concerned does not comply with this requirement or if VDA CoC Packaging is of the opinion that the defects ascertained have not been remedied sufficiently, measures will be taken. Depending on the severity of the infringement, these measures include:a) Retesting by an authorized testing instituteb) Additional conditions imposed within the context of self monitoringc) External monitoringd) Withdrawal of VDA approval for the VDA KLT(s) concernedThe above measures can also be applied in combination. The costs incurred are to be borne by the KLT manufacturer concerned.The KLT manufacturer concerned shall be heard by VDA CoC Packaging with regard to all punitive measures.ObjectionsVDA symbol users may lodge a written objection with VDA against decisions on punitive measures within four weeks after receiving notification of these decisions. VDA will decide on the objection in consultation with the VDA CoC Packaging Committee.If VDA approval has been is withdrawn, the entire approval procedure must be completed again.6 Quality conditions and tests6.1 Quality conditionsThe VDA KLT system elements must have uniform, matte colouring and smooth surfaces that are free of foreign objects, cavities, cracks, webbing and other defects. Minor shallow, processing-related unevenness and pock marks are permissible if they do not impair fitness for use in accordance with VDA Recommendation 4500.Further quality conditions are described in the following sections.6.2 Test conditionsThe following quality tests are to be conducted with new KLTs, which must be at least 72 hours old and have been stored at room temperature until the time of testing.The dimensional tolerances stated in the test dimensional drawing in the Annex must be observed.6.3 Tests6.3.1 Inspection of external appearanceThe general outer appearance in accordance with 6.1 is to be inspected and documented.6.3.2 Inspection of colourThe colour is to be inspected in accordance with the RAL values specified in the tables in Section 2.2 and to be documented. See the Annex for details.6.3.3 Dimensional inspectionThe dimensions specified in the inspection dimensional drawing in the Annex are to be measured and documented. See the Annex for details.6.3.4 Inspection of markings and identifiersThe external markings and identifiers are to be inspected in accordance with Section 2.3.1 and to be documented.6.3.5 Weight check of VDA KLT system elementsType of test:12 each empty, dry VDA Universal KLTs are weighed individually.ConditionThe tare weight of any VDA KLT system element may not deviate from the target weight for that element by more than ±1%.6.4 Application-specific testsThe application-specific tests represent practical use conditions. The objective of these tests is to obtain quick, reproducible results from quality tests.6.4.1 Drop testsDrop tests are performed for the Universal KLT and loading unit cover plate elements of the VDA KLT system.Quality assurance or verification by means of drop testing is not necessary for the KLT lid and securing plate elements of the VDA KLT system.6.4.1.1 Drop tests for VDA Universal KLTs – temperature: (+23 ± 2) °CType of test:Empty VDA Universal KLTs (R-KLT and RL-KLT) are dropped at room temperature (+23 ± 2) °C from a height of 4 m (F-KLT: 2 m) onto a rigid, level floor.The KLTs (R-KLT, RL-KLT, F-KLT) must be suspended for drop sequence 2, 3 and 4 in such a way that the short and upright edge, long and upright edge, or short, long and upright edge are at an angle of 45° to the rigid, flat ground.Drop sequence:1. Impact on the full base of the VDA Universal KLT2. Impact on the bottom long edge3. Impact on the bottom short edge4. Impact on a bottom cornerNumber of VDA Universal KLTs per drop test: 3ConditionsAfter the drop tests the empty VDA Universal KLTs must still be functional; they may not burst, splinter or show any signs of cracking.6.4.1.2 Drop tests for VDA Universal KLTs – temperature: (+50 ± 2) °CType of test:Empty VDA Universal KLTs are heated to a temperature of +50 °C over a period of four hours. After this the VDA Universal KLTs are dropped individually at room temperature (+23 ± 2) °C from a height of 4 m (F-KLT: 1 m) onto a rigid, level floor. The drop sequence, impact angle and number per drop test are as stated in Section 6.4.1.1. The drop tests up to the final impact on a corner must be carried out within 5 minutes of removal of the VDA Universal KLTs from the heating chamber. The individual drop tests are to be carried out at consecutive equal time intervals of one minute each.ConditionsAfter the drop tests the empty VDA Universal KLTs must still be functional; they may not burst, splinter or show any signs of cracking.6.4.1.3 Drop tests for VDA Universal KLTs – temperature: (-20 ± 2) °CType of test:Empty VDA Universal KLTs are chilled to a temperature of -20 °C over a period of four hours. After this the VDA Universal KLTs are dropped individually at room temperature (+23 ± 2) °C from a height of 2.5 m (F-KLT: 1 m) onto a rigid, level floor. The drop sequence, impact angle and number per drop test are as stated in Section 6.4.1.1. The drop tests up to the final impact on a corner must be carried out within 5 minutes of removal of the VDA Universal KLTs from the cooling chamber. The individual drop tests are to be carried out at consecutive equal time intervals of one minute each.ConditionsAfter the drop tests the empty VDA Universal KLTs must still be functional; they may not burst, splinter or show any signs of cracking.6.4.1.4 Drop tests for VDA loading unit cover plates – temperature: (+23 ± 2) °CType of test:VDA loading unit cover plates are dropped at room temperature (+23 ±2) °C from a height of 1.5 m with a specified drop test orientation (see Annex) onto a domed surface.Drop sequence:1. Impact on the first long edge2. Impact on the second long edgeNumber of VDA loading unit cover plates per drop test: 6。