Scale Your Infrastructure with Better Cable Solutions

Why Every Industrial Operation Needs a Cable Grouping Solution

A cable grouping solution is any method, product, or system used to bundle, route, protect, and organize cables, hoses, and tubing in a structured way – keeping them secure, accessible, and protected from damage.

Here are the most common types used in industrial settings:

• Heli-Tube® spiral cable wrap – wraps around bundles, allows breakouts at any point, reusable
• Cable ties and bundle separators – quick fastening for temporary or permanent grouping
• Cable trays and wiring ducts – channel-based routing for larger runs
• Cable combs – keep individual cables evenly spaced in high-density environments
• Cable stackers – mount-based organizers for conveyor and automation systems
• Corrugated tubing and conduit – rigid or semi-rigid protection for routed bundles

Unmanaged cables are more than an eyesore. Leading system integrators have identified cable issues as the number one reason for downtime in robotics cells. In data centers and server rooms, tangled, unlabeled cables can turn a simple fix into hours of searching and rework. Structured cabling, by contrast, can reduce that search time from hours to just a few minutes.

The stakes are real – whether you’re running an automated manufacturing line, a public utility installation, or an aerospace assembly. Disorganized cables fail earlier, block airflow, create safety hazards, and slow down every maintenance task that follows.

This guide walks through the full picture: the types of solutions available, how to match them to your application, what standards apply, and how to build a system that holds up over time. For broader context on organized infrastructure design, the Structured cabling overview is a useful reference alongside M.M. Newman’s application-specific guidance.

Defining the Modern Cable Grouping Solution

In industrial infrastructure, a cable grouping solution is the backbone of operational reliability. Beyond just tidying up, these systems provide a logical framework for complex wiring. In high-density environments like data centers, structured cabling is essential for maintaining order among thousands of connections.

The primary goals of any robust cable grouping solution include:

• Organization: Grouping related cables, such as separating power from data, makes tracing and troubleshooting significantly faster.
• Safety: Proper bundling eliminates tripping hazards and helps prevent cables from snagging on moving machinery.
• Airflow Improvement: In server rooms and control cabinets, unmanaged cables can block critical ventilation. Organized bundles allow for better heat dissipation.
• Equipment Lifespan: Reducing mechanical stress on connectors and preventing corkscrewing in moving parts extends the life of expensive hardware.
• Scalability: A well-planned system allows for future expansion, making it easier to add or remove lines without disrupting existing infrastructure.

The Importance of Cable Management cannot be overstated. When cables are left in a disorganized mass, heat builds up and maintenance becomes far more time-consuming. By implementing a professional cable grouping solution, facilities can reduce time spent finding cables from hours to just a few minutes, directly impacting uptime and service efficiency.

The Versatility of Spiral Cable Grouping Solutions

Among the various methods available, Heli-Tube® spiral cable wrap stands out for its combination of protection, accessibility, and reusability. Unlike rigid conduit or permanent sleeves, Heli-Tube® is an expandable plastic cable harness that bundles wires, cables, hoses, and tubing firmly while still allowing routing changes when needed.

One of the standout features of this cable grouping solution is the ability to facilitate wire breakouts. Because of the spiral design, an individual wire can exit the bundle at any point along the run in any orientation. This is particularly useful in complex control panels where different wires need to route to various terminals.

Heli-Tube® wraps on like tape but can be removed and reapplied quickly, making it useful for prototypes and systems that undergo frequent changes. It resists abrasion, organizes, and insulates bundled lines. It is also available in a wide variety of colors for color-coded labeling, which is a best practice for identifying different circuits or voltage levels at a glance. Heli-Tube® can also clamp bundles to standoffs and robotic components, and it is available in both forward cut and reverse cut configurations. Whether you need a small diameter for compact assemblies or a larger size for industrial cable and hose bundles, the About Spiral Cable Wrap resources highlight the range of available sizes and materials.

Application-Specific Cable Grouping Solution Implementation

Different industries face unique challenges that dictate which cable grouping solution is most effective:

• Aerospace: Weight and space are limited. Solutions must be lightweight while resisting abrasion and temperature extremes. Certificates of conformance and certifications to various applicable Military Specifications can be provided.
• Robotics: Cables are in constant motion. The grouping method must support repeated flexing and torsional movement without accelerating conductor fatigue.
• Marine and Boat Manufacturing: Installations face harsh saltwater conditions. UV-resistant materials and abrasion protection are critical for long service life when bundling hoses, cables, and pneumatic tubes.
• Public Utilities: Outdoor installations demand UV-resistant materials. Ultraviolet-resistant black Polyethylene Heli-Tube® is specifically designed for long-term outdoor use in direct sunlight.
• Automated Manufacturing: Reliability is essential. Grouping solutions here focus on reducing downtime by protecting pneumatic tubes and electrical lines from oil, chemicals, and mechanical wear.

Industrial Materials for High-Performance Bundling

Selecting the right material for a cable grouping solution is just as important as the design itself. At M.M. Newman Corporation, we provide materials that meet stringent industry standards, including ISO 9001:2015 certification (Certificate Reg. No. C2018-00027), REACH, and RoHS compliance. Heli-Tube® is also a UL recognized component listed under category UZKX2, Component Wire Positioning Devices (file card number E83405 (M)).

• PTFE: PTFE (Polytetrafluoroethylene) Heli-Tube® spiral wrap features the widest operating temperature range of any material, functioning from -320°F to +500°F. It is chemically inert and non-flammable, with a flammability rating of UL VW-1 and meets ASTM D-3295 Group 4. Ideal for the most extreme aerospace or chemical processing environments. Standard color is Natural, with Black and other colors available upon request. RoHS Compliant.
• Nylon: Nylon Heli-Tube® spirally cut tubing is self-extinguishing and does not produce any toxic or irritating byproducts, even when exposed to an open flame or excessive operating temperatures. It is lightweight, highly abrasion-resistant, and recommended for use in enclosed environments where the possibility of fire exists. Available in Natural and Black. RoHS Compliant.
• Polyethylene: A versatile and cost-effective choice for general industrial use. Available in a variety of colors such as natural, black, blue, brown, and green, among others. An ultraviolet-resistant black version features UV absorbing properties that permit the Polyethylene Heli-Tube® to be used outdoors in direct sunlight for long periods of time.
• Fire-Resistant Polyethylene: Available in White or Black. Suitable for applications requiring a self-extinguishing material.

To ensure you Find the Right Spiral Wrap Material, consider the following comparison:

All listed temperatures are to be used as guidelines only. Custom specifications are also available — M.M. Newman can alter pitch, diameter, wall thickness, color, packaging, length, or material to meet your requirements.

Engineering for Robotics and Automated Manufacturing

In robotics, cable failure is the leading cause of revenue loss. System integrators frequently point to “corkscrewing” — where cables twist and eventually break inside their housing — as a primary culprit. A proper cable grouping solution in a robotic cell must account for dynamic movement.

Industry experts recommend a “less is more” approach. Rather than tightly binding cables with duct tape or excessive ties — which can actually accelerate failure — cables should be segmented. For a six-axis robot, dividing the run into three sections (axes 6-3, 3-2, and 2-1) with junction boxes and service loops allows the cables to move naturally with the machine.

Key rules for cable carriers include:

1. 60% Fill Ratio: The total diameter of all cables and hoses should not exceed 60% of the carrier’s internal diameter.
2. 10% Clearance: Always leave at least 10% clearance between any two cables or hoses to prevent friction and heat buildup.
3. Torsion Resistance: Use cables designed for continuous flexing and pair them with a spiral wrap that allows for independent movement.

Heli-Tube® spiral cable wrap is well suited for robotic applications because it clamps bundles to standoffs and robotic components while permitting breakouts in any orientation. By following these guidelines and using Heli-Tube® to organize bundles, you can Avoid Downtime: Spiral Cable Wrap and ensure your automated systems remain productive.

Compliance, Standards, and Installation Best Practices

Adhering to international standards ensures that your cable grouping solution is safe and legal. Several key guidelines govern industrial installations:

• DIN EN 61439: Regulates the requirements for low-voltage switchgear and controlgear assemblies, specifically regarding how cables are routed within enclosures.
• VDE 0100: Governs the safety of low-voltage installations, emphasizing the prevention of electrical fires and shocks.
• TIA/EIA-568: The standard for structured cabling in telecommunications, providing a roadmap for logical organization and layout.

In control cabinets, preventing overcrowding is essential for ventilation. Wiring ducts with slotted walls and clip-on covers are often used to maintain airflow. When using spiral wrap, ensure the bundle is not so tight that it restricts the natural bend radius of the cables.

Practical installation tips include:

• Separate Power and Data: To mitigate signal noise and interference, keep high-voltage lines away from sensitive data cables.
• Label Everything: Use color-coded Heli-Tube® or tags to ensure that any technician can identify a line instantly.
• Plan for Growth: Leave roughly 20% of your cable tray or carrier space empty to accommodate future expansions.
• Use Proper Installation Techniques: Spiral wrap is applied by hand, wrapping on like tape. Other components like connectors or specialized ties may require specific tensioning to prevent over-tightening.

For a deeper dive into these strategies, refer to The Ultimate Guide to Cable Management.

Frequently Asked Questions about Cable Grouping

How does a cable grouping solution reduce industrial downtime?

By organizing cables into logical, protected bundles, technicians can identify and replace faulty lines in minutes rather than hours. Furthermore, high-quality wraps like Heli-Tube® protect cables from mechanical wear, chemicals, and heat that cause premature failure, keeping the machines running longer between service intervals.

What are the advantages of using PTFE for cable protection?

PTFE is the premier material for extreme environments. PTFE Heli-Tube® spiral wrap can withstand temperatures from -320°F to +500°F, is completely non-flammable with a UL VW-1 flammability rating, and resists almost all industrial chemicals. This makes it the ideal cable grouping solution for aerospace, laboratory, and high-heat manufacturing applications where other materials would melt or degrade.

How do spiral designs facilitate individual wire breakouts?

Unlike a solid tube or a zippered sleeve, the gaps between the spirals in Heli-Tube® allow a single wire or a small sub-bundle to be pulled out of the main group at any point in any orientation. This allows for incredibly flexible routing in complex machines where multiple components need to be fed from a single main trunk.

Can Heli-Tube® be customized for specific applications?

Yes. M.M. Newman Corporation can alter pitch, diameter, wall thickness, color, packaging, length, or material to meet your requirements. Heli-Tube® is available in both forward cut and reverse cut, and in a wide variety of colors for special identification requirements. Cut lengths are available subject to factory quotation.

Conclusion

Since 1956, M.M. Newman Corporation has been a world-leading supplier of high-performance cable management products. Our Heli-Tube® spiral cable wrap is manufactured in the USA and serves as a premier cable grouping solution for industries ranging from aerospace and robotics to marine, boat manufacturing, public utilities, and automated manufacturing. With our ISO 9001:2015 certification (Certificate Reg. No. C2018-00027) and commitment to REACH and RoHS compliance, we ensure that every foot of wrap we provide meets the highest quality standards. Heli-Tube® is also a UL recognized component listed under category UZKX2.

In addition to our spiral wrap, we offer a distinct heavy-duty hot knife. This 60-Watt cutting device reaches temperatures of 900°F and is specifically designed for clean, precise cutting of materials like industrial awnings and sailcloth (note: it is not intended for use with spiral wrap).

At M.M. Newman Corporation, we pride ourselves on our efficient, just-in-time service and our ability to customize products to your exact specifications — whether you need a specific pitch, diameter, wall thickness, material, or color. Ready to organize your infrastructure? Explore our full range of solutions in the Heli-Tube® Spiral Wrap Category and see how we can help you reduce downtime and extend the life of your equipment.