TrayTender 2.0
Continuous Tray Processing. Zero Downtime.
The TrayTender 2.0 delivers uninterrupted automation for high-volume tray handling operations. Designed for those who demand maximum throughput and minimal operator intervention, this cart-style system processes up to twenty trays per cycle while allowing hot-swap cart replacement during active production.
System Overview
The TrayTender 2.0 is a compact, self-contained tray handling solution built around a dual-cart architecture. One cart delivers unprocessed trays while a second collects processed trays, creating a continuous workflow that keeps your robot working instead of waiting.
The compartmentalized design separates cart zones from the active processing area using safety Lexan panels and sensors. This means operators can remove a full output cart and dock a fresh input cart without stopping the machine. Production continues uninterrupted.
A robot (SCARA or 6-axis) can be mounted directly to the TrayTender frame, providing the ability to load/unload trays. The ambidextrous layout allows you to configure input and output carts on either side based on your floor plan and ergonomic requirements.
Key Specifications
Machine Footprint: 63″ (L) x 46″(W) x 84″ (H)
Tray Capacity: 20 trays per cart
Tray Size: 13″ x 24″ standard Mother Tray
Cycle Performance: 7.8-seconds first-tray load time; 2.9-seconds minimum tray-to-tray changeover
Maximum Part Weight: 10 lbs. per tray (15 lbs. total with Mother Tray)
Cart Design: 8020 chassis construction with four 4″ locking casters; dimensions 20″ (W) x 34″ (D) x 39″ (H)
The Mother Tray System
Every TrayTender 2.0 uses a proprietary Mother Tray system that standardizes handling while accommodating your unique part trays. The 0.75″-thick grey PVC Mother Trays feature asymmetrical locating pins and tapered alignment holes for foolproof stacking and consistent orientation.
Thermoformed trays nest into custom-machined cutouts, meaning the TrayTender 2.0 handles your existing packaging without modification. Mother Tray height can be adjusted to match part profiles, though taller configurations can reduce total tray capacity per cart.
Process Flow
The TrayTender 2.0 uses a coordinated system of elevators, a two-position horizontal shuttle, and a lift-and-locate assembly to maintain continuous tray flow.
The input elevator retrieves trays from the docked cart and raises them to the processing level. A horizontal shuttle moves each tray to the lift-and-locate station where the robot performs loading or unloading operations. After processing, the tray transfers to the output elevator and descends to the output cart.
This architecture allows simultaneous operations: while the robot processes one tray, the next tray is already in position on the shuttle, and the previous tray is being lowered to the output cart.
Built for Production Environments
The TrayTender 2.0 addresses the realities of high-volume manufacturing where every second of robot idle time costs money. Hot-swappable carts, a compact footprint, and configurable left-right orientation make this system adaptable to existing cell layouts without extensive floor plan redesign.
Next Steps
Contact Tessy Automation to discuss your tray handling requirements and receive a custom application assessment.