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USA NSA NATO
Secure key tape cassette
Special plastic canisters were used from 1977 onward, for the
distribution of cryptographic key material that was held on
8-level punched paper tape.
The device is constructed in such a way that, once a piece of key tape
has been removed from the device, it cannot be re-inserted [1].
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During the Cold War, most cryptographic devices that were used by the
US Army and by NATO, had to be loaded with a valid cryptographic key
prior to operation. In most cases, the key was valid for 24 hours, after
which new keys had to be distributed to the relevant users in the field.
Keys were usually created well in advance of their operational time slot,
so that there was sufficient time for their distribution. However,
during storage and transport, they were vulnerable to
espionage, as they could easily be copied.
The canister was developed to prevent this.
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The cansister measures 70 × 83 × 33 mm and weighs 48 grams without
the tape. It was available in grey and black and consists of two plastic
parts: a bottom and a shell that fits over it. The bottom part was loaded
with a freshly created key tape, after which the shell was placed over it.
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Bottom and shell were then joined by means of ultrasonic welding,
which results in a tamper-evident construction; opening the device
in any way, will leave visible traces. The internal construction of
the device ensures that the tape can only be pulled out, and cannot
be pushed back in again. This way it was impossible to make an
undetected copy of a classified key tape.
The image on the right shows a cut-away version of a key tape canister,
in which the plastic one-way construction is clearly visible.
The idea was registered in a patent of 15 February 1977.
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A canister usually contained more than one key, and in some cases even
more than one type of key. When a new key was required (usually around
00:00 hours), a piece of tape, equal to the length of the key, was pulled
from the canister and torn off. It was then used in combination with a
KOI-18 key tape reader (or equivalent) to load the key into an
electronic key fill device such as the
KYK-13, CYZ-10, etc.
The latter would then be used to transfer the key to the relevant
crypto devices.
It was also possible to load the key directly from the KOI-18
into a crypto device.
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The canister was suitable for 8-level (8 bit) key tapes,
that were made of paper or mylar.
It can hold keys of any length with no restrictions to the
key type, as long as it can be fitted on an 8-bit tape. In the same vein,
the KOI-18 tape reader
can process keys of any length and type. It does not
expect a checksum, but only checks the parity of the characters. Note however,
that other key transfer devices, such as the KYK-13
and KYX-15,
can only holds keys of a specific type. During the Cold War,
most cryptographic devices and key transfer devices used a
128-bit key,
of which the last 8 bits are a checksum.
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Once the canister was empty (i.e. all keys had been used), it had to be
returned, inspected and destroyed. To ensure that it was empty
before destruction, a special canister opener was developed around
1986. It is registered in US Patent 4768693.
A used canister can never be reused.
By the year 2000, it had become increasingly difficult to source paper tape,
and finally in October 2019, the US
National Security Agency (NSA) permanently
abandoned the use of punched tape for key distribution.
In addition, better methods for key handling had meanwhile become
available.
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h. [...] Key tapes classified NATO SECRET must remain in the custody of
NATO SECRET cleared personnel. When left unattended by all cleared personnel,
keyed terminals must be locked in approproved security containers or
installed in areas approved for the open storage of NATO SECRET material.
g. Handling of Key Material: The SPENDEX-40 keying material is most
vulnerable to HUMINT exploitation after it has been removed from the canister
and while it is held in electrical form in KYK-13s. In order to limit access
as much as possible to the keying material, the procedures outlined below will
be followed:
(1) Key tapes will be kept within their protective canister until shortly
before they are to be used. Canisters may be issued to users or maintenance
personnel for rekeying, but should be returned to the cryptocustodian immediately
after use for secure storage. Users should not normally retain possession of key
tape canisters, except in special circumstances, such as when user locations are
isolated and difficult to reach. Key tape canisters contain multiple copies
of the same keying material to support SPENDEX-40 rekeying during a cryptoperiod.
(2) Key tape segments, once removed from a protective canister, will be
destroyed as soon as possible after they have been used to successfully load
a SPENDEX-40 or KYK-13. As an exception, when the immediate destruction cannot be
witnessed, the key tape may be retained for that purpose, but in no case will
destruction be delayed more than 12 hours from the time the terminal is
successfully keyed. This means that personnel using the tapes to load the
SPENDEX-40 will normally destroy the tapes at the site, unless the tapes can be
immediately hand-carried back to the cryptocustodian after the successful loading
of the SPENDEX-40. All tape segments, used or not, must be destroyed at the
end of each cryptoperiod with the exception that the last tape segment in the
canister may be kept until new cryptovariable is successfully loaded at the
beginning of the new cryptoperiod and then destroyed. The KYK-13 must be
zeroised after loading the SPENDEX-40.
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From Tom Friend, a former C-5 Galaxy pilot, we received the following
contribution in which he reflects on the use of the
KOI-18 key tape reader
and the plastic canisters in which the key tapes were held and distributed,
as shown above.
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Many years ago I was a young C-5 Galaxy pilot, and the junior pilot on the
crew had what we considered a privilege (That is sarcasm): retrieving the
day's secrets.
That meant a walk to the vault in base operations, a signature for a sealed
canister of NSA punched key tape, drawing a KOI-18 from the COMSEC locker,
and carrying both back out to the airplane. Once auxiliary power was on,
the load would begin. You worked your way through every cryptographic device
the mission required, voice, data, IFF, frequency-hopping radios, navigation,
(Ahh the navigation, you had the Trippie inertial Navigation waypoints entry
to look forward to after secrets) connecting the fill cable, drawing the tape
through the KOI-18 at that particular pace you eventually learned in your hands
rather than your head, watching for the parity lamp, signing the log. Five to
twelve devices on a typical airframe, depending on the mission profile.
And then sometimes maintenance dropped auxiliary power, or someone needed a
panel open, and you got to do the whole thing again. Zeroize, walk back,
re-load, re-verify, re-sign. AHHHHHHH not that that ever happened.
The whole ritual was built around a single immovable fact: the cryptoperiod
rolled over every day, and at the Hotel Juliet hour every device in your net
had to be on the new key or your traffic went nowhere. The system worked
because it was boring, drilled, and standardized, the same procedure on a
flight line in Charleston, a hangar in Ramstein, a ramp in Kadena. Every day.
Every aircraft. Every device.
From memory, Tom put together a guide
that walks through the history of the
KOI-18, the DS-102 protocol,
the paper-mylar-paper tape construction, the daily turnover,
and eventually the end of the production line at Fort Meade in October 2019.
He also created an
in-browser simulation,
that takes you through the full
operator loop, vault retrieval, seal inspection, KOI-18 load and
fan-out to the sub-systems.
It's not intended as a training aid, but merely as a memory aid, for those of us
who did this, and for the curious who never had the chance.
➤ Read the KOI-18 Guide
➤ Try the simulator
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- Anonymous contributors, Plastic key tape canisters (without) tape - THANKS !
Crypto Museum, September 2013, March 2019.
- Tom Friend, KOI-18 Guide, KOI-18 simulator and Personal Recollections
ICCH newsgroup, 2 May 2026.
- Operational COMSEC Doctrine for the Spendex-40 (NU)
NATO SECAN, 9 October 1989.
CM302959.
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© Crypto Museum. Created: Wednesday 06 May 2026. Last changed: Thursday, 07 May 2026 - 07:26 CET.
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