A method for reducing cost and weight in paint roller manufacturing processes and other continuous processes for producing tubular goods from polymers. The method may utilize a perforated substrate such as a perforated polypropylene strip or may include a perforating step which removes overage from an unperforated substrate. The perforated substrate is fed onto a mandrel to form a tube. Adhesive is applied upon the outer surface of the perforated substrate. A cover may be applied about the tube, and the resulting product is then cut into finished-size paint rollers. The removal of the overage results in a reduction in the weight of the paint roller. In certain embodiments the overage from a perforation step is collected, and may be reused in a subsequent implementation of the method or resold.