How Wire Dereelers can be used to Increase Production Efficiency

The wire dereeler is often seen as having no positive effect on production quality, be it in the wire manufacturing industry, or any other sector. However, this is not really true. A constant tension de-reeler can be used as a time and labor saving mechanism, while helping to meet expected product quality requirements.


Wire Dereelers


Using the Dereeler – A Case Study

Let us use an example to illustrate the importance of this machine. A spring manufacturing company was researching new methods to increase their production efficiency. Their current method of dereeling wire was to cut 40 pounds of wire from the carrier, and then run it on a manual reel. The reels required a user to forcefully pull the wire from the feed. The wire would first go tight, and then become slack, repeatedly. Also, the inconstant tension would cause variations in free length, as well as load deflection. The organization then discovered the power dereeler.


How Did the Wire Dereeler Help the Situation?

The dereeler’s primary responsibility was to maintain constant tension on the wire. This eliminated the problem of the old reels. The constant tension wire payoffs allowed for greater accuracy and reduced variability in the wire. The engineers were able to control the positions of the wire hooks and maintain uniformity in the back pitch.

By using these payoffs, the spring manufacturer had the ability to place the entire carrier of wire on the dereeler. This arrangement led to minimization of coiler downtime. Another benefit was higher labor savings. Earlier, six people would be required to sort the wire. With the help of the dereeler, this number was reduced to just one person.

Overall, the spring manufacturer reduced tooling maintenance by 70%, and labor costs by nearly 80%. This case study showcases exactly how a wire dereeler can help increase the production efficiency of an organization, as well as create immense savings.


Scott Heran has been part of the business since he was young and attending industry association conventions with his parents Bob and Jean since he was eight years old.Scott has worked in a sales capacity at ACE for over 20 years. Scott graduated from John Carroll University. Married to Teresa, he is the proud father of two children and two grandchildren.