Packaging Innovation
When designing the new REELEX AIR payout tube, we focused on the essential functional component of the tube – where the product enters.
To that end, we improved everything that was needed, and removed everything that wasn’t.
The result is a backward-compatible, enhanced REELEX package offering lower cost, less material, smaller size and even smoother payout.
Welcome to the next generation of REELEX packaging.
Less Material, More Sustainable
Featuring an innovative I-Beam design, the REELEX AIR payout tube removes the superfluous, non-functional parts of the REELEX II payout tube (MP60).
The result is a new payout tube design that weighs 45% less than equivalent REELEX II tubes and uses nearly 40% less plastic. Less material and less weight while offering an improved environmental impact.
But it’s not just the tube that uses less material. Boxes use up to 40% less cardboard, and are up to 25% less expensive.
Less Cost
Less Material
(Even) Better Payout
REELEX AIR’s design features offer (even) better payout performance for many products.
These features include a smooth, rounded entry, which reduces friction and increases the bend radius of the product as it exits the package and an I-beam design which supports product loops and prevents them from prematurely unravelling.
These features result in an (even) smoother cable pulling experience compared with REELEX II – offering smoother pulling “feel”, and lower incidences of premature unravelling in products with inherent twist.
Smaller Package Size
REELEX AIR’s design allows the coil to compress significantly. By allowing the cable to rest inside the cutaways of the payout tube, the package can be significantly narrower without sacrificing payout performance.
Compared to a standard box of Cat 5 or Cat 6, REELEX AIR boxes are up to 2.5-inches (63mm) narrower than equivalent REELEX II boxes.
More Boxes per Pallet = Less Shipping Cost
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.
Pallet Examples
Cat 5e
Cat 6
Cat 6A
Overview Video
Frequently Asked Questions (FAQs)
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.
We anticipate REELEX AIR to be readily available starting in 2Q22, and will be supplied by Axjo; REELEX’s payout tube partner.
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.
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.
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.
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.
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.
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.