From board to tube: Our manufacturing process explained

At Stell, we’ve been manufacturing cardboard tubes and cores for over 150 years and while technology has evolved, our dedication to quality, precision and sustainability has remained constant. In this blog, we take you behind the scenes to show how we transform raw board into the reliable, made to measure tubes and cores used across industries every day.

• When manufacturing cardboard tubes and cores, the right materials are essential.
• Manufacturing cardboard tubes calls for precision winding to meet the demands of your products.
• Finishing touches are critical for ensuring maximum durability and reliability of the cardboard tubes and cores.

Gain an insight into behind the scenes of our production facility and find out how our cardboard tubes and cores are made.

1. From board to core: Selecting the right materials

Every Stell tube starts with high grade paperboard, this is sourced from responsible suppliers who share our commitment to sustainability. The type and grade of board used depends on the tube’s final use; it could be any number of industrial converting industries (paper, polythene, synthetic materials, etc.), label cores, tape cores, textile tubes- list goes on!

Once the board arrives at our factory, it’s precision-cut into narrow reels in preparation for the winding process. This early step is critical: accurate sizing ensures strong, consistent walls and minimal waste, helping us maintain both performance and environmental efficiency.

2. Precision winding: Crafting the tube

The core of our process is spiral winding, the stage where reels of board become a strong cylindrical structure. It has multiple layers of board bonded together using a water-based adhesive under a controlled pressure as they wrap around a steel mandrel.

By adjusting the number and thickness of layers, each tube is tailored to its intended function, it may need to be lightweight for packaging or extra-robust for heavy duty industrial use. Our advanced winding machinery ensures a smooth, consistent tension with uniform plybond to give optimal strength tubes.

We have a comprehensive range of packaging tubes and cores, with the capabilities to meet your exact durability requirements.

3. Finishing touches: cutting, drying, and quality control

Once the tube has been wound, it’s cut to the precise length required using high speed, computer-controlled knives. Our cores are then dried, cured, and inspected to confirm their dimensional accuracy and structural integrity.

We also offer a variety of finishing options – such as closures and printed outer wraps custom-designed to meet the specific inner dimeters and wall thickness specifications – ensuring every product is perfectly suited to our customer’s needs

Before leaving our factory, our tubes undergo rigorous quality checks, ensuring consistency and reliability across every batch.

Sustainability at every stage

Our entire manufacturing process is designed with sustainability in mind. We minimise our waste, recycle production offcuts and work closely with paper suppliers who prioritise renewable materials.

By continually investing in our energy generation onsite via an extensive solar panel array and bio-mass boiler, efficient machinery and processes, we ensure that our tubes and cores not only perform exceptionally but they also contribute to a more sustainable supply chain.

Discover how we can support your business

At Stell, manufacturing high-quality, high-performance cardboard tubes and cores isn’t just about production, it’s about precision, reliability and care. From board selection to final inspection, every stage reflects our 150-year legacy of quality craftmanship.

Contact us today to learn how we can become your trusted cardboard tube and core manufacturer.