Cable wire coil re-winding and strapping line video

Executive summary

Cable and wire are made on large drums but sold in small coils of set length or weight. Re-winding by hand gives coils of uneven length and shape, and loose coils open before they are strapped. A re-winding and strapping line pays the cable off the bulk drum, measures it, winds it into a coil on a servo-driven head, straps it and moves it out on rollers. This page covers the stations, sourced coiler data and how to work out length per coil.

Black cable runs from a pay-off through a guide and traverse on a blue frame into a coiling head with a gold-coloured flange plate. The finished coil is pushed onto a roller conveyor and passes into a strapping arch, which straps it radially through the eye at several points. A guarded measuring and cutting unit sits at the front of the line.

Table of Contents

What a re-winding line does

Bulk drums hold hundreds or thousands of metres. A distributor or installer wants 50 m or 100 m coils, or coils of a set weight, all the same size so they stack in a carton or on a pallet. On one wire project, 1,000 kg bulk coils had to be split into 9 kg, 25 kg and 30 kg packs. The line measures and cuts each coil to the set length or weight and straps it before it can open.

Line stations

  1. Pay-off: the bulk drum turns under tension control.
  2. Measure and cut: a meter counter measures the cable, and the cutter cuts at the set length.
  3. Traverse and coil: a traverse guide lays the cable evenly across the coil width while the servo head winds it.
  4. Push out: the coil is released from the head onto the roller conveyor.
  5. Strap: the strapping arch indexes the coil and applies radial straps through the coil eye at set positions.
  6. Outfeed: coils move on to wrapping, labelling or boxing.

The PLC holds the length, coil size and strap positions for each product.

Coiler data

Item FHOPE FCL-800 automatic coiler
Coil OD 500–800 mm
Coil ID 200–300, 250–500 or 300–600 mm
Coil height 80–200 or 100–300 mm
Product OD 5–16, 10–20 or 15–30 mm
Speed up to 80 m/min
Drive servo

Smaller cables use the FCL-600; cable range and pay-off size are confirmed at quote.

Length and weight per coil

Length ≈ π × mean diameter × turns per layer × layers; weight = length × cable weight per metre. For 10 mm cable in a coil 100 mm high, there are 10 turns per layer. With ID 300 mm and 5 layers, the OD is 300 + 2 × 5 × 10 = 400 mm and the mean diameter 0.35 m, so length ≈ 3.14 × 0.35 × 10 × 5 = 55 m (example only). The meter counter cuts at the exact length; this formula tells you the coil size it needs.

Selection checklist

  1. Cable OD range and weight per metre?
  2. Coil length or weight, and coil ID, OD and height?
  3. Bulk drum size and weight?
  4. Strap points per coil?
  5. Wrap, label or box after strapping?
  6. Output per shift?

Safety

We design coiling lines to EN ISO 12100:2010 for risk assessment, EN 415-10 for packaging machine safety and EN 60204-1 for electrical equipment. The cutter and coiling head are guarded, and the pay-off has tension control and an E-stop.

Engineering FAQ

Q: Can it cut by weight instead of length? A: Yes, with a weighing unit; length is the standard setting.

Q: How is the coil kept tidy? A: The traverse lays each turn next to the last across the coil height.

Q: How many strap points? A: Set per coil size; each strap passes through the coil eye.

Q: Can one line run several cable sizes? A: Yes, within the coiler range, using a recipe per product.

Next step

  1. Send your cable OD, coil length and drum size to info@fhopepack.com.
  2. We size the pay-off, coiler and strapping arch.
  3. We reply within 24 hours with a proposal and quotation.

Sources

  • FHOPE product pages: FCL-800 and FCL-600 coilers
  • FHOPE project correspondence on re-winding bulk coils into packs
  • EN ISO 12100:2010; EN 415-10; EN 60204-1
  • The re-winding line shown above

Last reviewed: 2026-10-20

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