More than 40 years of coiling, packaging and ancillary equipment know-how.

REELEX designs and manufactures specialized coiling machinery to produce REELEX coils and packaging.

REELEX Coiling Machine Components

How is a REELEX coil made?

Specialty equipment, unique electronics and advanced know-how.

Where it all happens.

The product enters the guide tube and exits the wire guide which are connected to the traverse. The traverse is controlled via unique electronics and REELEX-built drives for precise layering. The traverse moves back and forth and moves in sync with the rotation of the mandrel as the coil is wound.

The coil builds along the walls of the endforms, which require mathematically-derived curves designed to maintain coil shape and density. When the coil is finished winding, the outer endform attached to the endform arm is pneumatically removed, and the mandrel segments collapse. The coil is now removed from the machine and placed into its final package.

REELEX Machine Features

Advanced HMI

Unique HMI for unique equipment.

All new REELEX machines feature the G2 or G3 REELEX control systems, integrating equipment control with troubleshooting, on-screen manual, packaging calculator, multi-language support, product storage, networking capability and more.

Purpose Built

Over 40 years of specialty equipment know-how.

From the ground-up, all REELEX machines are designed and built at our Patterson, NY facility.

Because REELEX Packaging Solutions is the only manufacturer of REELEX coiling machines, every part is designed and manufactured in-house for dependability and performance.

Unique Electronics

Specially-engineered for proper coil formation.

The unique aspects of the REELEX coiling process require not only bespoke mechanical components, but custom electronics as well.

For example, the large amount of energy produced by the rapid changes in traverse motor speeds requires a highly specialized DC drive. REELEX uses drives designed by our engineers and built in-house to absorb this energy, while providing precise motor control.

Adjustable Precision

Ensuring the perfect fit.

Winding a REELEX coil is an extremely complex operation; which is why the electrical and mechanical components of the machine are designed to run in complete harmony while still allowing for flexibility.

Parameters such as holesize, weave ratios, density, hole shift and taper are all adjustable, allowing the coil to be fine-tuned to accommodate different packaging needs.

Adaptability

Easy integration.

REELEX equipment is designed to be incorporated with multiple components in a line, and can be adapted to include additional features. Stretch wrapping, spark testing, printing and other capabilities can all be added to existing machinery and control systems for seamless operation.

Superior Tension Control

Delicate handling for high-performance products.

One of the keys to precise coiling is tension control. Over 40 years, REELEX machines have improved tension control methods to overcome issues such as electrical performance issues on LAN cables. Today’s buffers are precise, lightweight components specifically designed to put minimal stress on the product while maintaining tension requirements.

Coiling Machine Models

Every REELEX machine is capable of making the same figure-eight, self-supporting REELEX coil, but do so at varying speeds and levels of automation. From the fully-automated D-2050, to the single-spindle D-750, we manufacture a wide range of coiling machines for various budgets, products and production needs.

Standard REELEX Machines

These machines are REELEX’s most popular coiling machine models, and are suitable for packaging all low-voltage and structured cable types, including Category cables, some fiber optic cables and other flexible cable constructions.

D-750

D-1500

D-2050

Boxes per Hour (1,000ft/305m)

40
90
45

Average Line Speed

0
Feet/Min
0
Feet/Min
0
Feet/Min

Operators

11 required, 2 suggested for maximum output.1 part time operator to fill box and tube magazines.

Online Capable

Features

  • G3 Control System
  • G3 Control System
  • Automatic cut and transfer
  • G2 Control System
  • Automated cut and transfer
  • Automated tube insertion
  • Automated boxing and gluing

Specialized REELEX Machines

These machines have been developed with unique features for specialty applications. While all REELEX machines make the same REELEX coil, these machines use unique traverse technology to allow for unique capabilities.

RS1

RS1

S290

Boxes per Hour (1,000ft/305m)

20
60

Maximum Line Speed

0
Feet/Min
0
Feet/Min

Operators

11

Online Capable

Capabilities

  • Linear traverse allows for wide variation in coil widths
  • Spool-winding capable
  • G2 Control System
  • G2 Traverse creates dense, precise coils and is ideal for small, slippery products like THHN or bare wire
  • G2 Control System

Ancillary Equipment

In order to support REELEX coiling machines, we also design and manufacture our own ancillary equipment, including dancers, payoffs and accumulators. These machines are specially-designed to achieve maximum performance from the unique characteristics of the REELEX coiling process, including precision tension control, rapid response to changes in line tension, and frequent starts and stops.

Motorized Payoffs

Dancers

Accumulators

Purpose

Feeds cable to REELEX machine by controlling supply reel in offline (rewind) packaging setups.Sets line tension by controlling the incoming speed of cable to the REELEX machine. Also accumulates product during startup and stop.Accumulates incoming product when REELEX machine is stopped during transfer between mandrels.

Usually paired with

D-750, D-1500 or D-2050 when used in offline (rewind) configurations.All REELEX configurations. Included as part of accumulator system.D-1500 or D-2050 when used in online (or “inline”) configurations

Capability

Rotates and brakes supply reels measuring up to 52 inches (132cm) diameter and 3,500 lbs (1,587kg)Controls line tension via digital air regulator and laser potentiometer. Accumulates up to 40 feet (12m)Accumulates up to 500 feet (152m) of product.

Online Capable

Features

  • Pneumatic loading
  • High performance brake
  • Accelerates to max speed in under 10 seconds
  • Digital air regulator connects to HMI
  • Laser potentiometer
  • High-performance lightweight sheaves
  • Laser potentiometers
  • Ladder logic function
  • Downward-dropping sheaves for rapid response
  • High-performance lightweight sheaves

Equipment Pricing

Between equipment buy-back programs, month-to-month leasing and most-favored licensee pricing, REELEX equipment acquisition is a low-risk, high-reward proposition.

REELEX Line Pricing

Coiling Offline from Supply Reel or Stem

In this configuration, the REELEX machine is rewinding from a supply source that can be stopped and started. This is typically a supply reel, but could also be other form of bulk supply such as stem or barrel package. If using a supply reel, the incoming line speed is controlled via a Motorized Payoff. This Payoff must be capable of stopping and starting the line each time a coil is produced, thus our REELEX-designed high-performance payoff is highly recommended.

Example Pricing if you RENT:

Rental Per MonthRS1D-750S290D-1500D-2050
REELEX Machine Rental*$1,190.00$1,271.00$2,810.00$2,405.00$6,005.00
Ancillary Equipment
UDA (Dancer)*Included with Payoff$351.00$351.00$351.00$351.00
Motorized Payoff*$1,567.00$1,271.00$1,514.00$1,271.00$1,271.00
Equipment Total*$2,757.00$2,893.00$4,675.00$4,027.00$7,627.00
Ongoing Royalties
Monthly Royalty Fees*$1,081.00$1,081.00$1,081.00$1,353.00$1,711.00

Example Pricing if you BUY:

Purchase PriceRS1D-750S290D-1500D-2050
REELEX Machine Price$74,500.00$75,100.00$125,000.00$164,700.00$675,000.00
Ancillary Equipment
UDA (Dancer)Included with Payoff$13,800.00$18,000.00$13,800.00$13,800.00
Motorized Payoff$51,320.00$59,800.00$59,800.00$59,800.00
Equipment Total$125,820.00$148,700.00$143,000.00$238,300.00$748,600.00
Ongoing Royalties
Annual Royalty Fees*$12,977.00$12,977.00$12,977.00$16,221.00$20,546.00

Coiling Online from Extruder

If coiling product coming directly from a constant-speed source (such as in line with an extruder), only the D-1500 or D-2050 are suitable, as they can switch between mandrels without operator intervention. However, because the incoming product must stop while the transfer takes place, an Accumulator is required to take up the incoming product. The accumulator is then emptied when the transfer is complete and the coiling machine begins winding again.

Example Pricing if you RENT:

Rental Per MonthD-1500D-2050
REELEX Machine Rental*$2,405.00$6,005.00
Ancillary Equipment
Accumulator System*$1,756.00$2,000.00
Equipment Total*$4,161.00$8,005.00
Ongoing Royalties
Monthly Royalty Fees*$1,353.00$1,711.00

Example Pricing if you BUY:

Purchase PriceD-1500D-2050
REELEX Machine Price$164,700.00$675,000.00
Ancillary Equipment
Accumulator$58,200.00$65,800.00
Equipment Total$222,900.00$740,800.00
Ongoing Royalties
Annual Royalty Fees*$16,221.00$20,546.00

*Adjusted annually per the CPI-U inflation index.
Terms and Conditions: EXW, Patterson, NY, USA. Prices subject to change without notice. Prices effective Jan 1, 2019. 

Questions? In need of service? Contact us!

REELEX Sales

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  • Samples of your product in REELEX

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REELEX Support

  • Technical questions

  • Support for current machine issues

  • REELEX machine manuals

  • Schedule service or contact a technician