Bale Infeed Challenges in Paper and Pulp Mills

Recycled fiber continues to arrive at paper and pulp mills in baled form, whether it's OCC or mixed recovered paper. A reliable and predictable bale infeed process is critical for maintaining pulper performance, consistent fiber quality, and smooth overall mill operations.

Many bales are tied with steel wires, which can create significant operational challenges. When wires enter the pulper, they increase ragger rope formation, slow down fiber processing, raise maintenance requirements, and in the worst cases, can damage equipment, causing unplanned downtime. Despite advances in automation elsewhere in the mill, manual wire cutting is still common at many bale infeed points, exposing operators to safety risks and producing inconsistent results.

With growing bale volumes and higher throughput demands, mills face increasing pressure to ensure that the very start of the recycling line runs efficiently, safely, and reliably. Automated bale dewiring and wire cutting solutions, such as those provided by Cross Wrap, address these challenges by removing or managing wires before the material reaches the pulper, helping mills achieve stable, cost-effective operations.

Safe and reliable stock preparation with proven dewiring soulutions

Cross Wrap provides automated solutions that simplify bale handling and wire removal, ensuring smooth, safe, and reliable stock preparation. With over 100 Dewiring Machines and Wire Cutters installed worldwide, including at major paper recyclers and board mills, these systems are proven to perform under demanding conditions.

The Cross Wrap Bale Dewiring Machine automatically cuts and coils steel wires before the material reaches the pulper. Its flexible design makes it ideal for both new installations and retrofits, even in compact layouts. By removing wires upstream, mills experience steadier pulper operation, less ragger rope formation, reduced maintenance, improved safety, and minimized downtime. Coiled wires are easier to manage, safer to store, and can be recycled, adding extra value for the mill.

Built in collaboration with customers, the Dewiring Machine handles both single-side and cross-wired bales in a single system. Material flow is kept consistent and controlled, and optional features like coil shredding and ferromagnetic separation further support efficient, clean, and safe mill operations.

"We saw the improvements in our process straight away when we started using the Bale Dewiring."
- Ruud Rijks, Production Coordinator, Papierfabriek

What Is Cross Wrap?

Cross Wrap is a global supplier of automated bale handling solutions for recycling and industrial applications. The product portfolio also includes Bale Wire Cutters, Bale Wrappers, Bale Openers, and custom conveyor systems.

Over the years, the Dewiring machine has been enhanced with features developed in close cooperation with our customers, including bale turning units, bale slice breakers for loose and steady material flow, coil shredders and magnetic conveyors for efficient wire handling and metal recovery, as well as custom-built conveyors and integrated weighing systems for improved traceability and process control. Bale flipping tables further improve safety by reducing manual handling and forklift use, ensuring smooth, reliable, and safe bale infeed operations.

These solutions are supported by Cross Wrap Life Cycle Services (LCS), covering spare parts, upgrades, maintenance, and long-term service support.

Read more: crosswrap.com

Image slideshow below: The Cross Wrap Bale Dewiring Machine automatically cuts, coils, and removes bale wires before the material enters the pulper.