88 percent truck transport volume saved with new rack for energy chain systems

readychain eco-rack from igus optimizes the use of truck loading areas and reduces shipping costs

Cologne, July 10, 2025 - The efficient use of loading space is becoming increasingly important in view of the growing volume of truck traffic on German roads. igus has therefore developed the new readychain eco-rack. The transport and assembly rack for pre-assembled energy chains is made of stable birch multiplex panels. In contrast to classic metal racks, it can be dismantled without tools. During return transport, this saves up to 88% of the original transport volume and reduces CO₂ consumption and transport costs. The eco-rack is now available for customers of the readychain service.

With its modular design, tool-free assembly and disassembly and easy handling, the readychain eco-rack offers maximum flexibility in the logistics of assembled energy chain systems. (Source: igus GmbH)

They are now a common sight on German highways: Truck convoys jammed in the right-hand lane for several kilometers. According to the Federal Environment Agency, around 231 million truck journeys were made in 2024, with a total distance of over 21 billion kilometers and a transported freight weight of 2.78 billion tons. According to forecasts by the Ministry of Transport, there could be a further increase of 54 percent by 2051. Congestion, noise and CO₂emissions will increase accordingly. In view of these figures, it is important for every company to consider the transport space of trucks as a valuable resource, to make optimum use of it and to save on delivery journeys. igus has therefore developed the readychain eco-rack, an innovative transport rack for shuttle packaging that can be used to reduce volume and costs when transporting pre-assembled energy chains by truck.

Modular design for easy return

The readychain eco-rack works as follows: It is based on blanks made from birch multiplex, a robust and dimensionally stable material consisting of several thin layers of birch wood. These blanks can be assembled as individual modules on a modified Euro pallet without tools . In combination with sheet metal elements that remain in the customer's application, a customized transport frame is created that positions the energy chain according to the geometry of the machine so that it can be connected without laborious lifting. After assembly at the customer's site, igus can dismantle the eco-rack without tools in just a few steps and transport it back in the truck to save space for the next use. "When we deliver an eco-rack, we need around 1.5 m³ of space for a customer's system. After dismantling, it is only 0.17 m³ - that saves around 88 percent volume compared to a conventional metal rack. The eco-rack is also lighter and can be dismantled in contrast to the heavy, welded metal rack," explains Markus Hüffel, Product Manager readycable & readychain at igus. A side effect of the lower weight is a reduction in fuel consumption for the truck.

readychain service relieves the burden on logistics and assembly

The eco-rack is another building block with which igus is making the readychain service more sustainable. With this service, energy chains reach the customer ready for connection. All cables from the in-house chainflex range are already laid and fitted with connectors, and sensors for predictive maintenance are already installed. This not only saves up to 75 percent assembly time, but also preparation time. "Customers no longer have to combine numerous components from different manufacturers, but can get everything from a single source with just one item number," says Hüffel. The system also reduces the burden on transport logistics. "As all the required components are delivered in one package, the number of individual transports is significantly reduced. This also helps to reduce traffic congestion." The readychain service is now available at 13 locations around the world. Every week, 400 ready-made energy chain systems alone leave the readychain factory in Cologne. Thanks to a high degree of automation in production, igus can offer individual assembly economically from a quantity of one.

Find out more about the readychain eco-rack at: www.igus.de/rc-eco-rack