In a typical recycling operation running at 20 bales per hour, a mix of cross-wired and horizontally wired bales can mean handling more than 120 wires every hour, adding up to roughly 1,000 wires in a single shift.
When operations run continuously 24/7, that quickly scales to over one million bale wires per year that need to be cut, removed, and managed.
What may seem like a routine task can become a major bottleneck for safety, maintenance, labor efficiency, and overall process flow.
Improving the First Step of Plastic Recycling
At Cross Wrap, we see automated Dewiring as a major opportunity to improve the entire plastic recycling process from the very first step. One of the key advantages of our technology is a high wire removal rate, helping recycling plants achieve cleaner material flow and more efficient downstream processing.
By automating bale wire removal before shredding, recycling plants can:
- Improve operator safety
- Reduce manual handling
- Minimize unplanned downtime
- Lower maintenance costs
- Extend downstream equipment lifetime
- Improve overall process efficiency
Automated Dewiring also creates direct labor savings. By replacing manual wire handling, operations can reduce the need for 1–2 operators per shift, allowing employees to focus on higher-value tasks within the plant.
At the same time, removing wires before shredding significantly reduces wear on downstream equipment, helping operations maintain stable production and avoid costly interruptions.
Modernizing Existing Recycling Lines
Improving recycling performance does not always require major new investments.
Today’s market uncertainty creates an opportunity for recycling companies to optimize existing processes and improve equipment performance through targeted retrofits and upgrades.
With more than 30 years of experience and a strong focus on customer needs, Cross Wrap helps customers maximize the value of their machinery throughout its lifecycle. Our modernization and upgrade solutions are designed to improve safety, efficiency, and productivity without the need for full equipment replacement. For example -Side Cutting upgrades for existing Dewiring machines or Bale Turning Unit addition for handling both one-sided and cross-wired bales.
These targeted improvements help recycling plants increase performance, reduce operational costs, and strengthen sustainability goals while extending the lifetime of existing equipment.
Supporting Customers Beyond Machine Delivery
Today, Cross Wrap has reached nearly 700 machine installations worldwide – from Svalbard to Tasmania. This global experience has shown us that long-term performance depends on more than just the initial machine delivery.
That’s why our support continues throughout the entire equipment lifecycle. We provide spare parts, maintenance support, upgrades, and modernization services to help customers maximize machine performance year after year.
