This article provides all that you need to know about tape and label cores and how they are used.
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A tape and label core serves as a sturdy, cylindrical base found in the center of rolls of tape or labels. Although resembling the core of a toilet paper or paper towel roll, it is crafted to offer enhanced durability and strength. Tape and label cores, while sharing a similar shape with those of paper products, vary in terms of strength, size, material composition, and thickness. Thicker cores are typically employed for handling heavier types of tapes and labels.
When evaluating tape and label cores, it's essential to focus on the core size, which denotes the core's inner diameter (ID). The combined overall diameter, comprising the core plus the tape or label, is termed the outer diameter (OD). Moreover, specifying the winding direction is crucial during purchase, as you have eight winding direction options available.
The rewind directions are defined by label placement, being either on the external side or the internal side of the roll. There are four specific rewind directions for labels placed externally and four for those placed internally, each presenting a distinct winding path. Among the eight available winding directions, options 5 and 8 are seldom used, while options 3 and 4 are frequently utilized and highly favored.
Tape and label cores are essential components in the packaging, printing, and converting industries. These cylindrical supports come in various forms and sizes, depending on the materials and manufacturing processes used. Understanding how tape and label cores are made can help businesses select the ideal core for their specific applications, improving performance, production efficiency, and product protection during shipping and storage.
Traditionally, tape and label cores are manufactured from tightly wound paper, formed on a mandrel, and secured with strong industrial adhesives. Kraft paper is the most commonly used material for these traditional paper cores due to its durability and cost-effectiveness. As core requirements have evolved, advanced materials and manufacturing techniques have led to the development of high-performance cores for specialized needs, such as those found in high-volume packaging, printed labels, electrical tapes, and industrial tapes.
Paper cores remain the industry standard due to their eco-friendly nature, recyclability, and affordability. They are utilized in countless applications, including masking tapes, pressure-sensitive labels, double-sided tapes, and thermal transfer ribbons. However, plastic cores are preferred in sensitive environments—such as cleanrooms or food and pharmaceutical packaging—where there is a risk of contamination from paper core dust. Plastic cores are also highly resistant to moisture, humidity, chemicals, and mechanical impact, making them a preferred choice in harsh processing environments. They can be made from advanced polymers such as high-impact polystyrene (HIPS), high-density polyethylene (HDPE), polypropylene (PP), polyvinyl chloride (PVC), and acrylonitrile butadiene styrene (ABS).
The manufacturing process for tape and label cores is similar to that of other cores, with the primary differences being their specialized size (usually measured in inches and millimeters rather than feet and meters), wall thickness, and surface finish. Although tape and label cores are designed to be as robust and durable as those used in heavy-duty industrial applications, they are optimized for compatibility with automated unwinding and rewinding machinery. This ensures smooth processing, minimal downtime, and reduced waste during production runs.
The choice of tape or label core depends on its intended application, which ranges from consumer products—such as retail labels, office tapes, and craft tapes—to industrial uses, including large-format printing, adhesive tape conversion, and specialty laminates. Cores must be engineered to support the roll weight, maintain dimensional stability, and endure the stress of high-speed winding and unwinding operations. The material type and wall thickness—whether plastic or paper—are critical factors in determining a core’s mechanical strength, longevity, and resistance to deformation.
It is important to distinguish between mailing tubes and tape/label cores. Tubes are primarily designed for storing and shipping items such as maps, posters, blueprints, or long, fragile products, focusing on content protection during transit. In contrast, tape and label cores are engineered for holding rolled materials like pressure-sensitive tapes, printable labels, or textile fabrics, and require enhanced structural strength and dimensional accuracy. Tubes are typically thinner and prioritize shipping durability, while cores are thicker, more resilient, and optimized for conversion processes and automated equipment compatibility.
Tape and label cores are made from either plastic or paper, depending on the core’s final use and the type of product being wound. Plastic is typically chosen for sturdy, heavier, and stronger-wound materials that demand high impact resistance and minimal particulate contamination, such as specialty industrial adhesive tapes, thermal transfer barcode ribbons, or medical-grade tapes. Paper cores are ideal for light to medium-duty tapes and labels, including packaging tape and retail price labels, and can provide excellent value and sustainability for many industries. In cases where strength is needed, paper wound cores can be manufactured with additional plies for added wall thickness. The manufacturing techniques for paper and plastic cores differ significantly, due to the material properties and intended end-use.
Paper cores are spiral wound cardboard tubes constructed in layers that may include one, two, or more plies. The liner, or inner core layer, and the wrap, the outermost layer, are made from various grades of specialty paper, including recycled paper, kraft paper, paper-adhesive composites, waterproof cardboard, or dense fiberboard. Recycled paper content is increasingly popular, making paper cores a sustainable packaging option for eco-conscious brands.
The core production process begins with converting large rolls of paper or cardboard into narrow strips, often called ribbons or plies. These ribbons can be precisely cut to specifications, ranging in width from a few inches (about 50 mm) to 10 or 20 inches (approximately 254 mm to 508 mm), depending on application requirements. Thickness is also customizable, from 0.008 inch to 0.050 inch (about 0.20 mm to 1.3 mm), to accommodate heavy or bulky tape and label rolls.
During paper core assembly, the paper strips are fed through a glue application station, where strong adhesives are applied to ensure secure bonding between layers. Manufacturers may use water-based, hot-melt, or solvent adhesives, depending on strength and moisture resistance requirements for the final core. The adhesive must fill the microscopic gaps between each ply, with a penetration depth typically under 20 microns (µ). Factors like adhesive type, bonding strength, core thickness, and the degree of ply overlap significantly influence the final compressive strength and integrity of the paper core. These variables are carefully monitored and optimized to meet client demands for load-bearing capacity, dimensional accuracy, and compatibility with automatic winding/unwinding machinery.
The mandrel—a long, cylindrical steel rod—serves as the form around which the paper plies are wound. The core’s internal diameter is determined by the mandrel size, while wall thickness is set by the number and thickness of plies. Depending on product requirements, the number of plies can vary between 1 and 50, with most commercial applications falling in the 3�30 ply range. Advancements in mandrel technology, such as adjustable or expandable mandrels, allow manufacturers to quickly switch core sizes and inner diameters, which enhances productivity and reduces lead times in custom tape and label core production. During winding, tension, speed, and adhesive application must be carefully controlled to ensure uniform layer bonding and precise dimensional tolerances.
After initial spiral winding and adhesive curing, the long tube is removed from the mandrel and transferred to the next processing stage, where it is cut to the desired core length using precision equipment.
Precision cutting is vital to ensure that each tape and label core meets end-user specifications. Several cutting techniques may be used, but all involve mounting the tube on a rotating mandrel and slicing it using a circular saw, knife, or automated blade system. While small production runs may be handled manually, automated cutters and PLC-controlled slitters are standard in high-volume manufacturing to boost productivity and guarantee uniform core widths with tight tolerances. Modern equipment can accommodate rapid changeovers, enabling production of custom core sizes for specialty converting, printing, and labeling applications.
Plastic tape and label cores are produced using engineering-grade polymers, including high-density polyethylene (HDPE), polypropylene (PP), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), high-impact polystyrene (HIPS), and recycled plastics. Each material offers unique mechanical properties suited for demanding applications and environments, including high strength, chemical resistance, temperature stability, and durability.
Plastic cores are available in variable wall thicknesses and diameters (from 0.5 inches to 3 inches or more), and are widely used in applications requiring consistency, cleanliness, moisture resistance, and dimensional stability over extended production runs. Industries that frequently utilize plastic cores include automotive tape conversion, food packaging, electronics, medical devices, and cleanroom environments.
Extrusion is the most common plastic core manufacturing process. During extrusion, plastic pellets or resins—processed from petroleum-based or recycled feedstocks—are melted and forced through a circular die to create continuous tubes with uniform diameter and wall thickness. The design of the die determines the final internal diameter (ID), while die geometry and screw speed influence wall thickness. Strict process control is essential to achieve core consistency and meet the dimensional requirements of automated rewinding machinery used by commercial tape and label manufacturers.
After extrusion, the continuous plastic tube is cooled and cut into lengths tailored for individual application needs. Automation allows for custom core lengths and quick batch changeovers, delivering flexibility to converters and end users seeking specific core dimensions for their winding processes.
The cutting of plastic cores requires heavy-duty saws or automated rotary blade systems to handle the hardness and resilience of engineering plastics. Precision is crucial, as even minor deviations can result in misaligned tape rolls, waste, or machine jams during rewind operations. Automated equipment with programmable logic controllers (PLCs) is often employed for large-volume production, providing consistent results—even with frequent core size changes—required by diverse customers in tape and label converting.
Once complete, plastic and paper cores are shipped to tape and label manufacturers or converters worldwide. Here, they are loaded into high-speed winding and slitting machinery for use in producing commercial adhesives, label rolls, security tapes, and specialty tapes. It is critical that core widths and diameters precisely match those of the finished rolls to ensure compatibility, prevent edge curling, and support efficient automation in packaging and distribution processes.
The wall thickness of a tape and label core is a key specification that determines core strength, load-bearing capacity, and durability during converting, storage, and usage. Proper wall thickness ensures that cores can withstand the mechanical stresses of rapid winding/unwinding, avoid ovality or collapse under heavy loads, and protect wound materials from deformation.
For paper cores, the most common wall thickness is around 0.125 inch (3.2 mm), though this can be increased for heavy-duty or wide format tape and label rolls by adding additional plies or using denser paper. In contrast, plastic core wall thickness is set during the extrusion process, with standard sizes ranging from 0.024 inch up to 2 to 3 inches (0.61 mm to 50.8 mm or 76.2 mm), depending on the requirements of the application.
Careful selection of wall thickness takes into account the specific tape or label width, core diameter, and weight of the wound product. Thicker walls generally increase crush resistance, minimize flex during use, and help maintain roll integrity during automated processing. Engineers and procurement specialists should consult with core manufacturers to specify the appropriate material and wall thickness based on product type, machinery requirements, and storage or shipping conditions. This ensures optimal performance, minimal waste, and cost efficiency in tape and label converting operations.
Due to their affordability and widespread availability, paper tape and label cores are among the most frequently utilized types of cores. The primary distinction lies in their winding method, with all windings forming cylindrical shapes composed of multiple layers of tightly wrapped paper. The two predominant forms of paper cores are spiral and convolute.
Convolute, or parallel, cores are crafted from a single sheet of cardboard, where the left edge is rolled over the right edge and adhered as the rolling occurs. Unlike ribbon-wound paper, convolute tubes are made from a continuous sheet, resulting in the paper edge being parallel to the tube's axis.
The design of convolute cores provides them with enhanced beam strength, making them suitable for more rigorous tape and label applications. As they are constructed from a single layer of paper, convolute tubes typically have a slightly lower cost than spiral-wound cores. These tubes are generally lightweight and easy to handle but are restricted in the variety of available sizes.
Spiral cores are manufactured by winding ribbons of paper at an angle on a mandrel to form a continuous spiral. The paper for spiral cores is thinner than that used for convolute cores and is made from kraft paper, recycled paper, or certain forms of coated papers. As each layer is applied, it is glued with a high strength industrial adhesive that securely holds the ribbons of paper and provides a smooth even surface.
The spiral core manufacturing process results in a highly smooth surface that is resistant to unraveling or separating. The multiple layers involved in spiral cores give them added strength, durability, and resistance to crushing, allowing them to support heavy loads. In contrast to convolute paper cores, spiral cores are available in a broad range of sizes, from those used in toilet paper rolls to those designed for holding duct tape.
Thermal tape cores, which can be made from either plastic or paper, are designed to hold delicate paper coated with a chemical that changes color when exposed to heat. These specialized cores for thermal tape typically have an inner diameter of 13 mm and 25 mm (0.5 in and 0.98 in) with a wall thickness of 3 mm (0.12 in).
Plastic cores, being extruded, are produced with fixed dimensions. They can be either solid or honeycomb-structured and are available in various colors, such as white, black, green, and blue.
Kraft paper is commonly used in the production of paper cores because of its outstanding strength, durability, and sturdiness. Unlike other types of paper, kraft paper is unbleached, which allows it to retain its structural integrity. Made from wood chips or recycled paper, kraft paper is supplied in large rolls that are cut to the required size and shape for making tape and label cores.
The term "kraft" is derived from the German word meaning strength, force, resistance, and power, aptly describing the paper's superior qualities. The key components for producing kraft pulp include wood fiber, water, chemicals, and heat. The process starts with the cooking of wood chips.
The production of kraft paper starts with the steaming, heating, and cooking of wood chips in pressurized containers called digesters, using a solution known as white liquor. During this cooking process, the tough wood chips are converted into pulp, which is treated with chemicals to enhance its strength and flexibility. In the pre-steaming phase, the wood chips are moistened and heated with steam, allowing water and air to fill the cavities within the chips.
Inside the digester, the wood chips enter at temperatures below 100°C (212°F) and are then cooked at temperatures ranging from 170°C to 176°C (338°F to 349°F) for several hours. The combined liquids, referred to as black liquor, contain lignin fragments, carbohydrates resulting from the breakdown of cellulose, and a mixture of sodium carbonate, sodium sulfate, and other inorganic salts.
Wood chips are composed of two primary structural components: lignin and cellulose. During the kraft paper manufacturing process, it is essential to separate the cellulose from the lignin, as cellulose is the key ingredient in kraft paper production. The chips transition from the pre-steaming stage to the cooking stage within the digester, which may be either vertical or horizontal.
During the recovery process, the pulp undergoes washing and screening. The weak black liquor, which is a mixture of lignin and other substances, is passed through evaporators until its concentration reaches 65%. This concentrated black liquor, rich in energy, is then burned in a furnace.
The wood chips are discharged into a collection tank at atmospheric pressure, releasing steam and volatile compounds that are subsequently condensed and collected. As the chips enter the blow tank, their fibers are separated and broken open.
During the washing and cleaning stage, the kraft pulp is subjected to various processes to remove black lignin and other impurities. Waste liquids are also removed through high-temperature and high-concentration methods. Pulp washing can be performed using single-stage or multi-stage approaches.
The effectiveness of pulp washing depends on factors such as cooking methods, fiber materials, pulp hardness, temperature, pressure, and the degree of vacuum applied. The process is carried out using different types of equipment, including vacuum drums, twin roll presses, single screw presses, disc filters, and gravity disc thickeners.
During the screening process, screens are used to remove larger pieces of shives, knots, dirt, and debris. These screens are arranged in stages to create a cascade effect. This process separates the brown pulp from contaminants, resulting in clean kraft pulp. The separation is achieved through centrifugal forces that push the pulp against the walls of the pressure screener.
The color of kraft pulp is attributed to residual lignin, which is removed during the bleaching process to enhance the pulp's physical and chemical properties. This process involves the use of bleaching agents and can be carried out through reductive or oxidative methods. Equipment used in bleaching includes screw conveyors, drum washers, roll mixers, pulp chloridizers, and bleaching towers. Kraft paper undergoes less intense bleaching compared to other papers because excessive bleaching can weaken the pulp fibers.
The pulp and water mixture is spread over a large mesh screen, where most of the water is drained using gravity, suction, and vibration. In the press section, additional water is removed as the pulp mixture is squeezed between cloth-covered cylinders called wet felts. This is followed by the drying section, where steam is used to reduce the moisture content of the pulp to between 2% and 6%.
During the size press process, a starch solution is applied to the kraft paper to improve its strength. In the calendar stack, the paper is pressed to achieve a smooth finish. The finished paper is then wound onto a reel by a winder. Once the reel is formed, it is cut to appropriate sizes for shipping.
Cores used in the production of tape and labels are supplied to manufacturers of these products. The type of core employed varies depending on whether the tape is clear, colored, heavy-duty, or the specific type of label being produced. For tape, the process starts with a large roll of material that goes through several stages, including the application of adhesive, before being wound onto a core.
There are also variations in how cores are utilized during tape production. After cores are formed into tubes, they are cut to the width required for the tape being produced. In some manufacturing setups, cores are delivered as uncut tubes, and the tape material is applied to these long tubes before being cut to the desired width.
When using individual cores, the tape material undergoes several processes to improve its strength, usability, and alignment on the core. After these steps, slicers cut the tape into the specified roll widths. The tape bands are then wound around either plastic or paper cores. The length of tape applied is determined by the roll's design and specifications. Once the rolls are finished, they are ejected, and a new set of cores is prepared for the next batch.
In tape manufacturing that uses a tube as the core, the process resembles that of using a mandrel, where the material is wound around the tube after undergoing various quality assurance steps. The final stage is similar to the production of individual cores, where the long tube is cut to match the dimensions and width of the tape.
The production of labels follows a process similar to tape manufacturing, with key differences in label placement, printing, and types. Blank labels are die-cut and wound onto a core, while printed labels are applied to the material before being placed on the core.
When placing labels on a core, it's important to specify their winding direction, which can be set to one of eight possible rewind positions. The choice of rewinding method depends on how the labels will be removed from the core and whether the labels are wound out or wound in. The most common rewinding method, where labels are attached to the outside of the core, is typically found in rewind positions 1 through 4.
The rewinding position is determined during the manufacturing process when the roll of labels is mounted onto the core.
While tape and label cores are commonly known by these names, they are utilized in diverse applications for winding and rewinding different materials. The intended use of a core significantly influences its manufacturing process. This distinction is particularly evident when comparing cores used for paper towels with those used for duct tape.
Electrical tape cores are constructed from plastic to endure the specific conditions and environments in which the tape is applied. These plastic cores must be resistant to solvents and chemicals to ensure durability.
Price label cores are loaded into printing machines and are engineered to rotate and dispense labels during the printing process. Given the demands of label printing, these cores are built to be more robust and durable than other types. They are designed to support the weight of the labels, which are often heavier than materials used in other core applications.
Cash register tape comes in various forms, including carbonless two or three-ply rolls. The cores for cash register tape can be made of plastic or paper, depending on the type of cash register. These tapes are available in a range of widths, tailored to fit different cash registers. A crucial consideration for cash register tape cores is their ease of shipping and insertion into the cash register.
Gaffer tape is known for its high durability and versatility, available in a range of core sizes from one inch to four inches wide. Unlike many other types of tape, gaffer tape is constructed from heavy cotton cloth with a pressure-sensitive adhesive that is exceptionally strong. Due to its use in demanding applications, the core of gaffer tape must be robust enough to support the tape's weight and withstand the impact it endures during use.
Most equipment used for manufacturing tape and label cores is produced internationally, with China being the leading supplier.
The JT-50A is capable of producing cores with 2 to 24 layers with core diameters of 30 mm up to 250 mm. It comes equipped with an Emerson PLC and touch screen with all of the parameters of the core displayed on the monitor. Once the data has been input, the machine starts automatically using a frequency inverter for AC motor control. The unwinding angle is adjustable with a compact spacing structure. The JT-50A has an automatic glue spread with a glue recycle system and glue contained in a stainless steel tank. Single and double side coating is available.
The PTA-4120 is equipped with a PLC logic control system and a touch screen interface, along with a high-torque vector speed converter. It features photoelectric length positioning control that adjusts cutting speed automatically for enhanced accuracy. The modular design of the PTA-4120 simplifies maintenance and repair. Additionally, the PTA-4120 is noted for its low noise level during operation.
The KJT-4D core winding machine can produce cores with diameters ranging from 25 mm to 250 mm and wall thicknesses up to 15 mm. It utilizes a wax-based lubricant to manage friction between the paper core and the central shaft, facilitating more stable and precise control of the spiral gap. This feature enhances core quality and eliminates issues with oil stains. The machine's driving mechanism supports the production of thick-walled cores and offers adjustable winding speeds.
The Crown Spiral Core Machine is designed to produce custom cores tailored to specific design parameters, including various wall thicknesses, diameters, and lengths. It supports both inside and outside label wrapping with a specialized unwind reel splicing mechanism for continuous, stable production. The glue applicator features a tension adjuster and precise glue metering to ensure a consistent flow. Additionally, the belt reel on the Crown Spiral Core Machine delivers high-quality finished cores, and the servo motor-driven cutter system provides precise cutting.
The UBR Paper Core Making Machine is capable of producing cores with 5 to 30 plies, featuring sliced paper reels positioned on the top, middle, and bottom transfer rollers. It includes a paper lifting system with a small hoist. Each sliced paper reel is individually glued, with each gluing unit equipped with a pneumatic tension compressor to ensure tight unwinding. The machine's main drive utilizes a radial piston pump for energy-efficient pressure flow control. The pitch angle of the unwinding process can be easily adjusted either manually or remotely. Like other paper core machines, the UBR model is powered by a servo motor, enabling flexible changing rates and high cycle times.
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