How to choose a rack for mixed cable reel sizes of Ø737–2007 mm

Plants that handle mixed reel families often lose time in the same place: diameter changes force a new storage rule, a new picking route, or a new rack. A better approach is to treat the rack as an adjustable system. In the Carack layout, the support sits on a perforated upright, and the roller seat can be repositioned in 100 mm steps. This allows one rack family to hold reels from approximately Ø737 to Ø2007 mm without building a separate rack line for each diameter.

Group reels by diameter band and then assign the level

Start with two bands instead of a long list. Larger reels belong on the lower level because they are harder to lift, create a lower center of gravity, and need clearer access for the forklift. Smaller reels can go on the upper level if the centerline still aligns cleanly with the support rollers. In practice, a pair of supports should be treated as one reel seat unless the project agreement states otherwise. This keeps the loading path simple and prevents the rack from becoming a custom puzzle at every picking point.

Set the support pitch based on the reel centerline, not the catalog size

The useful number is not a rack size. It is the support line height relative to the reel centerline. The 100 mm pitch matters because it allows small corrections without changing the entire rack. For a mixed reel plant, this means the same upright can be adjusted for different core heights, while the roller support keeps the contact surface aligned. The close-up photo of the support shows the bolted roller assembly: twin metal rollers, heavy mounting bolts, and a blue upright. That is the mechanical reason the rack can be adjusted without relying on a fixed cradle.

Use the lower level for heavy reels and the upper level for lighter ones

For mixed Ø737–2007 mm inventory, the lower level should carry the largest and heaviest reels because it is safer for handling and easier to access with a truck or forklift. The upper level should not be treated as extra storage at any cost. It is the level for reels that can be lifted, rotated, and returned without pushing the operator into awkward reach zones. This is where the structure shown in the aisle photo matters: the braced rack keeps the bay rigid while multiple reel sizes sit in a single continuous run.

What does the auxiliary bay really add?

An auxiliary bay adds density when it eliminates duplication. If each reel diameter has its own isolated rack line, the plant pays twice: once in steel and once in aisle space. A main rack with auxiliary bays combines sizes into an organized lane, so the density gain comes from reducing dead gaps and redundant aisles. The exact increase is not a catalog number. It depends on the reel mix, aisle width, and how many diameters can share the same support logic. That is why the final layer count and load limit must be set in the technical agreement, not copied from a general brochure.

Where this layout fits and where it does not

This layout is a good option when the plant has mixed reel sizes, frequent movement, and the need to keep storage within a single aisle. It is not the right choice when each reel family must be stored in a separate certified cell, when core width is highly irregular, or when outdoor exposure requires a corrosion package that has not been approved. In those cases, the rack concept remains the same, but the coating, anchoring, and layer count must be reviewed before release.

Checklist for a mixed reel rack

• Confirm the reel diameter range and group sizes before defining the level height.
• Use 100 mm support adjustments to align the reel centerline instead of forcing a fixed cradle.
• Place heavier reels on the lower level and keep forklift access clear.
• Allow auxiliary bays to increase density by eliminating duplicate rack lines, not by overloading one bay.

Frequently asked questions

How many reels should I place on one layer?

There is no universally safe answer. A conservative layout treats one pair of supports as one reel seat, then checks whether smaller reels can share the same bay after verifying centerline and clearance. The final number must follow the project agreement.

Is the 100 mm support pitch a fixed catalog promise?

No. It is a practical adjustment method. The pitch gives the installer room to align rollers to different reel geometries, but the final adjustment still depends on reel diameter, core width, and the handling method defined for the project.