D-1500 Dual-Spindle Coiling Machine


What's New: Two-Stage Tension Control

When used in combination with the G2 control system, the new G2 UDA incorporates a digital air regulator and high-flow cylinder for adjustable tension control. This means each product can have their ideal tension control map, helping to mitigate the effects of physical pressure placed on the cable at the crossover point. What does that mean? That means high performance data cables stay high performance.

The D-1500 is a dual-spindle REELEX coiling machine designed for either rewind-line or Online configurations.

Unlike the D-750, which must be stopped after each coil is made, the D-1500 has a cut and transfer system that automatically switches the product to the empty mandrel after a coil is finished winding.

This allows the D-1500 to run continuously for seamless production and packaging when placed at the end of an extrusion line.

New (and refurbished) D-1500's are equipped with a G2 controller integrating equipment control with troubleshooting, on-screen manual, packaging calculator, digital tension control, multi-language support, product storage, networking capability and more.

D-1500s equipped with EC Safety Guarding now feature a completely new rotating-door guarding design. This guarding system completely shuts down power and air to the side of the machine that the operator has access to.

The D-1500 packaging line can be operated by a single operator, though two operators are recommended for maximum performance. This allows one operator to prepare the packages while the other tends to coil removal.


D-1500 Overview Video


Inserter BoxLifter

G2 Control System

The G2 Control System is a completely new operating system, hardware, cabinet and interface for all REELEX coiling machines. Integrating equipment control with troubleshooting, on-screen manual, packaging calculator, multi-language support, product storage, networking capability and more.

Learn More

Advanced Tension Control

The key to creating precise REELEX coils is controlling the tension as the product is wound. Every REELEX machine includes a specially-designed ring-sheave buffer system to maintain even tension and create a precise wind.

All machines come standard with 15" sheaves for high performance products such as Category 6, 6A and Fiber Optics.

Continuous Operation

The D-1500 is equipped with a cutter/grabber system which allows for continuous winding.

When one coil is finished, the product is automatically cut, and brought over to the second mandrel.

This capability allows the D-1500 to operate at up to 1,500 feet per minute.

Stretch Wrap Capable

The new automated Stretch Wrap module can be ordered with any new D-1500 or retrofitted to add additional packaging capability.

For low-margin products, shrink and stretch-wrapping options can significantly reduce packaging costs while introducing a fully disposable, lightweight and low-waste package.


Online, and in unison with an AC-300 accumulator, the D-1500 will run up to 1,500 feet (457m) per minute producing up to eighty 1,000 ft (305m) coils in an hour. Offline, the D-1500 will produce 30 to 50 coils per hour depending on payoff speed, reel size and operator skill.


The D-1500 is typically equipped with two 8 inch (20.3 cm) collapsible mandrel and 18 inch (45.7 cm) endform sets. However, depending on the flexibility and diameter of the product, 6-inch mandrels with 12 or 18-inch endforms are available along with a 10-inch/21-inch mandrel/endform sets for products with large diameters or bending radii.

Other options include mechanical and electrical spare parts kits.

EC Safety Guarding with automatic shield actuation is available for countries operating under European safety regulations.

The new Stretch Wrap Module is also available as an add-on to new or existing D-1500s.

If traditional spooling capability is also required, a SHS-750 single-head, or DHS-750 dual-head spooler is available. This machine connects through the controller and is a stand-alone spooling machine for packaging on traditional spools. This allows the operator to switch between REELEX or spooling operations on demand.


Maximum Spindle RPM 750
Number of Spindles 2
Online Capable Yes
Coils per Hour (Offline) 30 – 50 coils per hour Offline (varies with operator skill, payoff reel size and motorized payoff performance)
Coils per Hour (Online)

Up to 80 coils per hour Online with an extruder. Will follow extruder speed up to 1,500ft/min (457m/min)

Operators Required 1 or 2
Automatic Endform Removal Yes
Automatic Tube Insertion and Boxing No
Controller "G2" Industrial PC-based control system with integrated sliding control panel and LCD screen inside control cabinet featuring two speed control modes, real-time displays including program for troubleshooting and testing of all electronic and mechanical functions. Fully customizable touchscreen HMI operator interface with on-screen help, product recipe storage and retrieval, REELEX packaging calculator, maintenance functions, machine setup, multi-langual options and more.
Motors Two 5 HP (3.75 KW) DC, 1,750 RPM spindle motor and one 2 HP (1.5 KW) DC, 1,750 RPM traverse motor
Buffer System High-performance buffer with 15" sheaves suitable for products such as Category 6, 6A and Fiber Optics
Counter Footage counter mounted at output of dancer
Anti Reverse Automatic Anti Reverse AAR-1 mounted at input of buffer
Length, Width, Height 68” (173cm), 90” (229cm), 111” (282cm)
Color Equipment is painted Sky Blue (RAL 5015) unless otherwise specified at time of order. Custom paint other than RAL 5015 is a extra charge option for new equipment.
Air-Supply Requirement 70 psi (5 bar) minimum air supply required.
Power Supply Requirement 230 v (+/- 10%), 3 phase, 40 amps, 50/60 Hz. Transformer is available upon request.
Pricing - Machine
Machine Base Price (Purchase) $136,600.00
Rent/Month (Rental) $2,354.00*

Crating Charge

Pricing - Options
10” Mandrel / 21” Endforms $5,515.00

EC Guarding


Pricing - Royalties
Royalty Fees See Table and Information Here

D-1500 Line Layouts

D-1500 Online Layout

The D-1500 can be placed at the end of an extrusion line for high-speed packaging. The drawing above shows an entire D-1500 packaging line.

From the extruder, the product enters the AC-300 accumulator system. Like the name implies, the accumulator takes up extra product as it is being produced from the extruder. The product fills the accumulator as the coiling machine pauses while changes mandrels.

The UDA system at center serves to control the tension on the line by adjusting accumulator tension.

D-1500 Offline Layout

In an Offline configuration, the product is wound onto a supply reel. This supply reel is then placed in a motorized payoff system which accelerates and decelerates the supply reel on the line.

From the payoff, the product enters the UDA system, which controls the speed and tension of the line.

The product then enters the D-1500 for high-speed REELEX coiling.

Terms and Conditions: EXW, REELEX Packaging Solutions, Inc., Patterson, NY, USA. Terms: One third payable at time of order, one third at shipment, balance net 30 days after shipment. Prices subject to change without notice. Prices effective Jan 1, 2018. *Adjusted annually per the CPI-U inflation index. Prices reset in 2014, CPI-adjusted as reflected above effective Jan 1, 2018.