REELEX Calculator

Using the REELEX Packaging Calculator

Hole Size Input

Select a hole size based on what type of payout tube you intend to use, and the bending radius of your product. The hole size should be set so that the operator does not have difficulty inserting the payout tube.

Hole Size Guidelines:

REELEX I – 40 to 60°
REELEX II – 70 to 110°

All twisted-pair, LAN, fiber optic and coaxial cables should use EcoCore or REELEX II tubes (60°+)

Mandrels, Endform and Traverse

About 70% of REELEX machines are equipped with 8″ mandrels with 18″ endforms.

For manufacturers winding cable larger than 0.25 inches OD, or are packaging high-performance twisted-pair products like Category 6a etc., 10″ mandrels with 21″ endforms are recommended.

Machine Configuration Guidelines:

Typical Mandrel Diameters – 6, 8, 10
Typical Endform Diameters – 12, 18, 21
Traverse Stroke is almost always 12 inches on standard REELEX machines.

Variation

If your coil sizes are far off from calculated, you may have issues that should be addressed. See the packaging manual for more information.

Important Notes:

Some causes of coil size variation include improper tension, incorrect hole taper or density adjustment, mechanical issues, etc. Contact us if you need assistance.
This calculator is simply meant as a guide. ALWAYS create sample coils before ordering packaging materials.

Instructions

Enter in your product’s diameter, your desired coil length and your machine configuration.
Press “Calculate Size Range” button.
After pressing the “calculate” button, the program will provide you with a range of gain settings that can be used for this product.
Now, enter a gain setting between the minimum and maximum allowable values to see the corresponding coil diameter, package dimensions and minimum payout tube length for your settings. Add density and hole taper values if desired.

Calculator

1. Enter Product and Machine Information

A. Select Units

B. Enter Product Information

Product Diameter (in inches):

Coil Length (in feet):

C. Choose Payout Hole Size

Hole Size (in Degrees of Circumference):

D. Enter Machine Configuration

Mandrel Diameter:
4 inches
6 inches
8 inches
10 inches

Endform Diameter:
12 Inches
18 Inches
21 Inches

Traverse Stroke (in inches):

2. Coil Diameter Range Before Density or Hole Taper

Minimum Size

Coil Size At Minimum Gain (in inches):

Maximum Size

Coil Size At Maximum Gain (in inches):

3. Select a Coil Parameters

Minimum Average Gain Setting:

What is this?

E. Enter Desired Gain Setting

Choose a Gain Setting
Between Minimum and Maximum

Maximum Average Gain Setting:

What is this?

F. Enter Density Setting (if Desired)

What is Density?

G. Enter Hole Taper Setting (if Desired)

What is Hole Taper?

H. Press “Calculate” Button Below

4. Estimated Package Size Calculations

Calculated Coil Diameter

Estimated Packaging Dimensions

Always make coil samples before ordering packaging

A - Height (in inches): B - Width (in inches): C - Depth (in inches): D - Tube Length (in inches):

5. Machine Settings to Produce Calculated Coil

Use the settings below to produce a coil of the above calculated size on your REELEX machine. Please note that older equipment may not offer density and hole taper options. To upgrade your machine to newer software, please contact us.

This calculator produces mathematical results that do not always match up with real life. Product and production characteristics such as jacket materials, line tension and even temperature and humidity can all impact coil size. Always create sample coils before designing or ordering packaging.

PRESET 2 (Coil Length): Hole Size:

Lower Gain: Upper Gain:

Density: Hole Taper:

What Mandrel to Use?

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.