Packaging Flexibility

Because the REELEX coil does not rotate, products wound in REELEX do not depend on the package itself to dispense properly. Because the package is literally just a container, the coil can be packaged in a unlimited number of designs and materials. This flexibility allows manufacturers to present their products in unique and innovative ways; providing opportunities for product differentiation and competitive advantage.

This flexibility also allows REELEX to be one of the most environmentally-friendly packaging options currently available to linear products - providing a plethora of material and package design methods to achieve presentation, usability or environmental goals.

Most recently, the new SlingPack, ProFlex™ packaging and EcoCore™ payout tube systems have been introduced. These packaging options represent the latest packaging innovations, each created with a focus on the end-user experience, while adding environmental, cost-saving or process advantages.

Of course, REELEX is perhaps most commonly associated with the "pull box" package, invented and developed by REELEX Packaging Solutions (formerly Windings), and the standard package for structured cabling products for over 30 years.

REELEX Coil Types

EcoCore EcoCore EcoCore
  REELEX I EcoCore REELEX II

Payout Hole Size

40 to 60 Degrees

60 to 90 Degrees

70 Degrees and Higher

Payout Tube

Two-piece plastic tube comprised of a payout tube and a snap-on locking ring with wire clip.

Length: 2in to 6in length (5cm to 15cm)

Diameter: ø 0.75in (2cm)

Two-piece tube system combines readily available paper “cores” with unique plastic locking ring.

Length: 2in to 8in length (5cm to 20cm)

Diameter:ø 2in (5cm)

Single-piece funnel-shaped payout tube that “drops in” to the coil. Uses box design to capture payout tube (no locking ring).

Length: 6in length (15cm)

Diameter: ø 2.50in (6.35cm) at product entry

Recommended Product Diameter Range

Minimum: ø 0.01in (0.25mm)

Maximum:ø 0.15in (3.81mm)

Minimum: ø 0.05in (1.3mm)

Maximum: ø 0.50in (12.7mm)

Minimum: ø 0.10in (2.5mm)

Maximum: ø 0.50in (12.7mm)

Typical Supported Coil Diameters

ø 9in to ø 16in (23cm to 41cm)

ø 9in to ø 22in (23cm to 56cm)

ø 12in to ø 22in (30.5cm to 56cm)

Typical Product Examples

Security/alarm wire, audio cables, THHN, small single-conductor building wires, small fiber optic cables, hookup wires, plastic tubing.

With the exception of very small products, most products from building wire to twisted-pair cables are supported by EcoCore.

High-performance structured cabling (Cat 5e, Cat 6 and up), shielded cables including coaxial cables, less flexible products such as some drop wires.

Typical REELEX Packaging Options

EcoCore EcoCore EcoCore

Package Type

REELEX I Box

EcoCore Box

REELEX II Box

Typical REELEX Coil Diameters

ø 9in to ø 16in (23cm to 41cm)

ø 9in to ø 22in (23cm to 56cm)

ø 12in to ø 22in (30.5cm to 56cm)

Supported Payout Tube

REELEX I

EcoCore

REELEX II

Material

Cardboard

Cardboard

Cardboard

Estimated Cost $1.50-$2.50 per box* $1.25-$2.50 per box* $1.75-$3.00 per box*

Typical Package Examples

500 ft (150m): Security/alarm wire, audio cables, building wires.

1,000 ft (305m): Security/alarm wire, audio cables, building wires.

500 ft (150m): Most flexible low-voltage products and fiber optic cables.

1,000 ft and up (+305m): Most flexible low-voltage products and fiber optic cables.

500 ft (150m): Structured cabling, most low-voltage cables, and fiber optic cables.

1,000 ft and up (+305m): Structured cabling and fiber optic cables.

EcoCore EcoCore EcoCore

Package Type

ProFlex

SlingPack

Reuser Case

Typical REELEX Coil Diameters

ø 9in to ø 16in (23cm to 41cm)

ø 9in to ø 16in (23cm to 41cm)

ø 15in to ø 16.5in (38cm to 42cm)

Supported Payout Tube

REELEX I or EcoCore

REELEX I or EcoCore

Any

Material

Plastic Shrink Film

Stretch Wrap (Coil), Cardboard (Sling)

Injection-Molded Plastic

Estimated Cost $1.00-$2.00 per bag* $1.00-$2.00 per package* $20 per case, but reused frequently.

Typical Package Examples

250 ft (75m): Single-conductor building wires, flexible low-voltage products and fiber optic cables.

500 to 1000 ft (150-305m): Smaller flexible low-voltage products and fiber optic cables.

250 ft (75m): Structured cabling, low-voltage products and fiber optic cables.

500 to 1000 ft (150-300m): Single-conductor building wires, flexible low-voltage products and fiber optic cables.

750 ft (230m): RG6 and other Coaxial or Drop Cables.

1,500 ft (500m): Category 5e and other low-voltage cables.

* Pricing is estimated and includes payout tube and package. Costs vary considerably depending on vendor, quantity, material and location. Prices are provided for reference only.

New REELEX Packaging Innovations

SlingPack™

Combining the economic and waste advantages of Stretch-Wrap with the ease of handling, stability and shipping advantages of a cardboard box, SlingPack is a low-cost, low-waste package with a focus on the end-user experience.

SlingPack is an ideal way to add additional value to stretch-wrapped products from THHN to fiber optics and more.

ProFlex™

ProFlex is an entirely new REELEX package combining a shrink-wrap package with an integrated handle.

This new package offers an innovative new approach to linear product packaging and brings a low-cost, high-versitility platform to a wider range of products than ever before.

Learn More Learn More

The REELEX Box

Easily the most popular packaging type for structured cabling products, the REELEX box is known and trusted worldwide as the best end-user package available. Whether using REELEX I or REELEX II, installers have known and trusted the REELEX package for over 30 years.

Over 30 Years of Proven Packaging

From the heyday of telephone buildout and cable TV to today's high-speed networking and POE push, REELEX boxes have dispensed over a billion feet of cable since 1976. Learn more about our history.

Why the REELEX box?

Eco-Friendly

Compost it, recycle it, or sell it. When you use REELEX, you have disposal choices beyond just the dumpster.

REELEX packaging uses the most readily recycled materials in the world and together with EcoCore, make up the first package for wire and cable that is almost completely compostable, recyclable and made using post-consumer products.

Worried about waste? Empty REELEX packages take up to 39% less volume in a landfill as comparable spools.

Damage? No Problem.

Unlike spools which can be rendered unusable if dropped or damaged, the REELEX coil will still dispense perfectly, even when the package isn’t so perfect.

Because the REELEX coil does not rely on any internal packaging component for payout, a destroyed package will still dispense. That means fewer returns, and happier customers.

Brand Visibility

REELEX opens up unique branding and marketing opportunities and can incorporate value-added options within the package such as connectors or tools. Plus, REELEX boxes can serve as travelling billboards, putting your brand on the side of every box.

Because the REELEX coil is completely enclosed by the package, there is almost unlimited space with which to put graphics, instructions, phone numbers, websites... you name it.

Stackable

Reels and spools can roll, fall off shelves and are difficult to inventory, ship and stack.

Because REELEX boxes are cubical, they inherently stack and display far better than rolls, spools and regular coils.

 

Lightweight & Easy to Handle

Spools are awkward to carry, a pain to set up and often require extra equipment just to make their use easier.

With REELEX, the built-in handles make it easy to position and carry, and because there is no rotating mass, you can start dispensing whenever you want. No need for stands or brakes.

Easy to Ship

Reels and spools often require secondary packaging (including outer boxes) to ship.

But, with REELEX, no additional packaging is necessary. Just put on a label and send it out the door.

And because REELEX packages have no internal structure, they are far more lightweight than spools or reels.