Why a figure-eight coil?

No Tangles.

Tangle-free by nature.

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 Twists.

Opposing twists equals no twist.

While winding, the REELEX wind imparts a half-twist in one direction, then an equal half twist in the opposing direction. These twists cancel out when dispensing from the coil, effectively eliminating twist from the product.

Unlike linear-wound coils, which exhibit continuous twist on payout, REELEX packages eliminate twist – providing smooth, uninhibited payout performance.

No Overruns.

No rotation equals full control.

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. Installers experience payout that simply flows out of the package and stops when they stop.

What’s more, no rotation means stands, brakes, and payoffs are eliminated; as is any chance of overruns, resistance or tangling.

No Pigtails.

Bye piggy.

Opposing twists means the curling or “pigtail” effect exhibited by products with memory is eliminated. Linearly wound methods (spools, reels and linear coiling) impart continuous bending into the product when winding.

REELEX eliminates this bending by delivering product across the winding head, and doing so more than once per rotation. This eliminates the continuous bend in the product, which means the memory effect is broken up and is no longer evident after payout.

Parts of the REELEX Coil

Payout Hole

The key to payout performance.

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.

Gains and Crossovers

Art and science.

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

The gain 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.

Density Setting

Small adjustment, big effects.

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 may have 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 Category “7” / “8”.

The diameter of the mandrel defines the inside diameter of the REELEX coil. In general, the mandrel size should be selected based on the bend radius of the product.

Three standard size mandrels are available, with others available upon request.

Because a larger mandrel does not always equal a larger coil, the mandrel size should be selected based on the product OD. In general, a bigger mandrel is better for payout performance, while a smaller mandrel is better for maintaining coil integrity of highly flexible products.

For determine the estimated coil size of your product, consult the packaging calculator.

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.