Motorized Cable Reel Movers Deliver a Reel-y Safe Solution

In an impressive display of customer-focused problem-solving, MasterMover has once again demonstrated its leadership in engineering customized material handling solutions.

In this blog, we explore the latest addition to MasterMover’s extensive portfolio of custom engineered solutions.

Having recently designed and delivered two specialist cable drum handling systems for a customer in the defense industry, we’ve further cemented our reputation as the go-to problem solver across the industry.

3 Key Challenges in Cable Drum Handling

Size, Variety & Safety 

Subsea cables are the invisible backbone of global communications, carrying over 95% of international data traffic.

These cables are essential for internet connectivity, and telecommunications, and are sometimes even used for power transmission between regions.

Considering the crucial role these systems play in the infrastructure of the modern world; the effective handling of cable reels and drums is crucial for maintaining global connectivity.

For this customer, moving large and cumbersome cable drums and reels was challenging. They needed a safer, more efficient way to move a diverse range of heavy cable reels and drums.

Project engineers were tasked with finding a solution that could handle various drum sizes and weights while prioritizing worker safety in their production environment.

Each reel, weighing up to 66,000lbs., presented its own set of handling challenges.

The variation in drum size and materials, including both wood and metal constructions, added another layer of complexity to the task of finding a universal solution capable of safely moving the drums and reels.

Project Requirements

In this project, the customer's processes required the movement of large commercial cable drums both indoors and outdoors, including navigating a challenging incline at the entrance of the facility.

This required a solution that was not only powerful but also highly maneuverable and capable of operating reliably beyond a smooth factory floor.

However, perhaps the most pressing driver for this solution stemmed from a previous safety accident - a hand trap incident that occurred during the cable spooling process highlighted the urgent need for a safer, more efficient system.

This incident underscored the critical importance of developing a solution that prioritised operator safety without compromising on functionality and versatility.

Considering their unique requirements, this customer needed an expert – a business with a proven pedigree in designing and manufacturing custom handling solutions, leading them to contact the team at MasterMover.

MasterMover is No Stranger to Challenging Handling Processes

Rising to the challenge, our team of expert engineers worked with the customer to fully understand their application needs. Following a staged-gate process, engineers collaborated with the customer every step of the way, ensuring that any solution was fully fit for purpose and tailored to their specific operational needs.

Motorized Cable Drum Movers Deliver on Safety Improvements

Following a detailed consultancy and design process, MasterMover engineers created two custom cable drum handling systems designed to work alongside our electric tuggers.

Independently powered by batteries, the cable drum movers can also be utilized on their own, or combined with our pedestrian walkie tuggers to transport cable drums across the facility.

Working closely with the customer, this custom engineered cable mover system delivered on each of the unique requirements of the project:

Uncompromising Safety
At the heart of the new system is a design that eliminates the risk of finger trap incidents by fully mechanizing the spooling process and allowing operators to stand well clear of the operation.

This focus on worker safety ensures that the customer can carry out critical work without the risk of injury.

Versatile Handling Capabilities
Recognizing the diverse range of cable reels and drums on-site, MasterMover engineered a system capable of managing various drum diameters, types and materials – with a maximum capacity of 66,000lbs.

Working alongside our MasterTug electric tuggers, the cable drum movers enable this customer to achieve flexible handling processes across the facility.

This versatility ensures that the solution can adapt to the customer’s evolving needs and different drum specifications – whether that be the material, size or weight of drum.

Cable Spooling Feature
Perhaps the most innovative aspect of this custom cable reel mover is its unique ability to not only move reels safely but also facilitate the spooling of cables - or winding of cables back onto reels..

The system offers excellent versatility and allows operators to spool cables both on and off the reels. This feature greatly enhances operational efficiency and flexibility - making it perfectly suited to the customer's needs.

Key Features of the System 

• A single-design enables the movement of all reel and drum sizes for this customer
• A hydraulically-powered clamp allows reels to be clamped and lifted
• Motorized winding and unwinding of cables via a hydraulic motor
• Dedicated high-capacity battery pack to keep operations moving
• Braked spool motor ensures controlled cable management

Proven Experience in Custom Engineered Solutions

This project is a testament to MasterMover's position as a leader in custom engineering.

The custom-designed cable drum handling system demonstrates our ability to innovate beyond our core electric tugger solutions.

It showcases our engineering expertise in creating comprehensive material handling systems that address complex challenges across various industries, from manufacturing to defense and beyond.

For this customer, the ability to safely move and wind cables with a single system led to significant improvements in efficiency, reduced workplace accidents, and increased productivity.

As industries continue to grapple with the challenges of handling increasingly complex loads and systems, MasterMover is ready to deliver fully customized solutions that help shape the future of safe and efficient material handling.