Motorised reeling drums are electrically driven systems that automatically wind and unwind power, control or fibre optic cables as equipment moves. They offer an alternative to spring-loaded and manual reels.
If your operation relies on moving machinery such as overhead cranes and gantries, cable management can quickly become a problem across your operations. Trailing cables, worn spring reels or outdated systems often lead to downtime, safety risks and maintenance headaches.
Thankfully, in most cases, it is possible to retrofit an existing system with motorised reeling drums to relieve these common pain points.
At Metreel, we specialise in various types of cable reeling drums.
In today’s post, we’re here to shed light on retrofitting an existing system with a motorised reeling drum to guide you.
Can You Retrofit An Existing System With Motorised Reeling Drums?
As we’ve just established, it certainly is possible to retrofit an existing system so that it is motorised. However, one caveat is that a technical assessment is required first to determine if the work can go ahead.
So long as the assessment results in a green light, retrofitting motorised cable reeling systems offers a cost-effective way for businesses to modernise equipment without replacing entire installations.
For those new to the process, retrofitting motorised reeling drums is a specialised industrial process designed to upgrade manual or spring-operated systems to automatic electric, hydraulic or pneumatic power. Where retrofitting can go ahead, it’s often well worth it to ensure constant tension while also helping to prevent cable damage.
Key Assessment Factors
Structural Mounting: Adequate space and structural capacity to mount the drum safely.
Electrical Integration: Must have compatible power supply, control integration and synchronisation with travel motion.
Cable Type: Only flexible, reeling-rated cables with correct bend radii are suitable.
Duty Cycle: High-speed or continuous-duty applications require correctly specified motors, slip rings and cooling systems.
Typical UK Applications for Retrofitted Reeling Drums
Motorised reeling drums are commonly retrofitted to:
- Overhead cranes and gantries
- Transfer cars
- Port and dockside equipment
- Waste and recycling facilities
- Water treatment plants
- Steel and heavy engineering environments
Explore our material handling solutions to learn more about how we can improve safety and productivity in your business.
Benefits of Retrofitting Motorised Reeling Drums
When a reeling drum is motorised, it can maintain controlled cable tension, support longer travel distances, handle heavier cable loads and integrate with automated control systems.
Therefore, retrofitting delivers measurable operational improvements including:
- Improved health and safety compliance
- Reduced maintenance costs
- Increased cable lifespan
- Cleaner, more organised working areas
- Reduced downtime
- Better reliability in demanding environments
For many businesses, the reduced cable replacement costs alone can often make the investment of retrofitting well worth it.
Why Retrofit Instead of Replace?
For many commercial and industrial operators, full system replacement is costly and disruptive. Retrofitting offers a practical alternative that seeks to improve the existing system with the latest technical innovations. With a motorised system, this amounts to improving the capabilities of the reeling drum while also looking to minimise cable damage.
Common Problems That Lead to Retrofitting
Sometimes, retrofitting is necessary when there are health and safety risks or financial consequences of not doing so:
Trailing Cable Hazards
Loose cables create trip risks, forklift interference and accelerated cable wear. A motorised drum keeps cables safely tensioned and off the ground.
Frequent Cable Failures
Repeated flexing or poor tension control can cause core breakages, insulation damage and unexpected downtime. Motorised systems provide consistent, engineered tension control to extend cable life.
Increased Travel Distance Requirements
If your equipment has been modified or repositioned, existing cable systems may no longer be adequate. Motorised reels support longer and more demanding travel paths.
Automation & Modernisation
Many UK facilities are upgrading to PLC-controlled systems, smart manufacturing environments and improved safety compliance. Motorised reeling drums integrate directly into control panels and motion systems.
When Retrofitting Isn’t Possible
Although retrofitting is viable in most scenarios, it may not be appropriate if:
- Severe space restriction exists
- Structural loading limits are exceeded
- Extremely high-speed travel requires alternative powerfeed systems
- Existing infrastructure cannot support electrical integration
In which case, an alternative powerfeed solution would be a better fit for the needs of your business.
Unsure whether a motorised or spring-operated reeling drum is best for your application? The Metreel team can offer you tailored advice when you contact us. Until then, our reeling drum brochure can provide more information including product specifications.
Have A Question About Motorised Reeling Drums? Ask Our Experts
With proper engineering assessment, most cable reeling drums can be modernised without full replacement. In doing so, this works to improve the safety, reliability and long-term performance of your industrial equipment.
If you are experiencing cable failures, safety concerns or increasing maintenance costs, retrofitting your existing system with a motorised reeling drum could be a smart and cost-effective upgrade.
Contact Metreel today to discuss retrofitting your system with motorised reeling drums.
Or, for any other help or advice please give us a call on 0115 647 0157.