Paper Tubing Packaging
Spiral Wound Tube Manufacturer
As a prize winning business, Western Container continues to improve and innovate to produce our high-quality products and provide exceptional customer service. In accordance with our success, we are expanding our operation to better meet customer demands with a state of the art $8 million 74,375 square foot manufacturing facility southeast of the city of Janesville, Wisconsin, that will produce our industry standard spiral wound tubing.
New Spiral Wound Tubing Facility
The new location will specialize in high strength film core spiral wound tubing using two cutting edge manufacturing lines from TCM Solutions. The two lines will be augmented with automated palletization to increase efficiency and productivity. Additionally, to improve the speed of distribution, the facility will have eight shipping docks for enhanced material flow and fast shipment of the finished spiral wound tubing.
Increasing Efficiency at Western Container
In our continuing efforts to increase efficiency, Western Container has invested in palletizers for end of line automatic stacking of products. One of the newest developments in material handling, palletizers automatically stack, arrange, sort, and prioritize products for smooth and economical movement of finished products in preparation for shipping or further processing. Palletizers lessen the need for handling of products and combine the operations of weighing, counting, sorting, labeling, and wrapping into one unified automated function.
As a producer of the highest quality spiral wound tubing in the industry, Western Container has taken another leap forward in its goal to produce the best products on the market. The technologically advanced Janesville facility is one more step in our continuing desire to meet and exceed the needs of our customers.
Advantages of Spiral Wound Tubing
In the many years that Western Container has been manufacturing spiral wound tubing, we have been recognized for our dedication to detail and for being the most progressive manufacturer of spiral wound tubing in the industry. The quality of our products can be seen in the creative and innovative ways our customers use our spiral wound tubing by applying it to unusual applications that test and stress its strength.
As a highly durable and sturdy product, Western Container spiral wound tubing has been used to protect products and materials due to its high impact resistance. Using the expertise and knowledge of our engineering staff, and the visions and concepts of our customers, we have been able to produce spiral wound tubing products that perfectly match customer expectations.
Formation of Spiral Wound Tubing
Spiral wound tubing production by Western Container uses a tube winding machine coupled with in-line multi-knife cutters. Paper rolls are cut into narrow width ribbons that are rewound into rolls on a rewinding stand. The large ribbon rolls are loaded into a tube manufacturing machine and coated with an adhesive. They are then wound at a helical angle of less than 90° over a mandrel, a cylinder used for shaping the tubing. The carefully selected adhesives have been engineered by Western Container engineers to be compatible with the winding materials to ensure a tight, secure, and lasting bond. The thickness of the tubing is dependent on the thickness of the paper ribbons, the thickness of the adhesive, and the number of turns of the ribbons.
The helical twisting of the paper ribbons forms a bond with each layer as the plies are lain upon each other. Pressure, to ensure tight adhesion, is applied by a flexible belt that wraps around the layers of paper ribbons. The process ensures the creation of a secure, tight, and solid bond between the different ribbons to produce a strong, sturdy, and durable tubing.
An important aspect of spiral wound tubing is the need for dimensional accuracy with tight interior diameters (ID) controlled by the mandrel to accurately meet tolerances of ± 0.010 inch. The outside diameter (OD) is determined by the material used with tolerances of ± 0.035 inch. Once the winding is completed, the tubing is cured before being cut to lengths, fabricated, and printed.
Spiral wound tubing by Western Container has superior mechanical properties and characteristics with resistance to tearing, abrasions, and strength. These are a few of the many reasons Western Container is the leader in spiral wound tubing manufacturing.
Film Cores Construction
At Western Container, film cores are constructed from plies of materials of different thicknesses to achieve specific tolerances and crush ratings. We offer film cores with diameters beginning at 3.025" up to 8.025" using regular Kraft liner material with outer surfaces of glazed Kraft or printed with one up to four colors off line printing.
Cores can be 0.192” up to 636” long with wall thicknesses from 0.036" to 0.750". Depending on dimensions, tolerances may be as precise as ± 0.010" or ± 0.025" depending on the diameter/wall thicknesses and internal dimensions.
Western Container’s new facility, in Janesville, has two lines of core manufacturing equipment from TCM Solutions that are the newest development and next generation in spiral wound tubing manufacturing equipment using innovative and technologically advanced engineering.
High Strength Spiral Wound Tubing for Demanding Applications
Spiral wound tubing from Western Container is engineered for high performance across packaging, converting, film processing, and industrial material handling. Each tube is produced with controlled winding tension, uniform adhesive distribution, and consistent ply bonding to support applications that require durability, dimensional stability, and repeatable performance. Our manufacturing approach focuses on predictable tolerances, clean edges, and reliable crush resistance so procurement teams and engineers can specify tubing with confidence.Advanced Production Capabilities
Our spiral wound tubing is manufactured using modern winding systems designed for accuracy, speed, and consistent layer adhesion. Automated controls regulate ribbon feed, adhesive application, and winding angle to maintain tight ID and OD tolerances across long production runs. Multi knife cutting systems support clean, repeatable lengths with minimal variation. Automated palletization improves downstream efficiency by preparing finished tubing for shipment with uniform stacking, labeling, and load stability.Material Options and Performance Characteristics
Western Container produces spiral wound tubing using Kraft liners, specialty papers, and engineered adhesives selected for strength, stiffness, and surface quality. Wall thickness, ribbon width, and ply count are configured to meet specific crush ratings, dimensional requirements, and handling conditions. Tubes can be produced with glazed Kraft, printed exteriors, or custom finishes to support branding, identification, or downstream converting needs. The resulting tubing offers strong resistance to impact, abrasion, and deformation during storage, transport, and processing.Precision Tolerances and Quality Control
Dimensional accuracy is maintained through controlled mandrel sizing, calibrated winding tension, and continuous inspection. ID tolerances as tight as ±0.010" and OD tolerances as tight as ±0.035" are achievable depending on material configuration. Each production run is monitored for bond integrity, straightness, surface quality, and mechanical performance to ensure consistent results across high volume orders.Engineering Support and Customization
Our engineering team collaborates with customers to configure tubing for unique load requirements, environmental conditions, or equipment specifications. Whether the application involves film cores, protective packaging, industrial sleeves, or specialty converting, Western Container provides guidance on material selection, wall construction, and performance characteristics to match project requirements.FAQs
What Materials Can Be Used in Spiral Wound Tubing?
We offer Kraft liners, specialty papers, and engineered adhesives selected for strength, stiffness, and surface quality.How Are Tolerances Controlled During Manufacturing?
Tolerances are maintained through calibrated winding tension, controlled mandrel sizing, and continuous in process inspection.Can Spiral Wound Tubing Be Customized for Specific Applications?
Yes, tubing can be configured for crush resistance, wall thickness, surface finish, and dimensional requirements based on project needs.What Industries Use Spiral Wound Tubing?
Common applications include packaging, converting, film processing, industrial manufacturing, and protective product handling.The staff of experts and engineers at Western Container are ready for any challenge you have for us. With the opening of our new facility and its technological advances, we are more than ready to meet and exceed your requirements. Call us at 1-800-393-7917 for a quote and consultation.