You're familiar with the gitterbox from the production hall, warehouse, or technical documentation. You know it's durable, stackable, and fits any forklift in Europe. Yet, sometimes, with a specific component, machine, or racking arrangement, a standard basket simply doesn't work as it should. In this article, we explain when deviation from the norm makes engineering and economic sense, what parameters can actually be modified, and what it's like to work with a manufacturer when ordering a custom-made product.
What is gitterbox and why has it become a standard in industrial logistics?
The Gitterbox is a steel transport and storage container with a bar frame and welded mesh filling. Its history dates back to the mid-20th century, when European railways sought a standardized method of transporting goods. The result was UIC 435-3 and DIN 15155 standards, defining the dimensions, load-bearing capacity and construction requirements of the so-called UIC mesh pallet – and it was this standardization that determined the global success of the format.
The popularity of gitterbox is due to several practical advantages:
- Convertibility – containers from different manufacturers fit the same forklifts, racks and transport systems.
- Stackability – stacking improves the utilization of warehouse and cargo space.
- Durability – the steel structure withstands many years of use in demanding conditions.
- Content visibility – mesh holes allow you to identify the goods without opening the container.
Standardization is a huge advantage – until the specificity of the product or process begins to limit it.
When are standard gitterbox dimensions no longer sufficient?
A standard basket works perfectly for thousands of typical applications. However, there are situations where its performance becomes a problem.
- Specific dimensions of components
Manufacturers of large-sized components—stamped sheet metal, bumpers, and aluminum profiles—often find that standard gitterboxes are too low or too narrow. Components protrude beyond the edges, risking damage and making stacking difficult. Small components, on the other hand, fall through overly large meshes or require spacers, which generate additional costs. - Production line requirements
In automated plants, containers must fit perfectly into the conveyor slots or loading robots. A difference of just a few centimeters can mean the need to redesign the line or order a container tailored to the existing infrastructure. - Space optimization
High-bay racks have strictly defined clearances. A container 100–150 mm lower can allow for the addition of another storage level in the same hall without expanding the building.
Gitterbox dimensions – what can be changed and to what extent?
An experienced mesh basket manufacturer doesn't limit themselves to a catalog. Virtually every design parameter can be customized:
| Parameter | Scope of modifications |
| Base area | Any size – smaller or larger than the standard 1200×800 mm |
| Height | Reduced (e.g. 600 mm) or increased (over 1000 mm) |
| Load capacity | Adapted by the selection of profiles and mesh density |
| Mesh size | From 15 mm upwards (standard 50×50 mm) |
| Floor and walls | Mesh or sheet metal lined (for small and loose components) |
| Finish | Powder coating, hot-dip galvanizing or electroplating |
Reducing the mesh size to 15–25 mm makes the container suitable for transporting screws, gaskets, or small castings without additional inserts. Sheet metal on the floor or walls eliminates the problem of goods falling out and allows for the storage of bulk or wet materials.
Foldable or rigid gitterbox basket – what to choose?
Rigid gitterbox It is simpler in design and cheaper to produce. It works well wherever containers circulate in a closed loop – for example, between production halls and a warehouse, or between a factory and a regular customer.
Foldable Gitterbox It allows you to reduce the volume of an empty container by up to 70–80%. A single HGV trailer can accommodate several times more folded baskets than rigid ones – an invaluable advantage when delivering to multiple recipients or long-distance reverse logistics. The higher production cost is usually recouped after just a few transport cycles.
Applications of gitterbox containers in various industries
Wide range of configuration options makes it possible gitterbox mesh baskets have been used in very different environments:
- Automotive – Containers transport dies, castings, and bumpers between suppliers and OEM factories. Reduced height or inserts are often required to protect painted surfaces.
- Agriculture – The mesh-lined gitterbox allows for air circulation, which slows down the spoilage of fruits and vegetables. Hot-dip galvanized versions are suitable for field use and pressure washing.
- Trade and distribution – Logistics centers use baskets for order picking and buffering. Matching dimensions to the racks can significantly increase warehouse throughput.
- Heavy industry – foundries and forges need containers with increased load-bearing capacity – versions with thicker wire and a steel floor work well here.
- Hotel and laundry services – Laundries serving hotels transport linens in gitterboxes with sheet metal floors. The foldable version is popular here due to its reverse logistics.
What does the process of designing a custom gitterbox container look like?
Ordering a custom-made gitterbox doesn't have to be complicated. An experienced manufacturer guides the customer through the steps.
- Requirements analysis
The starting point is a discussion about what is to be transported, in what environment (temperature, humidity, contact with chemicals), what the space constraints are, and whether the container will work with existing systems (racks, conveyors, forklifts). - Selection of construction
The designer selects the frame profile, wire diameter, and mesh size. The load-bearing capacity must take into account not only the static load weight but also the dynamic loads during loading and stacking. - Choice of finish
This is one of the most important choices affecting durability and cost:
- Powder coating – economical, available in any RAL color, ideal for dry and chemically non-aggressive environments.
- Galvanic zinc plating – a thin zinc coating providing corrosion resistance under standard conditions.
- Hot-dip galvanizing - thick zinc coating (from 50 µm upwards) ensuring long-term resistance in aggressive environments: outside buildings, when washed with water, in contact with fertilizers.
- Prototype and validation. For larger series, the manufacturer makes a prototype for verification under real conditions before starting serial production.
The Strumet company produces transport and storage containers for over 30 years – Gitterbox was the first product in its offering. This experience translates into specific engineering knowledge: how to select a profile to ensure a container is durable and as lightweight as possible, and how to design hinges for the folding version to withstand thousands of cycles. Furthermore, Strumet offers painting and galvanizing in one place, which shortens the execution time and simplifies the logistics of the entire order.
FAQ – frequently asked questions about Gitterbox baskets
What are the available dimensions of the Gitterbox container and can they be fully configured?
The standard Gitterbox container has internal dimensions of 1200 x 800 mm and a height of approximately 970 mm, but the manufacturer can make it in any size. The base area, height, mesh size, and floor and wall type can be changed without predetermined limitations.
What is the difference between hot-dip galvanized and powder-coated gitterbox?
Hot-dip galvanizing provides a significantly thicker and more durable anti-corrosion coating – indispensable in outdoor environments, when washed with water, or in contact with aggressive substances. Powder coating is less expensive and offers a wide range of color options, but is primarily effective in dry, indoor conditions.
Is a custom-made Gitterbox container more expensive than a standard one and what does the price depend on?
The unit cost of a custom-made gitterbox can be higher than a catalog container because it doesn't benefit from the economies of scale of mass production. The price is influenced by the complexity of the design, the chosen finish, the batch size, and any prototype costs. For larger orders, the difference from the standard can be minimal, while the benefits of improved fit can be significant.
How long does it take to process an order for custom mesh baskets?
The lead time depends on the project's uniqueness, the chosen finish, and the manufacturer's current workload. Typically, the entire process—from requirements analysis to prototype production and production run delivery—takes from a few to a dozen weeks. The exact deadline is determined individually after the order has been analyzed.
