Presenting the Next-Generation REELEX Package

Introducing EcoCore™ - the next generation REELEX packaging system. A direct replacement for both REELEX I (small tube) packaging as well as REELEX II (big tube) packages, EcoCore brings together the best attributes of REELEX I and REELEX II®, while offering unique features, cost advantages, a slimmer profile and a focus on sustainability.


EcoCore replaces the typical plastic payout tube with a simple, off-the-shelf, spiral-wound recycled paper tube (also known as a "core"). To secure the core to the package, a specially-designed plastic locking ring is inserted into the core through a hole in the package. The PLR effectively sandwiches the package wall between the PLR flange and the tube, securing the tube to the package and preventing the tube from becoming dislodged.

Upgrade Your Packaging.


Compared with REELEX I (small-tube) packages, EcoCore offers better payout performance for all products without a significant increase in package size. When equipped with the density software upgrade, REELEX machines will wind the same size or smaller coils with EcoCore versus REELEX I.

Compared with REELEX II® packages, EcoCore offers equal or better payout performance in a 1.25" narrower package - making EcoCore the highest-performing all-around REELEX package.

The EcoCore package offers cable manufacturers a high-performance packaging option that is cheaper, smaller and greener than other packaging options while using a more efficient box design and unique features not found anywhere else.

EcoCoreWhile the PLR (Plastic Locking Ring) can be purchased directly from REELEX Packaging Solutions, the tube itself can be sourced from your local paper tube supplier - usually the same vendor that supplies your REELEX boxes. And because there are no plastic molds that determine tube length, the ideal tube size can be matched to every package and every product, improving payout performance of all products, even stiffer cables.


EcoCore offers equal or better payout performance than existing REELEX II packages, but because the tube profile is straight and not tapered, packages can be 1.25 inches narrower without jeopardizing payout performance. EcoCore also uses an ideal 2.00 inch tube diameter for maximum payout performance - allowing REELEX I packages to upgrade to REELEX II performance without a significant increase in package size.


Paper tubes and cores are used in a wide variety of industries and products, from paper towels to mailing tubes. As a result, spiral-wound paper tubes are common and easily sourced from most corrugated suppliers (such as your local box vendor). This abundance means competition is high and prices are low - making the EcoCore tube system up to 25% cheaper than comparable REELEX II plastic tubes.

What's more, because EcoCore allows the REELEX package to be narrower, boxes can be smaller, use less cardboard, and fit more boxes per pallet and per shipment - decreasing per-unit shipping costs.


EcoCore combines a recycled paper tube with a plastic ring made from recycled materials, and uses up to 90% less plastic than an equivalent REELEX II tube. The carton and payout tube itself can be manufactured from post-consumer recycled paper fibers and combine to create a package that is up to 1.25 inches narrower than comparable REELEX II packages. These features result in a REELEX package that uses less material, produces less waste, and is more efficient to ship.


EcoCoreInsert EcoCorePayout EcoCoreStrength

Simple Cardboard Tube

The basic concept of EcoCore is to use readily available (and cheap) cardboard cores as the payout tube, and fasten these cores to the package via glue or a specially-designed locking ring called a "PLR".

Because EcoCore uses common off-the-shelf paper cores, payout tube cost (tube plus locking ring) is less than $0.20, and can be sourced from a wide range of local suppliers without tooling investments.

Optimum Payout Performance

EcoCore uses an ideal 2.00" diameter, which provides excellent payout performance for all flexible products large and small.

Whereas the longest injection-molded plastic tubes are maxed out at 6" lengths, EcoCore tubes are readily available in any length you choose - ensuring every product uses the ideal tube length for maximum performance.

Incredible Strength

This isn't a toilet paper roll. The 1/8" thick spiral-wound paper core can withstand well over 100lbs of crushing strength before deforming - much greater than plastic.

This strength makes EcoCore ideal for wrapped coils such as those used with the Reuser Case, since stacks of wrapped coils on pallets can put well over 90 lbs of pressure on the bottom coil - potentially causing tube deformation with plastic tubes.

EcoCore on the D2050

A new option to the D2000 family, the D2050 can now be configured to package cables using the EcoCore payout tube system. On the D2050, the tube is physically glued into the package, eliminating the need for a PLR, and making the entire package 100% compostable and recyclable.

What's Included?

D2050s equipped for EcoCore usage include, tube hopper, elevator, gating mechanism, automatic flanger, a modified tube inserter and additional glue applicator that glues the tube to the package. The extensiveness of these additions means the addition of EcoCore is a $1,500/month option.

That sounds like alot.

Rental is more, but per-package payout tube cost is dramatically less. 65% less than REELEX II plastic tubes. That means for a typical production run of 18,000 boxes/month, more than $3,000 in packaging material costs can be saved - far outweighing the $1,500/month rental increase. That means overall savings range from 10% to 20%, while offering your customers a 100% recyclable, compostable package that is up to 10% narrower than REELEX II boxes, is extremely rugged and features as good or better payout than REELEX II.

Glued EcoCore Package Features

Manual Box Assembly


1. Insert Tube

A regular spiral-wound paper tube of 1/8 inch thickness, 2.00 inch ID and appropriate length is inserted into the REELEX coil.

2. Locking Ring

The coil and tube is placed into the box and the inside end of the coil is threaded through the tube, the box, and the PLR. The PLR is then pushed firmly into the paper tube - securely locking the tube, coil, and ring to the package.

3. Pull Loop

A loop is created with the inside end of the coil and the end is inserted back into the PLR. This loop makes the product easily available to the end user.

4. Finished Package

The looped end of the cable is conveniently recessed into the PLR, yet is readily available to the end user. This allows all of the carton's panels to be as flat as possible - allowing boxes to be stacked with minimum negative space.