Wire and Reel Handling Systems
Automated Storage for Spools, Reels, and Cable Inventory
What Is A Wire and Reel Handling System?
Wire and reel handling systems are engineered to store, dispense, and rewind wire, cable, and tubing spools safely and efficiently. Unlike fixed racks or shelving, these systems rotate your reels automatically to the operator’s level—saving time, space, and manual handling.
At Vertical Storage USA, we design and install automated Spool Vertical Carousels and custom Reel Racks that organize cable inventory, improve ergonomics, and reduce clutter. Each solution is tailored to your reel sizes, weight, and workflow needs.
Key Advantages
Automated Spool Retrieval
Motor-driven vertical carousels deliver the selected reel directly to the operator level, eliminating climbing or reaching for upper reels.
High-Density Vertical Storage
Store up to 16,000 lb total system capacity while reducing floor space by over 70% compared to fixed spool racks
Versatile Carrier Configurations
Carriers can handle spools up to 30” diameter × 23” wide, with 750 lb per carrier capacity. Our Options include Singles, Dual Singles, and Double Deeps.
Integrated Measuring & Rewinding
Add an optional Counter Coiler Assembly to measure and rewind wire up to 5/8” diameter directly from the carousel—ideal for electrical wire handling and assembly operations.
Safe, Controlled Operation
Equipped with safety keypads, emergency stops, and full guarding from floor to top. Built to OSHA and ANSI standards.
How It Works
The system operates as a vertical carousel, rotating carriers in a closed loop around a motorized drive system:
- Each carrier holds multiple spools mounted on steel shafts.
- Operators select a reel via keypad; the carousel automatically brings it to the ergonomic pick height.
- Wire can be pulled or rewound directly using optional counter coiler and guide arms.
- Adjustable carrier spacing and modular arms accommodate different spool diameters.
For a similar automated retrieval process, see our Vertical Lift Modules (VLMs) and Automated Storage & Retrieval Systems (AS/RS).
Common Applications
Frequently Asked Questions (FAQs)
What types of reels can these systems store?
Wire and reel handling systems can store a wide range of spool types, including copper and aluminum wire, cable reels, tubing, and flexible conduit. Carriers are adjustable for reels up to 30” in diameter and 23” wide, making them ideal for both light and heavy-duty applications.
Can the system handle different spool sizes on the same machine?
Yes. Each carrier can be configured for single, dual single, or double-deep arrangements, allowing you to mix different reel sizes and diameters in the same carousel. This flexibility helps optimize storage density while maintaining accessibility.
How does the counter coiler assembly work?
The Counter Coiler Assembly attaches to the front of the carousel at operator height. It allows you to measure, rewind, and cut wire up to 5/8” in diameter directly from the carriers — ideal for cable assembly, kitting, or prep stations.
Is the system powered or manual?
All spool vertical carousels are fully motorized and electronically controlled. Operators select the desired carrier using a safety keypad, and the system automatically rotates to bring it to the retrieval level.
How much space does a spool carousel require?
A typical unit stands around 19 feet tall, with 2 inches of side and rear clearance and 12 inches of ceiling clearance for safe operation. Despite the height, carousels dramatically reduce floor space by storing reels vertically instead of in rows or pallets.
Can spool carousels be used outdoors?
No — spool carousels are designed for indoor use only, with an operating temperature range between 40°F and 110°F.
Is installation included?
Yes. All systems are delivered and installed by certified technicians, with optional loading dollies or lift equipment available depending on site access. Each installation includes a 1-year parts and labor warranty and operator training.
Used & Refurbished Cantilever Racks
Save on cost without compromising safety or performance.
Explore our Used Equipment & Systems inventory for certified cantilever rack uprights, arms, and bases—ready for installation.
Start Your Project
Need a storage system built for long or oversized materials?
Let Vertical Storage USA design a cantilever rack solution that maximizes cubic space while keeping access fast and safe.
