Gantry Systems in the Pipe, Wire and Cable Industries

The Versatile Application of Gantry Systems in the Pipe, Wire and Cable Industries.

The pipe, wire and cable industries are pivotal to various sectors from telecommunications, to power distribution, those industries demand precision, products and processes efficiency, and reliability in their manufacturing processes. Gantry systems, with their versatility and robustness, smaller footprint than “old style” floor mounted take ups and payoffs, have become indispensable in this domain. This article explores the diverse uses of all types of gantry systems in the pipe, wire and cable industries, highlighting their impact on productivity and quality.

What are Gantry Systems?

Gantry systems, also known as column style, portal, stationary gantries, are mechanical devices designed to move horizontally along a pair of rails, or their arms move, while lifting reels or spools off the floor, allowing them to spin either freely or driven by a gear motor system. In the wire and cable industry, gantry systems typically involve the use of robotic arms, sensors, and specialized grippers to handle materials with precision, reducing the need for multiple human operators.

Key Applications of Gantry Systems in Pipe, Wire & Cable Manufacturing

1. Material Handling and Transportation

One of the primary uses of gantry systems in the pipe, wire & cable industry is for the material handling of reels and wound products. These systems efficiently and accurately wind and unwind heavy spools of pipe, wire and cable through the production process reducing the need for manual labor and minimizing the risk of damage. By automating the winding/unwinding process, gantry systems enhance overall operational efficiency and safety, while reducing the warehouse footprint, providing increased space for production, while enhancing throughput.

2. Precision Winding and Unwinding

Gantry systems are crucial in the winding and unwinding processes for pipe, wire and cable manufacturing. They ensure that pipe, wire & cable are wound uniformly onto spools or reels, which is vital for maintaining the quality and consistency of the final product. Precise control over tension and speed, enabled by advanced sensors and controls, helps prevent issues such as pipe bundle tightness, tube cooling, wire breakage, tangling or knifing. Gantry systems are also used in wire, pipe and cable distribution of repackaged flexible products from large reels to smaller ones.

3. Inspection and Quality Control

Integrating gantry systems with high-resolution cameras and sensors allow for meticulous inspection of pipes, wires and cables during production. These systems can detect defects such as surface irregularities, diameter variations, and insulation faults in real-time. Automated inspection not only speeds up the quality control process but also ensures higher accuracy compared to manual inspections. The inputs to the operating system from the sensors, may slow down or speed up the line, or fine tune the overall process, and signal when safety issues arise.

4. Cutting and Splicing

Gantry systems equipped with cutting tools are used to cut pipe, wires and cables to precise lengths. This application is essential for customizing wire and cable products to meet specific end customer specific order requirements. Automated cutting also ensures consistency and reduces material wastage, contributing to overall cost savings.

5. Precision Systems Movement

When level winding the product across the reel, the machine moves horizontally on tracks to accomplish this, or its arms move simultaneously left to right with the reel suspended between them, uniformly applying the product to the reel. This means that the wound product comes straight out of the extruder not moving from side to side it has a “0” fleeting angle, which is essential when utilizing an extrusion process, if the product moved from side to side, Then it would cause the extruded jacket to buildup unevenly.

6. Level Winding and Fleeting Angle

When level winding or traversing the product across the reel, the Gantry system moves horizontally not the wire, the extruded product stays straight out of the extruder line. Other winders usually move the product horizontally, this allows improper extrusion buildup on one side, or the other of the pipe or wire.

7. Palletizing and Packaging

After the production and quality control process, the finished “wound” product is then further processed utilizing integrated robotic arms, these can stack spools or coils onto pallets in an organized manner, these pallets can then be automatically wrapped, labeled, and conveyed to storage or directly onto a truck preparing them for shipping. Automated packaging solutions provided by gantry systems increase throughput and reduce the risk of damage during handling.

8. Integration with Other Automated Systems

Reel Power gantry systems can be seamlessly integrated with other automated systems in the pipe, wire and cable manufacturing lines, in a complete in-line or off-line setup, with conveyors, extruders, cutters, etc. This integration creates a cohesive and highly efficient production environment, where various processes are synchronized for optimal performance. Reducing a customers buying risk while improving their overall profitability by enhancing throughput.

Advantages of Using Gantry Systems

  • Increased Storage: Increases storage warehouse space over other reeling, coiling and spooling systems.
  • Increased Efficiency: Automating repetitive tasks with gantry systems significantly speeds up production processes, while reduces overall operator headcount, improving profitability.
  • Enhanced Precision: Gantry systems provide high levels of accuracy, ensuring consistent product quality.
  • Improved Safety: Reducing the need for manual handling of heavy materials minimizes the risk of workplace injuries.
  • Cost Savings: Automation leads to reduced labor costs and minimizes material wastage, while improving safety.
  • Scalability: Gantry systems can be easily scaled and customized to meet the evolving needs of the pipe, wire and cable industry.
  • Zero Fleeting Angle: The product remains straight and static, the machine moves horizontally, applying extruded product evenly to pipe walls or to the wire.

Check out our all Gantry products for Pipe, Wire and Cable Industries


Gantry systems have revolutionized the pipe, wire and cable manufacturing industries by enhancing efficiency, precision, and safety in various manufacturing processes. From material handling to quality control, these systems offer versatile solutions that meet the high standards required in this sector. As the industry continues to evolve, the integration of advanced gantry systems will likely play an even more significant role in driving innovation and productivity. Reel Power gantry systems improve profitability by increasing overall plan throughput, while reducing a customers buying risk by offering advanced equipment solutions from a known design and manufacturing equipment World Class Leader.