Packaging Solutions
Because the REELEX coil does not rotate, products wound in REELEX do not depend on the package itself to dispense properly. Thus, the package is literally just a container, allowing the coil to 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.
REELEX Package Components
REELEX Packaging Benefits:
Time and Labor Savings
Save 30% on time and labor on cable installations
Compared to using reels and spools, up to 30% savings in contractor labor can be achieved just by using REELEX. This translates to faster, easier installation jobs and significant cost savings for the contractor.
But don’t take our word for it. Download the case study by clicking below:
Environmental
Less waste, more recyclability
When compared with other packaging methods, REELEX allows the greatest opportunity to use recyclable, reusable, compostable, and reclaimed materials. Compost it, recycle it, or sell it. When you use REELEX, you have disposal choices beyond just the dumpster.
Worried about jobsite waste volume? Because spools and reels rarely get broken down prior to disposal, the volume they take up is enormous compared to their weight. Empty REELEX packages take up to 39% less volume when broken down as comparable spools.
Resilience
Damaged box? 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.
Cost
The lowest cost packaging option.
Because REELEX coils do not require internal components to function, packaging is simpler and less expensive. Whereas spools and reels need multiple components and require assembly, REELEX coils can be simply placed into a container. Even with license usage fees (included in graph at left), REELEX costs up to 40% less than equivalent packaging.
Ergonomics
Easy to carry, stack and store
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.
When shipping, 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.
More reasons to use REELEX:
Packaging Types
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.
Payout Tubes
All REELEX packages require a payout tube. The purpose of the payout tube is to ensure that each twist in the coil is resolved inside the package prior to existing the coil so as to result in smooth, twist-free payout. Payout tubes also serve to prevent the coil from rotating inside the package. If a payout tube is not used, some loops of the coil would exit the package resulting in twists and possible tangles.
FAQ: Frequently Asked Questions
Eventually, perhaps. After over 20 years of success, we believe REELEX AIR offers a more affordable, higher-performance drop-in replacement to the MP60. That being said, we will continue to support the MP60 for some time to come.
No! The royalty fee associated with licensing REELEX pays for all past, present and future patents and know-how.
Thinking about changing your packaging? Let us help! We have over 40 years of packaging expertise.
Yes! In most cases, REELEX AIR tubes can be used in place of the MP60 tube without changes to your current box design. Generally speaking, REELEX AIR is 100% backwards compatible and can be a direct drop-in tube for REELEX II packages. This means you can take advantage of many of REELEX AIR’s features, including cost savings without making any other changes to your packaging.
Please contact us if you have questions or would like samples.
Selecting a payout tube type depends mostly on product characteristics. Generally, the larger the product diameter, the larger the tube diameter.
REELEX recommends that all products larger than 0.20 inches in diameter (⌀ 5 mm) should use REELEX II or REELEX AIR. These larger tube types should also be used with products that have inherent twist (such as twisted-pair cables), or are relatively inflexible.
REELEX I payout tubes are recommended for flexible products less than 0.20 inches in diameter (⌀ 5 mm) and coil sizes less than 12 inches diameter (⌀ 305 mm).
REELEX I.5 or EcoCore tubes are between REELEX I and REELEX II / AIR and are recommended for products less than 0.20 inches in diameter (⌀ 5 mm).
Payout tube length depends on coil diameter and mandrel size. Generally the smallest tube size that may be used should protrude at least 1 inch past the inside of the coil wall. The longest tube that may be used should not exceed 50% of the coil diameter (in other words, should not protrude past the center of the coil).
For a guide and selection chart based on coil and mandrel sizes, please download the guide here:
By allowing the coil to compress and removing negative space, REELEX AIR offers a savings of 1 to 3 inches (up to 75 mm) in package width compared to existing REELEX II packaging.
Less width translates to more boxes on a pallet and huge increases in shipping efficiency. Smaller boxes are also welcomed by the end-user, with improvements to logistics efficiencies and shelf space utilization.
This results in a potential 25 to 50% increase in shipping density compared to standard REELEX II boxes depending on product type. Narrower boxes mean more boxes on shelves, less space in trucks and easier shipping and handling.
REELEX AIR offers improved payout performance for most products. This is due to two unique design features:
- The entry point of the tube now has a rounded edge, smoothing the contact point of the cable with the tube and increasing bend radius. This rounded input edge has the effect of smoothing jacket imperfections, providing less physical impact on the cable and providing the installer with an even smoother, quicker payout feel.
- The open sided design of the tube, when combined with the larger rounded entry “ring” acts as a small protrusion on the inside of the coil. This dimension serves as a guide to restrict premature unravelling of the REELEX coil which can occasionally cause payout issues in some products. This can be of particular benefit to highly flexible products or products with inherent twist.
REELEX AIR is currently only available in a 6-inch long variant. Ultimately, we anticipate having 4, 6 and 8 inch (10cm, 15cm and 20cm) variants.
Besides the 10% reduction in payout tube unit pricing, an increase of up to 50% more boxes per pallet translates to over 30% reduction in shipping costs per box. Let us make samples of your product to determine exact savings.
We anticipate REELEX AIR to be readily available starting in 2Q22, and will be supplied by Axjo; REELEX’s payout tube partner.
Yes! REELEX offers a field-retrofittable upgrade kit for D-2000s and D-2050s. This kit will make relatively minor changes to the gating mechanism, box table and switches, allowing REELEX AIR to be used on all automated REELEX packaging machines.
The only other change required will be adjustments to box sizing, if you choose to take advantage of the smaller box size. If not, REELEX AIR tubes are backwards compatible with existing box designs.
Absolutely! ProFlex packaging is not restricted to just REELEX coils.
Non-REELEX licensees must sign a separate license agreement to use ProFlex packaging. Royalty fees are indicated below. A US$3,500.00 one-time license fee is paid upon signing the license agreement.
ProFlex is part of the REELEX umbrella of patents, thus a current REELEX license agreement gives full rights to the use of ProFlex packaging.
No additional fees are payable to REELEX beyond those currently paid for the use of the REELEX system of patents.
ProFlex is a patented technology whose use is administered through a current and signed license agreement.
All products packaged by ProFlex, whether REELEX coils or not, use unique technology licensed by REELEX Packaging Solutions, Inc.