D-2000 Automated Packaging Machine

D-2000 Overview
D-2000 Manual


The D-2000 is a fully-automated packaging machine designed to perform coiling and boxing tasks continuously without the attention of a machine operator. This allows the manufacturer to achieve significant labor cost savings while maintaining high production rates and producing consistently high-quality coils.

The product enters the machine from either a motorized payoff or an extrusion line, is automatically coiled on a specialized turret-head mandrel, and then boxed and moved to a conveyor for further processing, palletizing or sorting.

The D-2000 REELEX Coiling and Boxing Machine includes a mounted buffer, a uniquely designed dual mandrel turret-style REELEX coiling head, a tube insertion device, and a box folding and gluing station. All operations are synchronized via a computer processor. This processor also includes troubleshooting, diagnostic, coil density and preset programs accessed via a keypad / LCD screen interface.

D-2000 Overview Video


Turret Inserter BoxLifter

Turret Mandrel Switching

The two mandrel assemblies on the D-2000 are mounted on a turret which moves finished coils to the boxing station while the empty mandrel winds a coil.

This setup allows for continuous operation and autonomous packaging.

Tube Insertion

The tube insertion mechanism on the D-2000 is completely pneumatic and includes tube separator, pickup and insertion components.

This device reliably places both Plastic and Fiber REELEX II tubes squarely into a coil without human intervention.

15-Inch Buffer Sheaves

Lightweight, low-inertia 15-inch buffer sheaves are standard on the D-2000.

These sheaves greatly reduce the amount spinning mass during the coiling process, significantly reducing the amount of stress placed on the cable.

Boxing and Gluing Station

The boxing station consists of pickup, folding and gluing components. When a finished coil is presented to the boxing station, the pickup places a box into the folding station which then folds each panel of the box around the coil. Glue guns then apply adhesive to each flap and secure each panel.


Typical rewind-line production rate is forty (40) coils per hour. Actual rates may vary depending on product type, supply reel length and the use of dual payoffs. Online, and in unison with an AC-500 accumulator, the D-2000 will run up to 800 feet (244m) per minute and produce up to forty-five (45) 1,000 ft (305m) coils in an hour.

The D-2000 buffer system includes 15” ring sheaves standard for packaging Twisted-Pair LAN and other high performance cables.

Line Layout (Rewind Configuration)


Maximum Spindle RPM 750
Number of Spindles 2
Online Capable Yes
Coils per Hour (Offline) 35 coils per hour Offline (varies with, payoff reel size and motorized payoff performance)
Coils per Hour (Online) Up to 45 coils per hour Online with an extruder. Will follow extruder speed up to 800ft/min (244m/min)
Operators Required 0
Automatic Endform Removal Yes
Automatic Tube Insertion and Boxing Yes
Controller Control panel and LCD screen featuring two speed control modes, real-time displays including program for troubleshooting and testing of all electronic and mechanical functions
Motors One 5 HP (3.75 KW) DC, 1,750 RPM spindle motor and one 2 HP (1.5 KW) DC, 1750 RPM traverse motor
Buffer System 15-inch (380 mm) ring sheave buffer designed for Category 6+ cables
Counter Footage counter mounted at input of buffer
Anti Reverse Automatic Anti Reverse AAR-1 mounted at input of buffer
Length, Width, Height 270” (6.8m), 181” (4.6m), 142” (3.6m)
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) Currently not available for purchase
Rent/Month (Rental) $5,821.00*
Crating Charge $2,000.00
Pricing - Options
10” Mandrel / 21” Endforms $250.00/month
Buffer Upgrade for Cat 6 & Higher Already Installed
EC Guarding $350.00/month
Pricing - Royalties (Fixed Schedule)
Annual Fee (If Purchased) $19,251.00
Monthly Fee (If Rented) N/A


D-2000 Online Layout

The D-2000 can be placed at the end of an extrusion line for high-speed packaging. The drawing above shows an entire D-2000 packaging line.

From the extruder, the product enters the AC-500 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 D-2000 rotates the turret from a full mandrel to an empty one. The finished coil is presented to the boxing and tube insertion station, while the empty mandrel begins winding another coil at such a speed as to empty the accumulator system.

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

Finally the product enters the D-2000 where it is wound into a REELEX coil, boxed, glued and presented to the conveyor.

D-2000 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 and then enters the D-2000.

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.