CABLE REEL RETROFIT KIT REDUCES DOWNTIME BY 75%

Customer Challenge
Plug-and-Play Cable Reel Retrofit System Improves Safety and Uptime in Harsh Steel Mill Environment

A high-volume steel production facility operating in a demanding industrial environment relies heavily on overhead crane uptime to maintain continuous production. The crane maintenance department oversees hundreds of cable reels used in critical applications such as crane drop cables, tundish and scrap cars, coil transfers, and work roll changers.

Previously, cable replacements on cable reels were time-consuming—often taking up to two hours—resulting in operational bottlenecks. Failures were often due to improper installation of cable or a lack of preventative maintenance. The service team needed a safer, more efficient solution to minimize downtime and maintain reliable overhead crane operation.

Amphenol TPC's Solution

To address these challenges, the facility implemented the ATPC Cable Reel Retrofit Kit—a rugged, plug-and-play cable retrofit system designed for fast installation and maximum durability in harsh environments like steel mills.

The retrofit kit includes:

• Super-Trex® Cable is built to withstand reeling tension, abrasion, impact, chemicals, and high temperatures. Available with a variety of cable types. 
• Amphenol MIL-C-5015 reverse bayonet connector with a ¼-turn quick disconnect for a tool-free, secure connection
• Short over-molded backend with IP69K-rated ingress protection and strain relief, ideal for tight cable reel enclosures
• Quick-disconnect interface inside the drum, eliminating the need to access the slip ring or thread new cable through grip seals

Available as a fully pre-terminated Plug & Play system or a field-terminable cable assembly, the retrofit kit offers flexibility for various installation needs. Its modular design also allows operations to keep spare kits on hand for faster, 30-minute emergency replacements. Watch it in action! 

CUSTOMER’S RESULT

The first installation on a rotating hook crane delivered immediate and significant benefits:

• 75% Reduction in cable replacement time from 2 hours to just 30 minutes
• Improved worker safety by minimizing time in hazardous areas and eliminating the need to adjust cable reel spring tension
• No slip ring rewiring is required, lowering electrical risk
• Reduced manpower needed for cable changeouts
• Increased crane availability, supporting continuous production

The success of this initial installation has led to broader evaluation and use across the facility.

Built for Harsh Applications

The Cable Reel Retrofit Kit is engineered specifically for demanding industrial settings where uptime is critical. Ideal for cable reel applications across the plant such as crane drops , transfer car payout systems, and other material handling applications, this system delivers durable, high-performance results with quicker maintenance turnaround.

The Cable Reel Retrofit Kit is compatible with major industrial reel brands such as Gleason Reel, Conductix-Wampfler, and Aero-Motive, the kit has helped many facilities reduce cable replacement time —a smart investment in productivity and reliability.

Conclusion

By implementing Amphenol TPC’s Cable Reel Retrofit Kit, this steel producer significantly reduced downtime, streamlined maintenance, and enhanced safety. With its fast-disconnect design, high-performance Super-Trex® cable, and IP69K protection, the retrofit kit is a scalable solution trusted in heavy industrial operations where uptime matters most.