Industrial Cable Assemblies factory

How to Store Industrial Cable to Prevent Tangling

Industrial cables are the lifeline of manufacturing plants, construction sites, and infrastructure projects—powering machinery, transmitting signals, and ensuring seamless operations. However, one of the most common and frustrating challenges with industrial cables is tangling. Tangled industrial cables waste valuable time (spent untangling), damage insulation (leading to safety hazards like short circuits), and reduce the lifespan of expensive cable assets. Whether you’re managing a warehouse of power cables, control cables, or specialty industrial cables, proper storage is the key to avoiding tangles. Below is a step-by-step guide to storing industrial cable effectively, designed to keep your cables organized, protected, and ready for use.

1. Start with Categorization: The Foundation of Tangle-Free Storage

Before storing any industrial cable, categorization is non-negotiable. Mixing different types of industrial cables—such as high-voltage power cables, low-voltage control cables, and delicate signal cables—creates chaos and increases tangling risk. Follow these rules for categorization:

• By Type: Separate power cables (used for electricity transmission) from control cables (for machine automation) and signal cables (for data transfer). Each type has unique flexibility and thickness; mixing them leads to uneven wrapping and tangling.
• By Specification: Group cables by diameter (e.g., 6mm, 10mm, 16mm), length (e.g., 50m rolls, 100m rolls), and voltage rating (e.g., 240V, 480V). For example, a 100m heavy-duty power cable should never be stored with a 10m lightweight signal cable—their size difference causes the smaller cable to get caught in the larger one.
• By Usage: Label cables as “in-use,” “backup,” or “retired.” Retired industrial cables (e.g., outdated models) should be stored separately to avoid confusion and accidental use.

2. Choose the Right Storage Tools for Industrial Cables

The tools you use to store industrial cables directly impact tangling. Generic storage solutions (like plastic bags or open shelves) are insufficient—invest in tools designed for the weight and flexibility of industrial cables:

a. Cable Reels: Ideal for Long Industrial Cables

Long industrial cables (50m or more) are most prone to tangling when left loose. Cable reels—available in metal, reinforced plastic, or wood—provide a structured way to wrap cables without kinks.

• Metal Reels: For heavy-duty industrial cables (e.g., 16mm power cables used in construction). Metal reels are corrosion-resistant and can support up to 50kg, preventing bending or warping that causes tangles.
• Plastic Reels: Best for medium-weight cables (e.g., 6mm control cables). They’re lightweight, easy to move, and cost-effective for bulk storage. Look for reels with a locking mechanism to keep cables from unwinding.
• Wooden Reels: A sustainable option for indoor-stored industrial cables (e.g., signal cables in factories). Ensure wood is treated to resist moisture (to protect cable insulation).

b. Cable Hooks and Racks: Perfect for Short to Medium Cables

For industrial cables under 20m (e.g., portable power cables for machinery), wall-mounted hooks or vertical racks are efficient.

• Heavy-Duty Hooks: Use steel hooks rated for at least 10kg to hang cables. Space hooks 30cm apart to prevent cables from overlapping. For example, hang 10m control cables on individual hooks—this avoids them getting twisted around each other.
• Vertical Racks: Modular racks with adjustable shelves let you store cables in a vertical position, reducing floor space and tangling. Add dividers between shelves to separate different cable types.

c. Sealed Storage Bins: Protect Small Industrial Cables

Small industrial cables (e.g., 2mm signal cables or patch cords) are easy to lose or tangle. Use sealed plastic bins with foam inserts to keep them organized:

• Line bins with foam cutouts to hold cables in place (preventing shifting during storage).
• Label bins with “signal cables – 2mm – 5m” to avoid rummaging (a major cause of tangling).

3. Control the Storage Environment to Preserve Industrial Cables

Environmental factors don’t just damage industrial cables—they also contribute to tangling. For example, moisture weakens insulation, making cables more prone to kinking; extreme heat softens plastic, causing cables to stick together. Follow these environmental guidelines:

• Temperature: Keep storage areas between 15°C and 25°C. Avoid storing industrial cables near heaters, furnaces, or direct sunlight (which can melt insulation and cause tangling when unwrapped).
• Humidity: Maintain humidity levels below 60%. Use dehumidifiers in damp areas (e.g., basements) to prevent mold growth on cable jackets—mold makes cables sticky and harder to separate.
• Cleanliness: Keep storage spaces free of dust, debris, and oil. Dust accumulates on cable surfaces, creating friction that leads to tangling; oil damages insulation and causes cables to cling together.

4. Implement Regular Inspection and Maintenance

Even with proper storage, industrial cables can develop tangles over time (e.g., from accidental movement or loose ends). Schedule weekly inspections to:

• Check for Loose Ends: Ensure cable ends are secured (e.g., with tape or reel locks). Loose ends can unravel and get caught in other cables.
• Inspect for Kinks: Kinks are early signs of tangling. If you spot a kink in an industrial cable, gently straighten it immediately—kinks weaken the cable and make tangling worse.
• Update Labels: Replace faded or damaged labels. Clear labeling ensures workers grab the right cable quickly, reducing the risk of moving or shifting other cables (which causes tangles).

5. Train Your Team on Proper Handling

Human error is a top cause of industrial cable tangling (e.g., workers dropping cables or storing them incorrectly). Provide training to:

• Teach Wrapping Techniques: Show workers how to wrap industrial cables in a “figure-8” or “over-under” pattern—these methods prevent twists and tangles. Avoid wrapping cables too tightly, as this can damage insulation.
• Emphasize Storage Rules: Make sure workers know to return cables to their designated spots (e.g., “10mm power cables go on reel 3”). Post visual guides (like posters of the storage layout) in the workspace.
• Highlight Safety Risks: Explain that tangled industrial cables aren’t just a hassle—they can cause trips, falls, or electrical accidents. When workers understand the risks, they’re more likely to follow storage protocols.

Why FRS Industrial Cable Factory Is Your Best Partner for Tangle-Free Solutions

Effective industrial cable storage starts with high-quality cables that are designed to resist tangling—and that’s exactly what FRS Industrial Cable Factory delivers. As a leading manufacturer of industrial cables with over 10 years of expertise, FRS doesn’t just produce premium power cables, control cables, and signal cables—we engineer them to make storage easier.

Our industrial cables feature:

• Kink-Resistant Insulation: Made from durable PVC and rubber blends, FRS cables stay flexible without developing kinks—even when wrapped on reels or hung on hooks. This reduces the risk of tangling during storage and handling.
• Consistent Thickness and Flexibility: Unlike low-quality cables (which vary in thickness and flexibility), FRS industrial cables have uniform dimensions—making them easier to categorize, wrap, and store neatly.
• Durable Jackets: Our cables’ jackets resist moisture, dust, and oil—perfect for the climate-controlled storage environments we recommended earlier. They stay clean and non-sticky, so you won’t struggle to separate them.

But FRS goes beyond just cables. We also provide tailored storage support to our clients:

• Customized Reels and Accessories: We offer high-quality metal and plastic reels (matching the sizes of our industrial cables) and durable labels—so you can implement the storage methods outlined in this guide right away.
• Storage Consultations: Our team will assess your workshop or warehouse and create a personalized storage layout (e.g., where to place reels, hooks, or bins) to minimize tangling.
• After-Sales Support: If you have questions about storing your FRS industrial cables, our experts are available 24/7 to help—whether you need tips on wrapping or advice on climate control.

At FRS, we believe that industrial cables should work for you—not against you. By combining our premium, tangle-resistant cables with practical storage solutions, we help you save time, reduce costs (from damaged cables), and maintain a safe, efficient workspace. Whether you need industrial cables for manufacturing, construction, or infrastructure, FRS is committed to delivering products that meet your storage and performance needs.

Choose FRS Industrial Cable Factory—where quality cables and smart storage solutions come together.