All About Double Wall Flanges Reels for Wires

Double wall flange reels are essential tools in the wire and cable industry, offering strength, durability, and easy handling for various applications. In this blog, we answer the most common questions to help you understand the value and use of these reels for wires.

1. What is a Double Wall Flanges Reel?

A double wall flange reel is a reel or spool with two layers of wall material on the flanges (the side disks) that provide additional strength and stability. These reels are designed to store, transport, and dispense wires, cables, and other flexible materials. The double-wall structure reinforces the reel, making it suitable for heavy loads and high-stress environments.

2. What are the benefits of double wall flange reels compared to regular reels?

Double wall flange reels offer several advantages over standard reels:  

Increased durability: The reinforced double-wall design resists deformation under heavy loads.  

Enhanced load capacity: Ideal for storing and transporting long or heavy cables.  

Better protection: The dual walls reduce the risk of flanges breaking or bending, preventing damage to wires.  

Reusable design: Many double wall reels are designed to be reused multiple times, reducing waste.  

Smooth cable handling: Wires unwind easily, minimizing tangles and damage during use.

3. What materials are used to make double wall flange reels?

Double wall flange reels are commonly made from:  

Steel: Extremely durable and suitable for industrial environments, especially for heavy-duty wire spools.  

Plastic (HDPE or PP): Lightweight, corrosion-resistant, and suitable for outdoor applications.  

Wood: Often used for larger cable reels, but less common for reusable double-wall models.

Each material offers unique benefits, such as plastic’s resistance to rust or steel’s ability to carry high loads. The choice depends on the specific application, storage conditions, and budget.

4. What types of wires are commonly used with double wall flange reels?

Double wall flange reels are versatile and can handle many types of wires, including:  

Electrical cables  

Fiber optic cables  

Communication wires  

Control and instrumentation cables  

Welding wires  

These reels are especially useful in industries like telecommunications, construction, and manufacturing, where large spools of wire need to be transported and unspooled efficiently.

5. How are double wall flange reels used?

The usage process typically involves the following:  

1. Wire winding: Wires are wound onto the reel by an automatic or manual winding machine.  

2. Transport: The reel is secured for transport, often with forklifts or lifting hooks.  

3. Unwinding: At the site, the reel is mounted on a stand or reel holder for smooth unwinding of wires.  

4. Reuse: If the reel is reusable, it can be returned for refilling and used multiple times.

These reels help ensure efficient storage and easy handling during installations or in production lines.

6. Are double wall flange reels suitable for outdoor use?

Yes, plastic and steel double wall reels are often suitable for outdoor use. Plastic reels are highly resistant to corrosion, UV exposure, and moisture, making them ideal for outdoor environments. Steel reels can also be used outdoors if treated with anti-rust coatings to withstand weather conditions.

7. How do I choose the right size for a double wall flange reel?

Choosing the correct size depends on several factors:  

Wire length and diameter: Ensure the reel can hold the total length without overloading.  

Load capacity: Check the reel’s weight-bearing capacity, especially for heavy cables.  

Flange diameter: Larger flanges are suitable for long wires, ensuring the reel can wind the wire neatly.  

Core width: The internal width should match your wire’s dimensions to prevent tangling or kinking.

Manufacturers often provide detailed size charts to help you pick the correct reel based on your wire specifications.

8. Can double wall flange reels be customized?

Yes, many manufacturers offer customization options, including:  

Size adjustments: Custom diameters and widths for specific wire lengths.  

Color coding: Different colors for easy identification.  

Branding: Logos or labels printed on the reel for easy tracking and identification.  

Material upgrades: Specialized plastic or coatings for specific environments (e.g., UV-resistant plastic).

Customization is particularly useful for companies that need efficient inventory management or want to reuse reels across multiple projects.

9. How do I maintain double wall flange reels?

Proper maintenance ensures the longevity of your reels. Here are a few tips:  

Inspect regularly: Check for any cracks, warping, or loose bolts on steel reels.  

Clean after use: Remove dust, grease, or residues, especially on plastic reels.  

Store properly: Keep reels in a dry place to prevent rust on steel components.  

Rotate inventory: Use older reels first to prevent unnecessary wear and tear from prolonged storage.

10. Are double wall flange reels environmentally friendly?

Yes, double wall flange reels can contribute to sustainability in several ways:  

Reusability: Many reels are designed to be reused multiple times, reducing waste.  

Recyclable materials: Steel and plastic reels can often be recycled at the end of their lifespan.  

Reduced transportation costs: With their durability, these reels minimize the need for replacements, saving on logistics.

Some manufacturers also offer buy-back programs for used reels, further promoting sustainability.

Conclusion

Double wall flange reels for wires are a smart choice for industries that require durable, efficient, and reusable solutions for handling cables and wires. Their strength, versatility, and ability to protect wires make them indispensable tools for a variety of applications. Whether you’re in construction, telecommunications, or manufacturing, these reels provide a reliable way to store, transport, and dispense wires with ease.

By choosing the right reel and following proper maintenance, you can maximize both performance and longevity while keeping your operations running smoothly.