Introduction

The increased competition within the wire, cable and fibre optic market, obliges cable manufacturers to become more and more competitive regarding both the technological aspect and the quality and reliability of the manufactured products. Considerable investments have been made in research, development and implementation of new manufacturing lines, as well as in new alloys and compounds in order to meet the growing demands of international telecommunication carriers or energy suppliers. However, cable manufacturers currently offering increasingly high performance and high-tech products should not neglect a factor that is vital and indispensable for their brand image: how can the cable be protected during storage and transport up to its exportation?

A drum is not "merely" a packaging

Stocking on the production site or the transport of the finished product must not in fact be underestimated. If the optical fibre or cable is damaged, the final customer will obviously refuse it and, as a result, the image of the cable manufacturer will be tarnished. Therefore it is necessary to provide in advance the most suitable packaging for his product, that is the drum (cardboard, plastic, wood, metal) depending on the product to be “packaged”, and to take into consideration various parameters to define it according to the stresses associated with the storage and transport operations: will the drums be handled with care, will they be suitable to withstand the load? Is it possible to avoid shocks and, if not, will the drum be able to protect the cable? Will storage on site be prolonged and what about the weather conditions?

5.2m Ø metal drum

It must be remembered that the weight of a drum accounts for approximately 8 to 10% of the total weight of the load to be supported. Below this threshold there is a risk of drum damage thus obliging the cable manufacturer to rewind his product. This involves a considerable loss of time and a serious risk of damage as well as an increase in maintenance costs. The drum must therefore be both light and sufficiently reinforced so as to support heavy loads under the most severe maintenance conditions.

A "custom-made" metal drum manufacturer

Established in 1974 and managed by Messrs DEPREUX, Joly S.A. is a French enterprise of average importance with 38 employees, and is specialized in the study, design and manufacture of metal drums and reels. Notwithstanding its relatively small size, the company has continuously evolved thanks to its high-quality products and to its extremely flexible infrastructures allowing a very rapid response. Joly S.A. has also managed to attract the interest of major cable manufacturers thanks to its accurate research carried out in very short times, offering products in compliance with specifications.

S.A. Joly stand during the latest Wire Düsseldorf 2002 fair

Some of the products exhibited at Wire Düsseldorf 2002

Moreover, Joly S.A. consists of two specialized production sites. The research, prototype preparation, and drum design are carried out in the Aniche site, near Douai in the North of France. The second site, based at Gron near Sens, is only a production centre. The two sites which use the same production tools, enable to optimise the distribution of the tasks assigned to the various teams and to decentralize production for an improved flexibility. The Aniche site, with an area of 17,000m2 (4,500m2 of which are covered) assures the manufacture and delivery of drums in France and in the North of Europe while the Gron site, with an area of 9,000m2 (1,600m2 of which are covered) guarantees the same services for the South of Europe and overseas. This distribution strategy allows the company to meet all the demands of new customers and even of urgent orders without compromising other customers included in the initial programme.

One of the latest company innovations : the Rehau reel

An important investment in productivity

In order to dispose of the most suitable production tool to meet the demands of these special markets, the French company has not hesitated in investing in a new machine shop. Some former investments had previously been made with the integration of an initial model of high-performance presses, new types of welding stations (with more suitable welding implements) and stamping stations. A new press has been developed following the first one for the manufacture of drum flanges. This press has been specially designed by and for Joly S.A. As a result, it is not a universal type press but a “custom-made” production tool. The first type of press was specially designed for the manufacture of “standard” drums, while the second type can be used for “custom-made” drums, materials that are more important in terms of weight/resistance, or for more traditional operations such as maintenance equipment.

Compartment metal drums (Ø 4,800mm, 150 tonne capacity)

Research, Development, Service

The company policy applied by Joly S.A. consists of a constant improvement to satisfy the customer’s specific needs. For this reason, the French company has provided an engineering and design department able to meet all “standardized” and “custom-made” requirements, while constantly working on the implementation of new prototypes and new drum designs, the utilization of new materials, etc… Operating in close cooperation with the customer’s technical department, the French company immediately examines the problems brought up by the cable manufacturer and suggests a perfectly suitable solution, a drum “drawing” (or a prototype, if required) as well as a manufacturing term and a complete estimate.

Stamped metal drums ranging from Ø 315 to Ø 760mm

Being aware of the fact that today time is a key factor of the Quality of the Service offered to the customer, a Joly S.A. team is always available to suggest a suitable solution to meet the customer’s necessities, obligations resulting from costs, delivery terms, spatial requirements and, of course, the final budget while also being able to transfer onto the site rapidly. As a result, the company plays the role of technical consultant and the extremely short response time offers the customer the possibility of defining the various parameters to improve its strategy. In order to anticipate the needs of cable manufacturers, the company’s research department designs prototypes, new drawing concepts and studies the use and application of new metals.

From standard to custom-made, from drums to accessories

Joly S.A. works in close cooperation with leading international cable manufacturers (Alcatel, Pirelli, Acome, Tréfileurope, etc…) and with the Ministry of Defense, the National Navy as well as with geophysical companies buying high-tech cables for sonars and umbilical cables, which are stored for many months on metal drums as well as cables for offshore applications requiring large metal drums for undersea cable laying.

An innovation that has attracted a great interest
Joly S.A. designs and manufactures metal drums with metal staving and built-in cradles (patented), guaranteeing efficient and safe protection for more fragile cables and fibres. The metal staving process enables metal drums to be “packed” by means of a shaped strip of metal or with panels made of thin galvanized sheet. The staves can be removed by means of a key thus making it easier to disassemble and assuring a faster execution (for example 4 minutes for a Ø 2,400mm metal drum). This design ensures a better protection of fragile cables, with the weight of the drum being 30 to 40 per cent lighter than a wooden drum with wooden staving.

Phases of staving process for metal drums (Joly patented) for an easy, fast and reliable packaging, performed by means of a shaping steel strip or galvanized steel sheet panels

To ensure maximum safety during transport, storage and handling on site, Joly S.A. has specifically designed a cradle suitable for each type of drum that has been approved by the various insurance companies.

An extensive range of metal drums
In addition to the production of metal drums with metal staving, Joly S.A. has expanded its production range to cover the manufacture of standardized or “custom-made” drums and associated supports. In order to offer an appropriate solution for any type of packaging, the French company proposes a wide range of metal drums machined with smooth or corrugated flanges, drums with solid or stamped flanges, hot galvanized drums, compartment drums, take-down drums with removable barrel, special drums with conical barrel and “stamped” metal drums.

Dismountable metal drums

Metal drums for drum twister

Compartment metal drums (Ø 5,300mm, 120 tonnes capacity)

Handling material
The company has also expanded its production range with the manufacture of winders-unwinders including simple and double coiling winches, pulling systems such as bicaterpillars and tricaterpillars for various undersea laying cable applications.

Double coiling winch with hydraulic motorisation (Ø 4,600mm - 50 tonne capacity)

Export metal drums
Most of export metal drums are equipped with a folded metal staving protection (Joly patented) as well as with cradles suitable for storage and handling purposes. In particular, the French company has been involved with critical plants (both from a technical and manufacturing point of view), concerning export contracts with China, Taiwan, Uruguay, Mexico, etc… where the relevant specification sheets mentioned transport loads for cables exceeding 20 tons and requiring metal drums with a diameter larger than 4m.

Traversing winches for the Middle East: Kinematic Unwinding
T: tensioner ; Rs: upper pneumatic wheel (Ø 560 x 280mm) ; Ri: lower pneumatic wheel (Ø 540 x 400mm) ; M5: hydraulic motor ; M6: hydraulic motor ; F1: cable tensioning force (150daN) ; vd: unwinding speed (from 0 to 15m/s) ; Ts: cable supporting force (500 daN)

Traversing winches for the Middle East: Kinematic Winding
B: metal drum (Ø 3,200/1,800-2,800mm) ; C: coil ; P: pinion ; M1: hydraulic bearing motor ; PM: motorised pulley lined with para rubber (Ø 1,830mm) ; M2: hydraulic wheel motor ; V: traversing screw; E: traversing nut ; M3: hydraulic motor ; M4: electric gear motor; PL: idle pulley (Ø 1816mm) ; T: tensioner ; ve: max. winding speed (from 0 to 2.5m/s) ; F: max. winding force (1,500 daN) ; vt: traversing speed (from 0 to 12.5m/s) ; v ct: traverse frame displacement speed (6m/min.).

Traversing winches for the Middle East: Unwinding system
T: tensioner ; Rs: upper pneumatic wheel (Ø 560 x 280mm); Ri: lower pneumatic wheel (Ø 540 x 400mm) ; M5: Danfoss MMS 200 151F0204 hydraulic motor; M6: Danfoss OMS 200 151F0204 hydraulic motor; F1: cable tensioning force OBC (150daN) ; vd: unwinding speed (from 0 to 1.5m/s) ; Ts: cable supporting force (500 daN)

Flexible metal drums for aerial transport

New handling equipment
This year Joly S.A. has taken advantage of its engineering and design department for the design and manufacture of special winches equipped with hydraulic or pneumatic motorization for drums (diameter ranging from 760 to 1,600mm), designed for multiple applications (maritime or terrestrial).

A great achievement
The company has also accomplished a great achievement in the technical field with the study, design and manufacture of equipment for research and seismic exploitation in the Middle East. The order included six assemblies of hydraulic traversing winches equipped with associated accessories (traverse frame equipped with a rubber pulley with tension device) and with flexible drums for aerial transport. These systems which have been installed on exploration rigs, have met with the customers’ great satisfaction and also offer Joly the opportunity to develop other projects in the near future.

New flexible metal drums for aerial transport

Conclusion

Established in 1974, Joly S.A. is known by the major cable manufacturers who rely on the French company and who have permitted it to develop through the manufacture of new materials suitable to meet any requirement whatsoever. With 28 years of know-how in the design and manufacture of metal drums, Joly S.A. has learnt to understand and to adapt to the needs and expectations of an increasingly demanding sector that recognizes Joly’s unique capacity of meeting all requirements while adapting to any priority (budget, delivery time, types of drums or handling materials) thanks to its quality services and flexibility.

Pneumatic winch (Ø 4,000mm) equipped with traverse system for Sonar cables

Metal drums for export including metal staving (Joly patented) and built-in cradle

Today Joly S.A. is no longer considered as a “mere” manufacturer of metal drums, but as a quality and reliable enterprise that has become a major specialist in “critical projects”.