This article provides comprehensive information about paper tubes, paper core and composite cans. You will learn how these paper and paperboard products are made and their materials of construction as well as paper tube applications, advantages and drawbacks.
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Paper tubes are constructed by winding multiple layers of paper or paperboard together, forming robust, hollow, usually cylindrical forms. These layers are adhered together using laminating or bonding adhesives. The wall thickness of these tubes can differ, depending on the number of layers incorporated during the creation process.
Commonly known as paper cores, paperboard tubes, paper cans, fiber drums, fiber tubes, paper tubing, wound tubes, composite cans, coreboard tubes, and sometimes erroneously as cardboard tubes, these are used in a variety of applications. The term "cardboard tube" is technically inaccurate, as true cardboard is made up of three layers of kraft paper with a corrugated middle layer.
Paper tubes, paper cores, and similar products are manufactured by winding layers of high-strength paper or paperboard, most commonly brown kraft paper. Industrial paper tubes and cores can include one, two, or multiple plies to achieve the required wall thickness and structural integrity for varied uses, such as shipping, packaging, and converting processes.
The innermost layer, known as the liner, and the outermost layer, called the wrap, can be composed of durable materials like foil, polyester film, or specialty treated paper for added protection. These outer layers can provide important features such as moisture resistance, oil resistance, enhanced graphics or branding, high-gloss finishes, and custom colors. These protective properties make paper tubes and cores ideal for both consumer packaging and industrial use.
The two primary types of paper tubes and cores are spiral wound tubes and convolute (parallel wound) tubes. Spiral wound paper tubes are created by winding paper plies at a continuous angle around the tube axis, offering excellent uniformity, length control, and strength for everyday applications like mailing tubes, poster tubes, paper straws, and core inserts. Convolute wound cores and tubes, in contrast, are produced by wrapping the material edge-to-edge at a right angle or parallel to the axis. These convolute tubes excel in high-crush strength, rigidity, and dynamic load resistance, making them essential as heavy-duty industrial cores in manufacturing and converting operations.
In a spiral wound tube, the multiple layers are bonded with adhesives at an angle for superior column strength. This construction is especially suited for use as shipping tubes, protective packaging cylinders, and display poles. For convolute tubes, the parallel layering creates tighter bonds, offering increased compression strength and bending resistance. These characteristics are valuable for engineered paper cores in industries such as textiles, flexible packaging, paper mills, plastic film, and adhesive label production.
Typically, paper tubes have thinner walls and are primarily designed as lightweight containers or retail packaging for consumer goods, mailing, and specialty products. Adhesive tape cores, craft and hobby tubes, and paper cans for food packaging are common examples.
Meanwhile, paper cores have substantially thicker walls. This heavy-duty construction makes them indispensable as winding cores for converting operations where webs, films, textiles, nonwovens, carpets, foils, and industrial papers are produced as continuous rolls. These robust cores support the weight and tension of large-diameter or high-speed winding without collapse.
In papermaking, machines generate giant parent rolls—often called machine rolls, jumbo rolls, or tambour rolls—which are later converted, slit, or rewound into consumer-sized rolls using dedicated winding machinery and paperboard cores. Other industries, including flexible packaging, plastic films, textiles, and abrasives, also use these large-diameter converting cores to wind and process various materials efficiently.
Not all paper tubes are restricted to packaging—many serve as critical industrial machine components. For example, high-performance paper cores are engineered for use in rolling mills or film extrusion plants, where superior compressive strength, dimensional stability, and resistance to deformation are critical. These industrial paper tube solutions are tailored to handle heavy loading, high-speed processing, and demanding environments.
For smaller rolls, such as adhesive tape, labels, aluminum foil, tissue paper, or commercial film, thinner spiral wound packaging cores are favored for consistency and smooth handling during dispensing. These small-diameter products are commonly found in offices, households, retail, and specialty packaging sectors.
The production of custom paper tubes and cores leverages precise cutting techniques—such as rotary blade or saw methods—to manufacture a full range of finished products, including composite cans, eco-friendly shipping tubes, push-up tubes for cosmetics, pyrotechnic tubes, display poles, carpet cores, concrete column forms, and other specialty engineered paper products.
Large fiber drums, composite drums, and paper straws are also produced using a similar winding process. Convolute winders are preferred for composite and fiber drum production, creating sturdy but lightweight containers that are an eco-friendly alternative to steel drums for the shipping and storage of bulk goods and chemicals. Paper straws, recognized for their sustainability, are manufactured at high speeds with spiral winders to meet food safety standards and replace single-use plastic straws.
For end-users and buyers in industries such as packaging, converting, manufacturing, and logistics, custom paper tube manufacturing delivers solutions tailored to precise size, performance, material, and environmental specifications. Leading paper tube manufacturers and paper core suppliers offer design, prototyping, and short-run options to support innovation and meet diverse industrial and consumer requirements.
Although most commercial paper tubes are designed with a cylindrical or round cross-section, advanced custom paper tube manufacturing capabilities enable the creation of tubes in a wide variety of shapes—including square, oval, hexagonal, triangular, and other geometric profiles—using specially engineered winding mandrels. These non-round paper tubes can be strategically designed to match product contours, maximize storage and shipping efficiency, and minimize the need for excess packing materials.
Tapered paper tubes or paper cones are manufactured with cone-shaped mandrels and are widely used as yarn carriers in the textile industry, as well as in carpet and fabric winding. Their unique shape offers stability and managed tension during high-speed unwinding operations, supporting smooth processes in spinning, weaving, and dyeing lines.
For specialized protection, paper tubes may be slit or cut longitudinally to create half-shells. These half-shell protective covers are invaluable for protecting large paper rolls, coiled metals, or other cylindrical products during shipping and handling. They can be easily secured with tape or connective H-profiles, streamlining large-format packaging solutions and reducing manual labor compared to traditional tube insertion methods.
Innovative applications in industries such as retail, food and beverage, pharmaceuticals, construction, textiles, and even fireworks manufacturing rely on the versatility of both round and custom-shaped paper tubes. Choosing the right paper tube shape and design ensures optimal product protection, branding, and process efficiency.
If you are seeking reliable solutions for shipping, specialty packaging, commercial winding, or custom manufacturing, partnering with a trusted paper tube supplier or industrial core manufacturer can help you achieve cost-effective, sustainable, and high-performance results tailored to your business needs.
Paper tube and core manufacturing is a sophisticated converting process used to produce high-strength, durable cylindrical structures for packaging, shipping, and industrial applications. This process involves web slitting, web winding, and lamination or adhesive bonding—key steps that transform raw paper materials into rigid, reliable paper tubes or fiber cores. Multiple layers, or plies, of paper or paperboard are spirally or convolutely wrapped around a steel mandrel, using high-strength adhesives to form a robust, multi-layered tube. This manufacturing technique ensures exceptional crush resistance and structural integrity, making paper tubes suitable for a wide range of winding and packaging needs.
Based on my experience, plies generally range from 2 to 10 inches (50 to 250 mm) in width, though some can be as wide as 20 inches (500 mm). The thickness of each ply typically falls between 0.008 and 0.050 inches (0.2 to 1.3 mm). The total number of plies can vary from 1 to over 50, but cores with 3 to 30 plies are most commonly used for industrial and commercial applications like shipping tubes, textile cores, and protective packaging.
The core strength of a paper tube depends on several engineered variables: the bond strength of the paperboard plies, the ply thickness, the bond area or overlap, and the quality of the adhesive used. Paperboards themselves may be produced in a single, dense sheet or formed by laminating multiple plies for added strength. This flexibility allows for custom tube configurations, meeting stringent requirements for paper cores used in paper mills, film converting, textile winding, carpet rolls, and more. End users benefit from paper tubes' versatility, sustainability, and customization options.
| Process Steps in Manufacturing Paper Tubes | |
|---|---|
| Machinery Utilized | Paper Tube, Paper Core and Paper Tube Product Manufacturing Process Steps |
| OffRotary Slitting Machine | Jumbo Roll Unwound and Slit into Narrow Paper Strips or Plies |
| Winder / Unwinder | Winding of Narrow Paper Strips or Plies |
| Fork Lift Turk, Carts or Material Handler | Stacks of Paper or Paperboard Rolls Moved to Winder |
| Winder - Unwinder or Unwinding Stands | Multiple Rolls of Narrow Paper Strips Loaded on to Unwinder Spindles/Shafts |
| Winder - Adhesive or Glue Applicator | Adhesive Applied to Narrow Paper Strips |
| Winder - Wrapping & Forming Mandrel | Paper Ply Strips Wrapped on to Mandrel to Continuously from Spiral Tube |
| Inline Printing & Labeling Unit | Labeling Wraps with Printed Graphics Applied to Paper Tube in Inline Process |
| Inline Cutter | Spiral Paper Tube Cut into Shorter Lengths |
| Tube Drying Oven | Spiral Paper Tube Lengths Cured or Dried in Oven |
| Offline Printer or Label Wrap Applicator | Labeling Wraps with Printed Graphics Applied to Paper Tube in Offline Process |
| Recutter or Offline Cutter | Longer Tubes Cut in to Required Smaller Lengths for End Use |
| Conveyors, carts or Material Handler | Cut to Length Paper Tubes Moved to Secondary Finishing Cutting and Closeure Operations |
| Tube Finishing Machinery | Deburring, De-dusting, and Polishing or Skiving when Smoother Surface Finish Requited |
| Punching or Die Cutting Equipment | End Notching, Slotting, Window Cutting, Perforating, Embossing |
| Tube End Forming and Capping Equipment | End Forming, Plug Insertion, Capping or Flanging & Capping |
| Conveyors, Carts or Material Handler | Finished Tube Moved to Palletizing and Packaging Machines |
| Palletizer & Packaging Machines | Paper Tubes Stacked and Packaged on Pallets, in Boxed or On Steel Carts |
| Loading Docks and Trucks | Packaged Paper Tube Products Loaded onto Trucks and Shipped to Customers |
For those interested in the technical foundation of the paper tube manufacturing industry—including engineers, purchasing managers, and designers—reviewing related patents and technology definitions on the USPTO website can offer deeper understanding and specialized insights into how these durable fiber products are made to precise specifications for countless commercial and industrial uses.
Subclass B31C in the United States Patent and Trademark Office (USPTO) offers cooperative patent classification (CPC) and technology definitions for paper and wound tube manufacturing processes. Specifically, B31C 9/00 refers to the "Simultaneous forming of cylindrical and conical shapes by winding separate webs, such as in the production of bottles." Understanding these standards can help you evaluate new proprietary manufacturing methods when seeking out custom or advanced paper tube solutions.
The paper tube manufacturing process can encompass web winding, folding, and precise bending, allowing the production of tubes and cores in a range of shapes—round, square, oval, or conical—to meet specialized packaging, storage, and product protection requirements.
In spiral wound paper tube manufacturing, wide jumbo rolls of paper, paperboard, and liner materials are converted into highly engineered narrow ribbons via a rotary slitting machine. These ribbons are critical to creating tubes with consistent wall thickness and superior crush strength for demanding uses, such as mailing tubes, carpet cores, textile tubes, and point-of-purchase display tubes. The narrow ribbons are precision-wound into "poker chip" stacks, then staged for transport to spiral winding machinery.
Once loaded, narrow ribbons from multiple rolls are simultaneously guided, adhered, and taped to the steel winding mandrel. By precisely offsetting the leading edge at an angle less than 90 degrees to the mandrel's axis, the ribbons form a continuous spiral, resulting in a high-integrity laminated tube. This advanced method produces tubes with superior roundness and uniformity—essentials in both automated and manual material handling.
The steel mandrel's outer diameter determines the inner diameter of the final tube, while the overall wall thickness is controlled by the number and thickness of plies, as well as adhesive distribution. These parameters are tightly controlled in high-volume production, ensuring that paper tubes, mailing tubes, and paper cores meet stringent customer tolerances.
During spiral winding, strong water-based or hot-melt adhesives are applied to the plies before winding. Various adhesive application techniques—such as roll coaters, reverse roll, slot die, extrusion, brush, spray, blade, and dip coaters—ensure a consistent, reliable bond and boost the tube's axial and radial strength.
Once plies are wound, a robust fabric-reinforced endless belt applies uniform pressure, compacting layers and advancing the tube with high friction. These tube forming belts (Nitta, Passaic, Rainbow) are engineered for strength and easy cleaning, with seamless construction to avoid tube marking—critical for high-speed, defect-free production.
The finished laminated tube is then cut to exact length—inline or offline—with rotary blade cutters or saws, addressing the needs of customers requiring tight tolerances, burr-free edges, and consistent lengths for applications like film, textile, or foil winding. Additional finishing such as deburring may follow to prepare for downstream use or packaging.
Versatility is another major strength of spiral tube manufacturing: different ply combinations allow for tailored product properties. Specialty liners (foil, waxed or coated paper, plastic film) can be applied to the inner or outer diameter to increase moisture, grease, or chemical resistance—ideal for food-grade paper tubes, protective postal tubes, and moisture-sensitive cores.
Custom-printed ribbons offer strong branding opportunities, while layer selection influences durability and printability. By collaborating with an experienced manufacturer, you can design custom tubes for specific packaging, shipping, or converting requirements, including heavy-duty spiral wound cores for steel or textile mills.
In convolute tube manufacturing, wide ribbons are wound around the mandrel parallel to its axis, producing a single longitudinal seam and maximizing beam strength. This method enables production of heavy-duty paper tubes and paperboard cores designed for industrial web handling—whether in paper, textile, film, or abrasive industries. Higher pressures and tensions during winding eliminate voids and optimize adhesive contact, resulting in extremely robust, dimensionally stable tubes and cores.
An external metal roll applies uniform pressure, increasing adhesive penetration and minimizing air entrapment. This enables production of beam-strengthening convolute tubes—often the gold standard for critical web winding, unwinding, and rewinding applications in industrial production lines.
Common high-strength convolute tube applications include:
When specifying a paper core, consider not only the dimensions and ply composition but also its function as a mechanical element—serving as a shaft, chuck, or spindle in industrial web handling and fabrication machinery. For lighter-duty applications, such as label and tape dispensing or mailing tubes, spiral wound tubes often suffice. For high-stress or heavy roll winding, convolute-wound paper cores provide the necessary rigidity and load-bearing capability.
The spiral and convolute tube manufacturing processes may be combined to engineer multilayer tubes with unique properties. For example, a spiral wound kraft tube may be finished with an outer layer of white paper or plastic via a convolute winding process, integrating full-color graphics, custom branding, or functional coatings for composite cans and premium packaging tubes. This hybrid approach is popular in retail, promotional, and luxury packaging sectors.
Paper tubes and cores are ubiquitous in daily life. They're integral to products such as paper towels, tissue rolls, aluminum foil, and plastic wrap. Open your kitchen cabinet and you'll likely find paper canisters, composite cans, and other reliable paper tube containers. The same core manufacturing technology is found in fiber drums, drinking straws, and disposable paper cups.
Machines for producing fiber drums, straws, paper cups, and composite cans utilize technology and design principles similar to those in automated paper tube winding. Innovations in these machines support higher production speeds, enhanced dimensional control, and specialized tube performance.
Leading paper tube manufacturers and original equipment manufacturers have developed patented and proprietary technologies for producing tubes and cores with superior strength-to-weight ratios, lighter weights, and tailored mechanical or chemical barrier properties—such as the SIRPAK® linear tube forming system for non-round composite cans.
After formation on a spiral or convolute winder, paper tubes are cut to the required finished lengths. This step is pivotal for producing packaging tubes, mailing tubes, or industrial cores that meet exact customer size requirements. Inline rotary blade cutters allow for high-speed, continuous cutting; for thicker or specialty tubes, offline saws or recutters are used. Inline cutting is ideal for long production runs requiring tight tolerances—important for packaging, protective mailing applications, and industrial core manufacturing.
Rotary blade cutting offers extremely clean, sharp edges and very low variation in length, making it well-suited to converter and printer customers who require consistent precision. For thicker-walled tubes, saw cutting is sometimes necessary—but it typically generates more dust and requires additional deburring. Understanding the available tube cutting processes is key when specifying custom tubes or industrial fiber cores for specific end uses.
The finished strength and appearance of a paper tube can be significantly enhanced by secondary surface treatments and finishing operations. Dip or immersion impregnation with wax, resin, silicone, or other waterproof coatings increases moisture resistance and food safety, crucial for packaging tubes, composite cans, and shipping containers. For specialty winding applications, machine operators may polish the internal and external tube surfaces, removing burrs for smoother loading and unwinding.
Custom printing, high-resolution graphics, and labeling wraps can be applied inline or offline, allowing brand owners and OEMs to differentiate their packaging and reinforce brand presence across product lines.
Depending on the application, tubes may be left open-ended for uses such as forms, spacers, or protective sleeves, or finished with specialty capping, flanging, or end-forming for conversion into paper cans, composite packaging, or sealed shipping containers. Tube end closures are a critical consideration in protective packaging, food packaging, poster tubes, and mailing tube applications.
Value-added manufacturing operations—like embossing, slotting, die-cutting, and window punching—support functionality for tape, label, and film winding. Side windows may be die-cut to create product viewing windows, while embossing boosts grip and handling in industrial tube or core use.
End closure options for paper tube packaging and product protection include:
Multi-part telescoping tubes—two-piece adjustable or three-piece premium designs—are often specified for high-end packaging such as wine, cosmetics, promotional kits, and valuable document storage. Rolled and crimped end closures offer distinctive product differentiation and improved performance in moisture protection and tamper-resistance.
Paper tube-based packaging isn't limited to dry goods. For wet or frozen products, such as frozen juice concentrates, flanged, sealed, and metal-capped ends provide reliable, leak-proof packaging. "Tin end" can seaming creates a hermetically sealed solution that meets FDA, food safety, and consumer protection standards.
Palletizing and packaging are final but vital steps in paper tube production that ensure products arrive safely and undamaged at customer facilities. Many manufacturers offer flexible palletizing solutions, including shrink-wrap, corrugated cartons, bundle strapping, and returnable steel carts to suit varying shipping, storage, and in-plant logistics needs. Robust packaging not only protects the product but also reduces costly damage during transit, improves warehouse efficiency, and enhances customer satisfaction.
Paper tubes, mailing tubes, and industrial cores are commonly shipped in:
Some paper tube manufacturers also provide contract filling, assembly, and direct packaging services, allowing users to integrate their finished goods into paper-based packaging, reduce supply chain complexity, and improve sustainability initiatives through the use of recyclable and biodegradable packaging tubes and cores.
The majority of paper tubes and paper cores are constructed from strong, reliable materials such as kraft paper and paperboard—derived from sustainable wood pulp, cellulose, or reclaimed fiber. These materials offer excellent strength-to-weight ratio, making them ideal for packaging, converting, winding, and shipping tubes. Typically, paperboard is considered to be 12 points (0.012 inches) or thicker (by TAPPI standards) and above 250 g/m2 by ISO standards.
Kraft paper is the industry standard for manufacturing high-strength paper tubes. Its long-fiber composition provides excellent burst strength, dimensional stability, and resistance to crushing or compression under heavy loads—key requirements for industrial cores, mailing tubes, and protective tubes. Kraft’s exceptional durability makes it a preferred choice for both spirally and convolutely wound products in challenging storage and transport environments.
Coreboard paper, a specialized grade of paperboard, is often manufactured from 100% recycled materials and engineered to meet the requirements of high-performance tube cores. Eco-friendly options such as uncoated recycled board (URB) are increasingly used in sustainable packaging and shipping applications.
Each paper tube comprises one or more plies, typically layered as:
Tubes can be engineered with single or multilayer combinations. These combinations may include specialty liners for moisture or vapor protection (foil, VCI, plastic), printable outer wraps for retail or branding, or food-safe plies for direct food contact packaging.
Common liner and wrap materials include:
Manufacturers can create engineered solutions with non-paper ply materials, such as electrically insulating papers, phenolic-impregnated kraft, aramid fibers (Nomex, Kevlar), and fiberglass webs for demanding industrial, high-temperature, or electrical insulation applications.
By selecting specialty combinations, users can address niche requirements for conductivity, anti-corrosion (VCI paper), high voltage dielectric strength, flame retardancy, or premium appearance for luxury goods packaging. Non-paper winding materials enable tubes and cores for use in medical, automotive, aerospace, and electronics industries, as well as for high-performance storage or transport solutions.
Three notable specialty tube types include:
Specialty ply materials and advanced adhesives further enable customization. Adhesives are usually water-based (e.g., polyvinyl alcohol, dextrin), with options for hot melt or thermoset resins in demanding applications. Tubes may be impregnated with wax, resin, silicone, or other polymers to impart specific barrier, mechanical, or electrical properties—opening vast possibilities for innovation in the paper tube, core, and composite can markets.
Whether your needs are in shipping, packaging, point-of-sale, protective storage, or industrial converting, understanding the range of materials, manufacturing processes, and finishing options will help you select or specify a paper tube solution that meets your requirements for strength, sustainability, branding, and regulatory compliance.
Paper tubes are made by winding multiple layers of paper or paperboard, while "cardboard tube" is technically incorrect, as cardboard includes a corrugated middle layer not present in true paper tubes.
Spiral wound tubes are ideal for applications like mailing, packaging, and tape cores, while convolute wound tubes offer greater strength for industrial winding, converting, and heavy-duty uses such as textile or paper mills.
Custom-shaped paper tubes, including square, oval, or hexagonal profiles, are created using specialized winding mandrels, allowing for tailored packaging, storage efficiency, and unique product contours.
Paper tubes are typically constructed from kraft paper and paperboard for strength, with specialty liners, foils, plastics, or recycled materials added for moisture resistance, food safety, and enhanced performance.
Finishing options include wax or resin impregnation for moisture protection, custom printing for branding, surface polishing for smoothness, and various end closures like plugs, caps, and crimped seals.
Yes, many suppliers provide eco-friendly tubes made from recycled content and offer local palletizing, including shrink-wrap, corrugated cartons, and returnable steel carts for streamlined shipping and sustainability.
Paper tubes are measured and specified based on their inner diameter (ID), wall thickness, and length. For packaging or containment applications, the ID and length should correspond to the dimensions of the product being packed.
The product being packed should fit snugly within the tube to prevent movement during shipping, while still allowing enough clearance between the product and the tube's inner diameter (ID) to ensure easy insertion.
For products such as powders, granules, chemicals, or grease, the required volume per paper tube canister will determine the necessary dimensions. The outer diameter is less critical for mailing tubes or any paper tube canisters.
In summary, the wall thickness of a paper tube affects its flat crush resistance. It should be thick enough to prevent crushing during shipping, handling, and storage, but not so thick that it increases costs and reduces the lightweight benefits of using a paper tube.
Paper cores used in heavy converting usually need thicker walls to endure the stresses from winding. The required wall thickness depends on the width and diameter of the web materials being wound. For example, a narrow adhesive tape roll for retail packaging can use a thinner wall, while a paper core for winding a large roll of tape, film, paper, or cloth converted from a jumbo roll requires a thicker wall.
The dimensions of concrete form or piling tubes are determined by the required diameter of the concrete piling or support. Typically, large inner diameter (ID) paper tubes are specified for these applications.
Dimensional tolerances are also an important consideration. Tight tolerances should only be specified if truly necessary for the application, as over-specifying them can unnecessarily increase costs. Fortunately, paper tubes and cores are formed on a steel mandrel, which provides excellent control over the tube's inner diameter (ID).
Paper tubes and cores can absorb and release moisture over time, leading to shrinkage, expansion, or changes in their dimensions. Dimensional stability depends on the tube's resistance to moisture absorption or drying out.
Blade-cut tubes can maintain much tighter tolerances than saw-cut tubes, which is important when the paper tube is used for spacing, masking, or protecting threads, shafts, spindles, and other mechanical components. The difference between smooth blade-cut edges and rough saw-cut edges is evident in the image.
| Dimensional Manufacturing Capability of Several Leading Paper Tube Suppliers | ||||||
|---|---|---|---|---|---|---|
| Leading Manufacturers of Paper Tubes and Cores | ID Range (inches) | Wall Thickness Range (inches) | Length Range (inches) | |||
| Min | Max | Min | Max | Min | Max | |
| Ace Paper Tube Corporation | 0.25 | 10 | - | 0.5 | - | - |
| Chicago Mailing Tube | - | - | 0.025 | 0.75 | 0.25 | 350 |
| Heartland Products Group LLC | 0.375 | 20 | 0.03 | 0.0725 | 0.5 | 60 |
| Paper Tubes & Sales | 0.51 | 30 | 0.03 | 0.75 | 0.25 | 53 |
| Valk Industries, Inc. | 1 | 16 | 0.018 (2 piles) |
0.75 (23 piles) |
0.375 | 50 |
| Wes-Pac Inc. | 0.5 | 10 | 0.025 | 0.5 | 0.25 | 300 |
| Western Container Corp. | 0.31 | 24 | 0.024 | 0.75 | 0.25 | 300 |
Understanding the capabilities of paper tube manufacturers can help determine what sizes are available and feasible. The table above reviews the manufacturing capabilities of several leading paper tube and core suppliers. Here is a summary of the dimensional manufacturing capabilities of these top suppliers:
While the table shows the range of available sizes, it is essential to contact the manufacturer to confirm whether they can produce a paper tube with your specific dimensions on their winders and cutters. For example, a paper tube with an inner diameter of 0.25 inches, a wall thickness of 0.75 inches, and a length of 0.375 inches may not be feasible.
Even if your project falls outside a manufacturer’s current capabilities, new tooling or machinery can be acquired and amortized for high-volume projects with sufficient annual order quantities. Paper tube tooling is generally less expensive than tooling for other manufacturing processes, such as injection molding or extrusion.
When ordering paper tubes, paper cores, or other paper tube products, it is crucial to discuss the end-use or application with the manufacturer. Their engineers and experts can recommend the appropriate materials and strength requirements (such as flat crush, radial crush, dynamic, or burst resistance), as well as any additional features or modifications needed to meet your specific application demands.
For instance, paper concrete form tubes must support the weight of the liquid concrete. If you are pouring concrete to a greater depth, the wall thickness and strength of the tubes must be adequate to handle the increased pressure.
Typically, commercial-grade form tubes can support concrete pours up to 20 feet in depth, while contractor-grade tubes are suited for pours up to 12 feet. Concrete form tubes are available in diameters as large as 60 inches, but the most common sizes are 6, 8, 12, 15, 16, 18, 20, 24, and 36 inches.
Paper cores for converting or winding web materials are commonly available with inner diameters of 3 or 6 inches, and come in various performance or strength levels. Higher-strength or higher-grade cores are suitable for larger finished roll sizes, heavier weight rolls, and higher winding or unwinding speeds.
The table below displays the paper core grades from the Graphic Communications Association (GCA) and the Composite Can and Tube Institute (CCTI). It outlines the minimum performance requirements for each grade. Additionally, CCTI offers Automated Paper Mill Core guidelines in an Excel spreadsheet to help determine the recommended core grade for your specific application.
| GCA and CCTI Paper Core Grades and Test Performance | ||||||
|---|---|---|---|---|---|---|
| Paper Core Inside Diameter(ID) (inch) | Paper Core Grade | Minimum Test Performance for the Grade Code | ||||
| GCA Code | CCTI Code | Harmonized or Combined Code | Flat Crush(lbs./4 inch.) | Dynamic or Cyclic Load Test(KN/10cm) | Flexural Stiffness or Bend Strength Test (kN-sq.m) | |
| 3 | L | 4 | 3-L4 | 600 | 15 | 6 |
| 3 | M | 6 | 3-M5 | 850 | 25 | 10 |
| 3 | F-Fiber | 9 | 3-F9 | 850 | 25 | 10 |
| 3 | H-Hight Strength | 12 | 3-H12 | 1000 | 35 | 12.5 |
| 3 | X-Extra High Strength | 14 | 3-X14 | 1200 | 42 | 15 |
| 3 | U-Extra High Strength | 16 | 3-U16 | 1400 | 50 | 17.5 |
| 6 | L | 4 | 5-L4 | 350 | 25 | 32 |
| 6 | M | 6 | 6-M6 | 400 | 35 | 35 |
| 6 | F-Fiber | 9 | 6-H12 | 750 | 60 | 55 |
| 6 | H-Hight | 12 | 6-H12 | 750 | 60 | 55 |
| 6 | X-Extra High Strength | 14 | 6-X14 | 800 | 70 | 60 |
| 6 | U-Extra High Strength | 16 | 6-U16 | 850 | 80 | 65 |
In addition, a paper tube or core inquiry or request for quote (RFQ) should include an estimate of the number of paper tubes or cores required and how often they will be reordered. Many custom paper tube manufacturers have minimum order quantities.
Moisture adsorption and water resistance can be important properties for many applications. Cobb testing is typically used to measure the moisture absorption properties of paper. A paper tube’s dimensional stability due to the resistance to moisture absorption or release (drying out) is another important property.
Shrinkage or swelling can cause paper products to warp or distort, which would be troublesome in paper core applications where the material is being wound up. A bent, warped or out-of-round tube would generate wrinkles and other defects in a web material such as adhesive tape, paper, plastic film or foil.
A TAPPI survey indicated 50% of the web breaks in paper mills were the result of roll or core defects. A large run of material could quickly turn into waste if the paper core straightness, roundness, and strength are not within the specifications required for the application.
Smoothness and the grooves from the spiral winding process can create wrinkles during web winding. External burrs from saw cutting could also generate a wrinkle. To reduce wrinkles, you might want to request that your outer paper core surfaces are skived and polished to increase smoothness.
A low-quality paper core can result in web breaks and exploding rolls, which can cause a paper mill or plastic film plant thousands of dollars and possibly damage equipment and harm workers. Several different mechanical tests are used to measure the strength and suitability of paper tubes and core for specific applications including flat or side-to-side crush, radial crush, flexural or bend, ring, and dynamic load testing.
The industrial test methods in this standard are divided into two parts. Part one determines the flexural modulus and Bending Stiffness of a paper using modal analysis and three-point bending testing procedures. Part two provides a method for calculating the theoretical critical speed of paper cores used on printing presses and high-speed web converting machinery.
Tests for performance under bending stresses and roll vibrations during winding and unwinding of web materials. Flexural stiffness is also a predictor for resistance to core explosions. Flexural strength or bend strength tests measure the resistance to a paper core sagging under an applied load to the center of a length. Sagging or distorted cores can cause vibration and misshapen rolls.
Tests for crushing performance of a paper tube or core during handling and transportation of a roll wound around a paper core. Flat crush strength tests push two flat plates or anvils against the outer walls of a tube to measure the crush strength. Flat crush strength is useful for paper tubes and composite cans for packaging applications.
For paper cores, the radial crush test better simulates the load conditions during winding.
Tests for performance under cylindrical loading during winding and unwinding in paper mills, plastic film plants and other web making facilities. Dynamic strength testing measures the maximum roll weight a core can support between core chucks in terms of lifetime or number of revolutions.
In my experience, I have found that materials often fail at lower stresses or loads when cyclic loading conditions versus static loads. Dynamic load or dynamic strength testing simulates the effect of cyclic loads generated by tension and the high-speed revolutions of the roll during winding.
Large rolls of paper, film and other materials generate an enormous amount of momentum during winding. When rolls are accelerated or braked the torque is transferred to the core through the core chucks and the tension of the web, which eventually results in core chewout or tearing apart of inner diameter of the core by the chuck. I believe that chewout is an area requiring improved test methods.
Two standards organizations, International Standards Organization (ISO) and Composite Can and Tube Institute (CCTI), provide test methods for flat crush testing: ISO 11093-6:2005 Paper and board — Testing of cores — Part 6: Determination of bending strength by the three-point method and Core Compression (Side-to-Side Flat Crush, CCTI T108). Composite Can and Tube Institute (CCTI) provides standards on measuring the dimensions of composite cans, tubes and core. CCTI also has standards for dimensional stability, water vapor permeability (moisture resistance), and warpage measurement.
The Technical Association of Pulp and Paper Industries (TAPPI) provides standards for the paper raw materials such as paper and paperboard used to manufacture paper tubes, paper cores, paper discs, paper caps, paper end caps and paper spools.
A wide variety of industries consume paper tubes to meet several different end use functions including:
Containing and packaging is probably the largest application segment for paper tubes. Mailing or shipping tubes are used to package large documents with folding such as maps, posters, prints of artwork, original paintings, blueprints or engineering drawings and architectural plans.
Powder tubes are designed for holding dry goods and granulated materials. They frequently feature rotary shaker or sifter tops to aid in dispensing, similar to disposable salt and pepper shakers.
Frozen lemonade and cookie dough are packaged in food-grade paper tube cans, which include liners and sealed ends to ensure the safe containment of the food products. Telescopic tubes are commonly used for packaging wine bottles, perfumes, and cosmetics.
Push-up tubes with oil-resistant liners are ideal for dispensing lip balms, lubricating grease, caulks, adhesives, deodorants, and repair compounds.
Chemicals, active pharmaceutical ingredients, pesticides, and fertilizers can be packaged in paper tube cans and composite drums by first lining the container with a plastic bag.
Another application that I find particularly intriguing is the use of paper tubes in construction. Large-diameter, spiral-wound paper tubes are employed to form concrete pilings by pouring concrete into the tube, which often includes rebar and remesh for reinforcement. Smaller-diameter paper dowel sleeves are used to create voids or channels within cast concrete, allowing space for communication cables, electrical wiring, and plumbing. Additionally, some architects have explored using paper tubes as framing materials for emergency or temporary shelters.
Paper tubes naturally dampen vibrations thanks to the fibrous structure of the paperboard. Additionally, they offer superior thermal insulation compared to metal tubing.
Specialized dielectric crepe or kraft papers can be used to create electrically insulating or dielectric paper tubes. Engineered papers and saturation with specially formulated resins can enhance either thermal conductivity or insulation properties.
Paper tubes are utilized to safeguard various mechanical components, including spindles, bolt threads, polished shafts, end mill teeth, plug gauges, and drill bits. By covering spindles or bolt threads with a protective tube, you can prevent impacts from other metal parts that might otherwise nick or distort the threads.
Paper tube masks are slid over threads or shafts to enable the targeted application of coatings or adhesives while protecting the areas covered by the mask from being coated.
Paper tubes serve as display poles to support signs in stores and exhibits. They are also used as spacers in packaging to prevent movement and protect products from damage. For example, paper tube spacers are employed to position and safeguard automotive wheel hubs during shipment. Additionally, paper tube spacers can function as reinforcing corner posts and supports within various packages.
Paper cores, paper cones, and paper spools are commonly used for winding, carrying, and dispensing materials such as wires, cables, tubing, foils, yarn, rope, and other roll stock. A paper spool typically features a paper core with two chipboard flanges. In the agricultural industry, paper cores are even utilized to roll up sod.
Paper tubes and cores have several advantages compared to plastic or metal tubes:
Paper tube and cores have drawbacks compared to similar products made from metals, plastic or glass:
| Paper Packaging Has Low Density | |
|---|---|
| Packaging Material | Density (Ib/ft³) |
| Kraft Paper | 43 |
| Aluminum | 168 |
| Glass | 157 |
| PET Plastic | 87 |
Industries are increasingly adopting eco-friendly and sustainable packaging solutions, like paper tubes, to lower their carbon footprint and enhance their image with customers. Many consumers favor eco-friendly packaging, which can influence their purchasing decisions.
The marketing, consumer acceptance, and cost benefits of paper tubes in packaging and product selection are evident. Additionally, using paper tubes can help lower costs associated with complying with environmental regulations for plastics and metals, as they are free from volatile organic compounds (VOCs) and heavy metals, which are often regulated.
Customers purchasing paper tube products should have to be as concerned with compliance to:
Paper tube and core manufacturing is a very eco-friendly and sustainable process for several reasons:
Collection and Reuse Programs - Many paper tube manufacturers have a paper tube and core collection and re-use programs to facilitate the gathering of used cores from their customers as well as paper and paperboard scrap from their communities.
Natural / Eco-safe Material – Paper tubes and cores are made from natural plant materials and are ecologically safe because they do not contain any toxic chemicals or heavy metals. Paper tubes buried in the earth will compost in 1 to 2 months and add nutrients back into the soil.
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