Twist and Tangle-Free Packaging

REELEX tangle-free technology is a patented method of winding a filamentary product (such as cord, wire, cable or tubing) into a figure-eight coil on a specialized coiling machine.

This unique coil dispenses from the inside-out without twists, tangles, snags or overruns. Because the coil does not rotate during payout, there is no inertia, and thus no need for payoff stands or brakes. And since the coil does not require any moving parts as a means of dispensing the product, it may be packaged in a wide variety of package shapes and materials, or simply placed in a cardboard box.

The REELEX coiling method cancels any twist in the product by using a traverse to precisely guide the product back and forth across the coil while winding. By weaving the product across the width of the coil, the winding process imparts a half-twist in one direction, and then back in the other direction. These twists cancel each other out as the coil is dispensed, resulting in low-tension, smooth payout without any twists, kinks, snags or tangles.

There are two types of REELEX coils: REELEX I and REELEX II™. Both coils feature the same coiling method, but REELEX II features a much larger payout hole to increase bending radius and payout performance of products that are too large, stiff or sensitive to bending for REELEX I. REELEX II or EcoCore is optimal for LAN cable, whereas REELEX I is acceptable for products like security/alarm wires, building wire, etc.

The product dispenses through a REELEX I, EcoCore™, or REELEX II payout tube which is inserted into a hole woven into the wall of the coil by the coiling machine.

Video Overview

Payout Tubes

All REELEX coils dispense through a small cylindrical component called a "Payout Tube". The purpose of the payout tube is to ensure each half-twist of the figure-eight resolves inside the coil, rather than outside. If no payout tube is used, the half-twists can create kinks and twists in the product which can cause payout issues.

Why a figure-eight coil?

No Twisting.

Because the REELEX coil cancels any twisting via a figure-eight pattern, the product dispenses from the package without any of the "pig-tail" effect commonly experienced with reels.

And, because of the way the product is wound, there is no twisting motion put into the cable during coiling. That means when you pull the product out of the package and let go, it won't curl up or twist.

No Tangling.

REELEX coils unwind from the inside-out through a payout tube. Each layer of the coil is separated by a crossover, which prevents knots and tangles from forming between loops. Innovative tube designs ensure smooth payout, even in cold temperatures or when packaging less-flexible products.

Just place the REELEX package on a surface and pull as hard as you need to. When you stop, payout stops.

No Rotation.

REELEX coils are self-supporting and do not rotate during payout. As a result, the end-user experiences low tension, zero inertia, and can pull product 30% faster than if using reels.

And, no rotation means payoff stands, brakes, and payoffs are eliminated; as is any chance of overruns, resistance or tangling.

It also means there is no bulky internal packaging components to dispose of. Just flatten the box.

Components of the REELEX Coil

Gains and Crossovers

If you picture a series of figure-eights stacked atop one another, the "gain" controls the distance between these stacks. Where the product crosses over itself is the "crossover". These must be staggered, or else the coil would not be cylindrical.

The gain (ratio) adjustments control the distances between wraps in a layer. Generally, the lower the gain, the less negative space in the coil and therefore the coil will be denser and result in a smaller diameter. However, if the gain goes too low the coil will start to increase in diameter, as layers have no where to go but build atop one another.

In addition to fine-tuning the diameter of the coil, the gains also adjust tension placed on the product within the coil. Higher gains will help ease the tension within the coil if the product being wound is sensitive to pressures or deformation.

Payout Hole

The hole size setting on all REELEX machines can be adjusted in degrees of circumference. The larger the setting, the larger the payout hole, however the coil size will also increase.

Any payout hole larger than 120° may produce a coil that may collapse or cause the product to slip. The hole size should be chosen so that a the machine or operator does not have a problem inserting the tube. REELEX I coils feature payout holes up to 60°, and REELEX II exhibit holes of 60° and greater.

REELEX machines can also alter the shape of the hole via Taper and Shift settings. These settings can be used to "tweak" the coil, but also serve an important role when coiling especially slippery products or extremely long coil lengths, as they maintain payout hole integrity.


Coil Density

The Density Program staggers the location of the crossovers so they occur at irregular intervals. In addition to allowing for increased coil density, the shifting of the crossovers have a significantly positive effect on the electrical performance of data cables such as Category 5e, Category 6 and more.

This means products that previously performed marginally in electrical testing can now be packaged in REELEX with little or no degradation in performance. Density is especially useful in packaging foiled or shielded products, as well as high-end LAN cables such as Category 6a and Catagory "7".

Why REELEX?

For Manufacturers

  • The best customer service in the industry
  • Great graphics and brand visibility opportunities
  • Product differentiation
  • Fewer returns
  • Less waste and easy recyclability
  • Easier shipping and palletizing
  • Incoming packages store and ship better than reels/spools
  • Lower material costs
  • Reliable machinery

For Distributors

  • Easy to stack
  • Can be shipped without external packaging
  • Product is protected while in inventory
  • Easier to label
  • Saves warehouse space
  • Simplifies storage
  • Package discourages tampering and theft
  • No splinters
  • Packages do not crack, shatter or break
  • Withstands wide range of climates
  • Still works, even if damaged - fewer returns

For End-Users

  • Up to 30% faster installation time
  • Greatly simplifies cable pulling
  • Eliminates need for stands brakes, "caddies", or an extra man to control reel
  • Easy to carry, simple to use; just pull
  • No tangles
  • Product does not twist or "corkscrew"
  • Less material waste, easy to recycle, environmentally friendly
  • No splinters
  • No reels or internal packaging to dispose of
  • Stores and protects unused product
  • Easy to stack and store