Packaging Causes

Kinking is often caused by improper packaging. In general the package should snugly fit the coil and the payout tube should extend as close to the center of the coil as possible for ideal payout performance.

Incorrect package size

The box is too large for the coil and shaking around during shipment. The coil should fit snugly inside the box with minimal room to move, rotate or change shape.

  • If the box is too big for the coil, the coil could slide or rotate within the package and cause unravelling and tangling issues. Many tangling problems in the field are caused by too large a box.

Incorrect payout tube length

Make sure the correct tube length is used. In general, the best payout performance comes from the inside end of the tube being as close to the center of the coil as possible.

  • If the payout tube is too short, the product will need to bend extremely sharply to exit the package, resulting in kinks and snags.

Incorrect payout tube size

For some products, REELEX II or EcoCore payout tubes are required for proper payout. This is particularly true of cables that have inherent twist, or are so flexible that they easily loop on themselves. If the product does not exit the package smoothly, consider using a larger diameter payout tube.

Product Causes

Thin jacket

Thin cable jacketing makes the cable vulnerable to denting and deformation even prior to reaching the REELEX machine, which the creates a point of resistance when the cable rolls over the edge of the tube. This dent then can create a "kink" under the right circumstances.

Inherent twist

Products with twist already built into the design could cause excessive twisting inside the REELEX coil. This can force sharp bends in the product upon payout, resulting in kinks and bends at the payout tube entrance.

Equipment Causes

Tension too high

High tension on the line can cause the cable to indent at the crossovers. This leads to a weakened area which will increase the chances of kinking at that the weakened point. These indentations also can cause electrical performance issues on twisted-pair cables.

Hole Size setting too low

A small hole size results in the cable requiring a very sharp bend in order to exit from either side of the payout tube. Increasing the hole size places the cable further away from the payout tube, which decreases the bend required to reach the payout tube.