Operational Challenges at Paper and Pulp Mill Bale Infeed
Most recycled paper bales are bound with steel wires. If not handled correctly, these wires can disrupt the pulping process, increase maintenance requirements, and create safety risks. As mills aim to improve operational stability and reduce manual work in stock preparation, automated Bale Dewiring has become an increasingly important part of the bale feeding process.
Bale wires remain a significant challenge in paper and pulp mill operations. When steel wires enter the pulper, they increase ragger rope formation, disrupt fiber processing, and raise maintenance demands, while also creating a risk of equipment damage and unplanned downtime. Although automation has advanced across many areas of the mill, manual wire cutting is still common at bale infeed points, exposing operators to safety risks and inconsistent results. With growing bale volumes and higher throughput requirements, mills face increasing pressure to ensure a safe, efficient, and stable start to the recycling process.
Automated Solutions for Safe and Efficient Bale Infeed
Cross Wrap offers industrial solutions for paper and pulp mills that automate bale opening and wire handling, helping mills keep stock preparation lines safe, steady, and efficient. With more than 100 Dewiring Machines delivered globally, including installations at leading paper recyclers and board mills, Cross Wrap solutions are field-proven in demanding mill environments.
The Cross Wrap Bale Dewiring Machine automatically cuts, coils, and removes bale wires before the material enters the pulper. Flexible and customizable, the machine is well suited for both new installations and retrofits in space-constrained mill layouts. By removing wires upstream of the pulper, mills achieve more stable pulper operation, reduced ragger rope formation, lower maintenance load, improved safety, and reduced downtime. Coiled wires are easier to handle, safer to store, and can be recycled, creating additional value for the mill.
Developed in close cooperation with customers, Cross Wrap Dewiring Machines support both one-side- and cross-wired bales with a single solution. Material flow is kept loose and controlled, supporting consistent pulper feeding. Removed wire coils can be crushed to improve storage efficiency, and ferromagnetic metals can be separated during wire processing, further supporting clean and efficient mill operation.
“Today we get money back from the wire recycling, and the pulper maintenance workload and costs have decreased significantly.” – Janne Ruoti, Factory Operations Manager, Sonoco Alcore Karhula board mill
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.
