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°
- EcoCore – 60 to 80°
- 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 60% to 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 6, 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.
This calculator does NOT take into account the variable density function available on REELEX coiling machines. The density upgrade can reduce coil sizes by an additional 5% to 15% from calculated.
If your coil sizes are far off from calculated, you may have issues that should be addressed. See the packaging manual for more information.
- 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.
Enter in your product’s diameter in inches, your desired coil length and your machine configuration.
Press “Calculate” button.
After pressing the “calculate” button, the program will provide you with a range of gain settings that can be used for this product (2. A and 2. B).
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.
1. Enter Desired Inputs
A. Enter Product Information
Product Diameter (in Inches)
Coil Length (in Feet)
B. Choose Payout Hole Size
Payout Hole Size (in Degrees of Circumference)
REELEX I = 40 to 60, EcoCore = 60 to 80, REELEX II = 80 to 120
C. Enter Machine Configuration
Mandrel Diameter (in Inches)
Endform Diameter (in Inches)
Traverse Stroke (in Inches)
Typically 12 inches
D. Press “Calculate”
2. Machine Coil Parameters and Coil Diameter Range
Minimum Average Gain Setting
Coil Size at Minimum Gain (in Inches)
Maximum Average Gain Setting
Coil Size at Maximum Gain (in Inches)
3. Select a Gain Setting between Min and Max
E. Enter Desired Gain Setting
Choose a Gain Setting Between Min and Max from Section 2
Corresponding Calculated Coil Diameter
Estimated Coil Diameter
4. Estimated Package Size Calculations
All dimensions are in Inches