Windak Group is advancing cable rewinding with automation technologies focused on quality monitoring, consistent cable laying and repeatable machine setup. Its Active Cable Inspection System, SafeWind technology and HMI-based recipe management help operators detect defects, maintain winding consistency and achieve reliable results across different production runs and shifts.

Aug 17, 2026

During a long rewinding cycle, a single large reel can contain many kilometers of cable. Maintaining consistent quality throughout the entire reel therefore requires much more than speed alone. Cable condition, tension and laying quality need to remain under control from the first meter to the last.

Windak develops its payoff, take-up and rewind solutions with this philosophy in mind: automation should support the operator, improve process consistency and help ensure that every finished reel meets the required quality standard.

Three areas are particularly important: continuous cable inspection, consistent cable laying and repeatable machine setup.

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Continuous Quality Monitoring

Windak’s Active Cable Inspection System adds an additional level of process control by monitoring the cable during operation. If a potential defect is detected, the system automatically stops the line.

With the Reverse Function, the operator can then move the cable back to the affected section for closer inspection and corrective action before continuing the rewinding process.

This combination of automated monitoring and operator control helps reduce the risk of a cable defect passing unnoticed onto the finished reel and supports more consistent product quality throughout the entire rewinding cycle.

Consistent Cable Laying

Windak’s SafeWind technology helps maintain stable and uniform cable laying throughout the rewinding process.

Its motorized laying arm moves up/down, in/out and left/right, keeping the laying point close to the drum and following the cable as the reel builds up.

Together with precise tension control, this supports consistent winding quality while reducing the need for continuous manual adjustment.

Repeatable Machine Setup

Different cable types and reel sizes require different winding parameters.

Windak’s HMI allows operators to store fine-tuned settings in more than 100 product recipes, making it easy to recall optimized parameters for future production runs.

This simplifies product changeovers and helps achieve more repeatable results across different products and shifts.

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Automation That Supports Quality

The value of automation in rewinding is not simply about replacing manual tasks. It is about giving operators better control over the process.

Continuous inspection helps identify potential defects, SafeWind supports consistent cable laying, and recipe management improves repeatability.

Together, these technologies help cable manufacturers achieve a more controlled, reliable and quality-focused rewinding process — from the first meter to the last.