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Brand Division Of Align Production Systems. Hedin Lagan & Align Production Systems Joint Venture
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From Concept to Operation: Cable Reel Handling Built for Industry

Solving Real-World Challenges in Cable and Wire Movement

Summary
Summary

Cable reel handling became a challenge when a customer in the cable and wire industry needed to transport large, heavy reels safely and efficiently within their facility. Align Production Systems provided a custom-engineered Cable Reel Transporter with a secondary lift and cradle to support various reel sizes up to 80,000 lbs, offering a reliable, battery-powered solution.

Key Highlights

Lift with Cradle Design

The transporter is designed to drive under cable reels stored on the floor and lift them from below using a fixed cradle mechanism. This allows for simple and secure pickup without manual handling.

Battery-Powered with Remote

Powered by a standard lithium-ion battery system, the transporter operates using a handheld remote, providing flexibility and visibility for the operator while maintaining safety.

Low-Maintenance, Heavy-Duty

Built to operate daily with minimal upkeep, the transporter features accessible components and a robust frame designed for industrial use, reducing downtime and service interruptions.

“Operators get a simple, remote-controlled system that picks up reels right from the floor—no cranes or extra handling required.”
-Blake Ringger, Product Engineer

The Problem
The Problem

The customer required a safe and efficient way to transport heavy cable reels throughout their facility. Previous handling methods were inconsistent, risky, or limited in mobility. They needed a solution that could support heavy loads, operate in confined areas, and allow for easy loading from the floor—without the need for overhead cranes or custom rigging.

The Solution
The Solution

Align Production Systems engineered a mobile Cable Reel Transporter designed to pick up and transport high-capacity reels. The transporter features a cradle with a lift, utilizing six custom low-profile cylinders that are hydraulically balanced to maintain an even load. With an 80,000-lb capacity, the unit was built for industrial use and designed to operate with a handheld remote for improved operator control and visibility.

Implementation & Results
Implementation & Results

Once integrated into the customer’s workflow, the Cable Reel Handling Equipment helped streamline the movement of large reels between workstations. Its battery-powered design and remote operation reduced delays typically caused by coordinating crane use or additional labor. The transporter enabled a faster, more predictable handling process, allowing teams to reposition reels quickly without disrupting production. As a result, overall material flow improved, and downtime related to reel transfers was significantly reduced.

CONCLUSION

Align’s Cable Reel Transporter is a dependable, safe solution for heavy reel movement. Its cradle-based lift and battery-powered mobility provide a foundation for simple material handling while maintaining flexibility.

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