This article contains a description of mailing tubes, how they are made, and their use.
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A mailing tube is a robust and durable cardboard container specifically designed for shipping long, slender items like rolled-up maps, banners, and posters. Its strong exterior ensures protection and security for the contents, while also facilitating easy handling.
Mailing tubes are available in various shapes, including cylindrical, triangular prism, and square prism forms. They are constructed from durable paperboard or corrugated board. Cylindrical tubes are created by winding Kraft and test paper around a mandrel, while triangular and square tubes are manufactured like foldable boxes. Regardless of their shape, all mailing tubes are built to endure the rigors of mailing and shipping.
Mailing tubes are made from Kraft paper, test paper, and paperboard, which are glued or folded into tube shapes. The selection of materials depends on the required durability, as these tubes may need to protect valuable items or confidential documents. Mailing tubes are sealed with options such as plastic or aluminum caps, folded cardboard, or tape. The choice of seal type depends on the nature of the items being shipped and the level of security needed.
Packing and shipping materials have evolved over time to address advancements in technology and different shipping methods. In the past, long items were typically placed in boxes or wrapped in paper, with no guarantee against damage during transit.
Today’s mailing tubes have been refined to meet the demands of contemporary shipping. Available in various lengths, widths, shapes, and materials, they are designed to cater to specific business needs. Their durability and strength ensure they perform effectively. Moreover, once they are no longer needed, the materials used in mailing tubes can be recycled and repurposed.
Telescoping mailing tubes, also known as adjustable tubes, feature a design that allows their length to be extended to fit various sizes of documents, maps, banners, parts, and posters. They are constructed with spiral-wound thick, heavy-duty cardboard walls. These tubes consist of a smaller tube that slides in and out of a larger outer tube, enabling adjustment to the length required for the item being shipped.
The robust construction of telescoping mailing tubes makes them suitable for shipping heavy and elongated items such as metal rods and long industrial parts. Their design facilitates quick customization to accommodate any length. To secure the tubes and prevent retraction, tape or a label is applied at the connection point between the tubes.
Snap seal mailing tubes, also known as crimped end tubes, eliminate the need for tape and end plugs. To use a snap seal mailing tube, one end is crimped while the other end remains open. Items can be easily inserted through the open end, and once fully loaded, the open end is crimped to seal the tube. This crimping process is simple and effective, providing a secure seal. Despite being among the most economical types of mailing tubes, snap seal tubes maintain a strong, rigid structure similar to other types of mailing tubes.
The convenient design of snap seal mailing tubes allows for quick opening and closing, creating a tight, firm seal that stays closed. These tubes are made from wound Kraft paper glued around a mandrel and are available in lengths ranging from a few inches to three or four feet.
The manufacturing of triangular mailing tubes is similar to that used to produce boxes. They are die cut with flaps to be folded and glued. The main benefit of triangular cardboard mailing tubes is that they lay flat and can be stacked without rolling or shifting. In the majority of cases, they are made of corrugated board with flaps and come in a wide variety of lengths from ones that are less than a foot up to ones that are three to four feet.
Triangular mailing tubes come with adjustable widths on their three sides, allowing manufacturers to customize them to meet specific product requirements. The dimensions of a triangular mailing tube include its length, the width of the sides, and the size of the opening, all of which can be tailored to fit the desired specifications.
Unlike cylindrical tubes, triangular mailing tubes offer different types of openings. One configuration features openings at both ends with three overlapping flaps to seal the tube. Items are inserted into the tube by sliding them through one end, similar to a cylindrical tube.
Another configuration resembles a box with flaps and a lid. In this design, one side of the tube acts as the lid, while the ends are sealed and glued like a box. Items are placed through the side of the tube, and after loading, the lid is closed and taped securely.
The variety of opening configurations in triangular mailing tubes allows for precise adjustment to meet specific product needs. This versatility contributes to the popularity of triangular mailing tubes.
Plastic plug mailing tubes are an alternative to snap mailing tubes and have a plug that fits into the end of the tube to replace the snap configuration. They are manufactured using the same method as snap mailing tubes by being wound on a mandrel with overlapping layers of Kraft paper. Plastic plug mailing tubes come in several different designs, which vary depending on the type of plug being used.
The variations in plastic plug mailing tubes primarily relate to the type of sealed end, which can be closed with a permanent metal plug, a cardboard flap, a permanent plastic plug, or a removable plug. The choice of end type depends on the manufacturer and the specific design of the tube.
Plastic plug mailing tubes are available in a wide range of lengths and diameters, with lengths extending up to several feet and diameters ranging from a few inches to nearly ten inches. The plugs are designed to fit snugly into the tube, creating an impenetrable seal that protects the contents from dust, dirt, water, and other contaminants.
Metal plug mailing tubes offer a more permanent and durable alternative to plastic plug tubes. Metal plugs come in different styles, including those similar to plastic plugs that can be wedged into the end of the tube, and self-gripping or self-locking plugs that are permanently affixed using a mallet after insertion.
Metal plug mailing tubes typically feature one accessible end, while the other end is permanently secured. The plugs are made from heavy-duty materials, ensuring they can withstand multiple uses. They are available in diameter sizes ranging from just over an inch to nearly nine inches.
In the mailing tube packaging industry, plastic, metal, or other forms of plugs are also known as enclosures and are specifically designed to meet the varying shipping needs of a wide variety of applications.
Curled end mailing tubes, also known as rolled edge canisters, come in various designs including two-piece, three-piece adjustable or telescoping tubes, and single-piece tubes. In one design, the circumference of one end of the tube is folded inward, and a round piece of heavy paper or cardboard is glued over the folded edges to secure the end.
In a two-piece adjustable curled end mailing tube, the telescoping section features a curled end sealed with a piece of paper or cardboard. A three-piece design includes a single-piece tube without end seals that fits into two separate curled end tubes, each with one end curled and sealed.
The different designs of curled end mailing tubes are illustrated in the diagrams below.
Paper cap mailing tubes are one of the oldest types of mailing tubes, featuring end caps made from paper shaped like cups that cover the ends of the tube. These caps are crafted from sturdy Kraft paper, with one end glued or stapled to secure it, while the other end remains removable for loading the tube.
Square mailing tubes are constructed similarly to boxes and are typically die-cut. They can be designed with one end open, resembling a long box, or with an open side, similar to a traditional box. Much like triangular mailing tubes, square mailing tubes are flat and stackable, preventing them from rolling or shifting. They are available in white coated paperboard or corrugated paperboard, both of which offer durability and can handle the demands of shipping.
Once shaped, square mailing tubes are delivered flat and must be folded by the user. This folding process is quick and can be secured with tape or glue to complete the setup.
Kraft paper is a key material used in producing corrugated cardboard and paperboard. It is employed as the outer layer of these boards due to its considerable weight, thickness, and durability. Kraft paper provides exceptional rigidity and stiffness to boxes and tubes, helping them retain their shape during use.
The production of Kraft paper involves pulping, a process where tree fibers are ground down into a pulp paste or slurry. Once processed, Kraft paper can be coated or laminated to improve its strength and protective qualities.
Paper production starts with transforming wood chips into wood pulp. The process begins by mixing the wood chips with hot water, sodium hydroxide, and sodium sulfide, and then placing them under pressure in large containers known as digesters. Each batch of pulp can range from 10 to 20 tons. The chemicals and water work to break down the lignin, hemicellulose, and cellulose, with the goal of separating lignin from cellulose, as lignin does not contribute to good paper quality.
Lignin is the component in wood that binds the fibers together and constitutes about 25% of a tree's structure. The remaining 75% is divided between 50% water and 25% cellulose fiber. The pulping process focuses on extracting cellulose fibers while removing lignin.
Initially, bark and large wood chips that are unsuitable for pulping are removed. The cleaned and suitable wood chips are then sent to the digester for chemical processing. It is in the digester that lignin is dissolved and separated from the cellulose fibers, leaving behind the desired cellulose for paper production.
Despite the effectiveness of the digester, some contaminants may remain in the fibers, which are addressed during the bleaching process. In this stage, the pulp is treated with bleach and water in a sequence of steps designed to eliminate any residual lignin. As the pulp undergoes bleaching, it progressively becomes whiter, resulting in a highly brightened end product.
After the bleaching process is complete, the pulp is ready to be converted into Kraft paper or paperboard.
Before the pulp is fed into the paper-making machine, various additives are introduced to improve its strength, with sulfate being the primary additive for Kraft paper. The pulp is then spread onto a wire screen to allow excess water to drain, causing the fibers to mat together. To advance the drying process, the paper layers move through a series of rollers and dryers, a process known as calendaring, which compresses, presses, and smooths the paper.
By the end of the initial drying phase, approximately 84% of the water content is removed from the paper. To ensure complete fiber bonding, the paper undergoes additional steam heating to finish the drying process before it is collected on steel cylinder rollers.
Kraft paper comes in various types, but only the strongest and most durable varieties are selected for producing cardboard mailing tubes. The paperboard and corrugated board used for manufacturing these tubes are made from the highest quality Kraft paper to ensure optimal strength and resilience.
Virgin natural Kraft paper is utilized in the production of cardboard boxes and mailing tubes due to its excellent tear resistance and high bursting strength. This type of Kraft paper can be layered to enhance durability and is essential for making both paperboard and corrugated board.
Recycled Kraft paper, which is less robust compared to virgin Kraft paper, is typically used for the inner layers of cardboard products.
Clay-coated Kraft paper is used for manufacturing boxes and is available in various finishes including white, glazed, grease-resistant, and ribbed.
Laminated Kraft paper features an additional coating that improves its strength and provides consistent quality. This type of paper is known for its dimensional stability and exceptional stiffness.
The types of Kraft paper mentioned above are just a few examples of its many varieties. Kraft paper is widely used for making paper bags, frame backings, steel production, and specialized packaging materials. The mentioned types are particularly common in the production of mailing tubes.
Cardboard mailing tubes come in two main types, each produced through distinct processes. The manufacturing of cylindrical cardboard tubes involves a specific set of procedures that differ from those used for creating square and triangular tubes, which follow similar methods to box production.
Square and triangular mailing tubes are created from sheets of corrugated cardboard or paperboard, which are cut and shaped accordingly. In contrast, cylindrical cardboard tubes are constructed by gluing sheets of Kraft paper and wrapping them around a mandrel.
The initial stage in producing cylindrical mailing tubes involves cutting large rolls of Kraft paper into narrower strips. Multiple strips may be combined and fed onto a mandrel to form the sides of the tube. Typically, sturdy and durable Kraft paper is utilized to ensure the tube remains rigid and robust.
The wall thickness of the tube is determined by the number of layers of Kraft paper wound onto the mandrel as well as the thickness of the paper itself.
Prior to the paper ribbons being wrapped around and fed by the winder onto the mandrel, they pass through an adhesive bath, which is a cascading gluing system that pumps glue onto each ply or layer of paper. As the access glue accumulates, it is wiped off and sent back into the system.
The winder collects and wraps layers of paper around the mandrel, continuously pulling the paper ribbons to create a spirally wound tube. The coordination between the mandrel, winder, and adhesive is crucial to the tube formation process.
The paper ribbons are wrapped around the mandrel, which sets the inner diameter (ID) of the mailing tube. Before the glue-coated ribbons are wound around the mandrel, an unglued inner liner is applied to prevent the glued ribbons from sticking to the mandrel, allowing the tube to slide easily for the cutting process. The thickness of the cylindrical mailing tube is determined by the number of layers of paper ribbons wrapped around the mandrel, including the thickness of the Kraft paper used.
The winding of paper ribbons around the mandrel is a continuous operation. Once each tube is formed, it progresses along the mandrel to the cutting machine. The machine grabs and rotates the tube while a cutter trims it to the specified length. Manufacturers may use different cutting methods, such as knives, saws, or other tools. The cutting process is designed to be swift to prevent burrs or rough edges, with the length of the mailing tube being determined by the movement of the cutter.
In one cutting method, multiple knives are arranged in a row. The spacing between these knives and their number are adjusted to achieve the desired tube lengths, allowing for the simultaneous cutting of several tubes to enhance production efficiency.
The initial phase in producing triangular and square mailing tubes involves designing the shape using computer-aided design (CAD) software. This software generates a graphic representation of the box's desired shape and dimensions. The design can either be a standard template suitable for various products or customized to fit specific customer requirements. The resulting graphic is reviewed to create a digital file, which is then used to produce a die for cutting out the box.
Mailing tubes are constructed from either paperboard or corrugated board, with the choice of material influenced by the intended use and expected handling conditions. Corrugated board is generally recognized as the more robust and resilient option compared to paperboard.
Paperboard – Paperboard is a widely used material in the packaging industry, commonly found in milk cartons and various commercial product packaging. It is produced from Kraft paper and test paper, with test paper making up the inner layers and Kraft paper forming the outer layers. Paperboard is suitable for mailing tubes that face less rigorous conditions and require less protection.
Paperboard is best suited for mailing tubes that are not subjected to severe handling and for packaging items that require minimal protection. Despite its strength, paperboard lacks the impact resistance offered by corrugated board.
Corrugated Board – Corrugated board is built to endure heavy-duty use. It comes in various forms, each featuring an outer layer of Kraft paper, a middle layer of wavy fluting, and an inner layer of additional Kraft paper or test paper. This construction makes corrugated board ideal for supporting substantial weights. Mailing tubes made from corrugated board are used for shipping heavy tools, equipment, and other substantial items. Due to their robust impact resistance, corrugated mailing tubes are often reused and are effective for both shipping and storage.
A cutting die is utilized to shape boxes from flat sheets of paperboard or corrugated board. The die features cutting edges known as rules, which can be either sharp to cut through the cardboard or slightly dull to score the material for folds, flaps, and other creases.
Foam is used on the die to secure the cardboard in place, preventing it from shifting and avoiding damage. This foam also assists in guiding the rules accurately into the sheet, ensuring precise cuts.
For large-scale production of mailing tubes, multiple dies are arranged around a rotating cylinder. As extensive sheets of paperboard or corrugated board move through, the cylinder rotates and presses the dies against the sheets, rapidly producing numerous mailing tubes.
Dies are available in various sizes, shapes, and dimensions. Box manufacturers maintain a range of dies that can be affixed to cylinders for the efficient production of mailing tubes. This method ensures high precision and consistent quality in the finished products.
After being cut by the die, the boxes are stacked, bound, and readied for shipment. They are kept flat to simplify the shipping process. This method applies to both triangular and square mailing tubes. By palletizing these flat tubes, hundreds can be efficiently handled and transported.
Similar to pizza boxes, triangular and square mailing tubes are folded by the end user as needed. When flattened, these tubes are more compact, making them easier to store and quickly accessible when required.
Advancements in modern technology have led to the development of an array of inventive and sophisticated boxes for product display and shipment. Among these innovations are the diverse types of cardboard mailing tubes, reflecting the continuous evolution in the industry. Manufacturers are dedicated to enhancing the durability and strength of their products to cater to the needs of both delicate and specialized items.
Cardboard mailing tubes play a crucial role in safeguarding products. Designed to endure the demands of millions of shipments annually, these tubes are crafted from various types of cardboard to accommodate both fragile items and robust tools. Their construction ensures reliable protection throughout the shipping process.
In contrast to bulky boxes intended for multiple items, cardboard mailing tubes offer a compact and efficient solution. Their small size and streamlined design allow for easy packing of either multiple items or a single item. This compact nature makes mailing tubes ideal for optimizing space during both shipping and storage.
Cardboard mailing tubes are extensively utilized for safeguarding sensitive and delicate items. Their sturdy, rigid walls and securely sealed ends ensure that the contents remain intact during transit. The construction of these tubes minimizes movement inside, providing enhanced protection against damage and ensuring that items arrive in optimal condition.
For many years, cardboard mailing tubes have been the preferred choice for dispatching blueprints, maps, designs, and prototypes for review or official purposes. Their secure, tight seals make them highly reliable for transmitting important or confidential documents. The robust construction of these tubes prevents breakage, safeguarding the contents and maintaining their confidentiality and security throughout the shipping process.
Shipping documents with envelopes, folders, or bulky boxes can be quite costly and inefficient due to their size and expense. Many companies have discovered that using cardboard mailing tubes for sending documents, prototypes, and plans offers a more economical and practical solution. The streamlined design of mailing tubes reduces shipping costs and saves space, making them a more convenient choice.
During sorting and collection, envelopes and folders often blend in with other mail, making them easily overlooked and mixed with regular or junk mail. In contrast, cardboard mailing tubes have a distinct shape and appearance that makes them immediately recognizable. Their unique design ensures they stand out, emphasizing their significance and ensuring they are not missed.
Given the numerous advantages of cardboard mailing tubes, choosing the right one for your shipment is crucial. Manufacturers typically provide guidelines to help customers select the appropriate mailing tube based on their needs. By paying close attention to these recommendations during the design and selection phases, you can minimize mistakes and protect your items from damage.
The first step in selecting the right mailing tube is to accurately measure the dimensions of the item to be shipped. The tube must be sufficiently large to fit the item comfortably. It's essential to measure both the length and diameter of the item, keeping in mind that for non-circular items, an approximate diameter should be used to ensure a proper fit within the tube.
For items with unconventional shapes, triangular or square mailing tubes might be more suitable, as they can accommodate irregular forms without requiring special adjustments.
Choosing the right durability for a cardboard mailing tube depends on the weight and nature of the item being shipped. For lightweight items like maps, blueprints, and posters, a standard paperboard tube may suffice. However, for heavier items such as tools and instruments, opting for a corrugated board mailing tube is more appropriate due to its enhanced strength and durability.
When shipping fragile items, special considerations are necessary despite their lightweight nature. These items need extra protection to prevent damage during transit. While paperboard mailing tubes may not offer adequate protection, corrugated board tubes are designed to absorb and withstand impact. For added security, select mailing tubes with internal padding or multiple layers of corrugation to provide enhanced protection for delicate and fragile contents.
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