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Canister
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].

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.
  

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.

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.
  

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.

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.   

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.

Three empty key tape canisters
Plastic canister with key tape
Grey key tape canister, plus cut-away
A canister holding a punched paper tape with the key variables
Grey key tape canister detail (cut-away)
Black key tape canister, plus cut-away
Black key tape canister (cut-away)
Black key tape canister (cut-away, top view)
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Three empty key tape canisters
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Plastic canister with key tape
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Grey key tape canister, plus cut-away
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A canister holding a punched paper tape with the key variables
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Grey key tape canister detail (cut-away)
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Black key tape canister, plus cut-away
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Black key tape canister (cut-away)
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Black key tape canister (cut-away, top view)

Related items
AN/KOI-18 Key Tape Reader
Key transfer devices (fill guns)
Spendex-40 secure telephone for voice, fax and computer
Secure Telephone Unit
Application
All cryptographic devices came with clear instructions on how to handle SECRET key material. Below is an example from the manual of the SPENDEX-40 voice terminal, which was interoperable with the American STU-II. In the NATO COMSEC manual [3], we find the following text:

   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.

Video footage
The instructional video on the right was issued by the NSA as a training aid for users of the STU-II secure voice terminal. The video shows the use of the canister, the key tapes, the KOI-18 tape reader and the KYK-13 key transfer device.

STU-II was the second generation Secure Tele­phone Unit, used by the US Government and by NATO from 1980 onward. In the 1990s it was replaced by the much smaller STU-III.

 More about the STU-II

  


Personal recollections
Tom Friend
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.

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

Related patents
Similar products
Metal cartridge with 5-bit key tape, used with the Philips Tarolex cipher machine.
Documentation
  1. KOI-18, Historical Overview & Operational Guide
    Tom Friend [2], 2 May 2026.

  2. KOI-18 Key Load Simulator
    Single-file in-browser KOI-18 procedure simulator (HTML).
    Tom Friend [2], 2 May 2026.
References
  1. Anonymous contributors, Plastic key tape canisters (without) tape - THANKS !
    Crypto Museum, September 2013, March 2019.

  2. Tom Friend, KOI-18 Guide, KOI-18 simulator and Personal Recollections
    ICCH newsgroup, 2 May 2026.

  3. Operational COMSEC Doctrine for the Spendex-40 (NU)
    NATO SECAN, 9 October 1989. CM302959.
Further information
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© Crypto Museum. Created: Wednesday 06 May 2026. Last changed: Thursday, 07 May 2026 - 07:26 CET.
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