Overview:
Batt Cables, one of the UK’s leading electrical cable distributors, recently opened a new 275,000 sqft logistics hub to support increasing customer demand. To keep operations running efficiently, they needed a specialist heavy-duty storage system capable of holding large cable drums safely and reliably.
Off-the-shelf pallet racking wasn’t an option. Wickens was selected to design and manufacture a fully bespoke solution engineered around Batt Cables’ equipment, workflows, and safety requirements.
the challenge:
Cable drums present unique challenges: heavy loads, size variation, and demanding handling requirements. Batt Cables needed a system that would deliver:
- Safe, long-term storage with no risk of structural movement
- Fast, efficient drum retrieval
- Improved organisation at the new high-capacity site
- A durable, futureproof solution for continuous industrial use
- Full compliance with health and safety best practice
This required a partner with genuine structural engineering expertise.
Why Batt Cables chose Wickens
Wickens distinguished itself early in the process by taking a highly consultative and engineering-led approach.
Project Manager Dan Kyle explains:
“Wickens listened to our requirement and designed a solution that we couldn’t find anywhere else. The team, including an in-house chartered structural engineer, gave us the confidence that they could deliver on the promises they made.”
For Batt Cables, this expertise was critical. Wickens not only understood the problem but also demonstrated the technical capability to design a system from the ground up, ensuring structural integrity, load-bearing capacity, and operational suitability.
Their responsiveness, clarity during the design phase, and willingness to tailor the solution specifically to Batt Cables’ needs made them the clear choice.
The Solution:
Wickens delivered a purpose-built heavy-duty cable drum racking system that maximises space, improves workflow, and withstands intensive daily use.
Key solution features include:
- Custom structural design validated by an in-house chartered structural engineer
- Heavy-duty frames and beams engineered to withstand significant drum weights
- Optimised drum positions to improve retrieval speed and reduce handling time
- A layout configured specifically for Batt Cables’ equipment, including drum movers and forklifts
- A durable, long-life build, ensuring the racking will remain safe and stable even under intensive use
The result is a purpose-built storage system that supports the site’s current needs while offering scalability for future growth.
Results:
Upon installation, the impact of the new racking system was immediately evident. Dan describes the result:
“Fantastic! Now that the racking is on site, you can see why Wickens are market leaders!”
Dan emphasises the effectiveness of the installation:
“The racking looks amazing. We are looking forward to filling it, and I know that it will significantly change our operating efficiency.”
The new system is expected to drive meaningful operational benefits:
✓ Increased Efficiency – The new layout and accessibility will streamline the process of loading, storing, and retrieving cable drums, reducing delays, and improving workflow.
✓ Enhanced Safety – Purpose-engineered racking significantly reduces the risk of drum movement, collapse, or unsafe handling conditions.
✓ Better Space Utilisation – The bespoke design makes optimal use of the new facility, increasing storage capacity without sacrificing ease of access.
✓ Long-Term Durability – The heavy-duty construction ensures a reliable system that supports Batt Cables’ growth for many years.
Impact:
Customer Experience
Beyond the quality of the final product, Batt Cables highlighted the service they received from Wickens:
“First class from start to finish. They are always available and very quick to respond.”
Wickens’ communication, reliability, and technical guidance contributed greatly to the success of the project.
Would Batt Cables Recommend Wickens?
“Yes, I would 100% recommend Wickens!”
