Modern paper recycling facilities are under increasing pressure to improve process stability, reduce maintenance costs, and maximize fiber recovery while handling growing production volumes. For mills processing recycled fiber, bale handling before pulping can have a major impact on downstream efficiency.

At Pabco Paper in California, automating bale wire removal has helped reduce process variability, minimize equipment wear, and create a more stable start to the recycling process.

Challenge Cross Wrap solved: Less wear, more efficiency

Previously, bale wires at Pabco were handled through ragger rope formation in the pulper. The purpose of the ragger rope was to pull bale wires through the process. However, because the incoming recycled material was already relatively clean, the ragger rope itself did not add production value. Instead, it created additional handling, maintenance, and disposal requirements.

As production volumes increased, manual wire removal became increasingly inefficient. Pabco wanted to eliminate ragger rope formation entirely and replace it with a dedicated automated bale wire removal solution.

Cross Wrap's solution: Infeeding process and consistency levelled up

Cross Wrap delivered a Bale Dewiring Machine together with conveyor systems to automate the bale opening process before pulping.

The front conveyor infeeds bales continuously into the process, while the dewiring machine removes and coils bale wires before the material enters the pulper. By eliminating wire handling inside the pulper, the system significantly improves process consistency and operational stability.

The solution also reduces wear on critical pulper components such as the rotor and extraction plates. Instead of being treated as waste, removed bale wires can now be recovered and sold as recyclable metal.

In addition, automation frees operators from manual wire handling tasks, allowing personnel to focus on more productive work while ensuring a smoother and more continuous production flow.

As Brian Bailey from Pabco Paper explains:

"The system has dramatically reduced process variability in consistency, which has had a dramatic impact on our overall process."

Project Details

Pabco Paper, located in Vernon, California, produces high-quality paper products for the building and packaging industries. The company uses 100% recycled fiber sourced from both pre- and post-consumer waste streams to manufacture wallboard lining and specialty paper grades.

• Material: DLK (Double Lined Kraft)
• Capacity: 20-25 tons per hour
• Cross Wrap Solution: Bale Dewiring Machine + conveyors

Smarter start to the recycling process with Cross Wrap's solutions

Efficient recycling begins before the pulper. By automating bale dewiring and material infeeding, paper mills can improve safety, stabilize production, reduce maintenance costs, and maximize operational efficiency.

Cross Wrap's Bale Dewiring Machine transforms a critical first step - bale infeeding, into a fully automated, reliable, and safe process. By cutting and coiling metal wires before material enters pulping or recycling lines, the system ensures smooth infeeding, reduces operator risk, and stabilizes downstream processes. With proven technology and global experience, Cross Wrap turns complex bale handling into a simple and efficient start to the recycling process.

"I am very satisfied with how Cross Wrap handled the machine installation - extremely flexible, and the service was truly professional. Also, their response to challenges was fast and solution-oriented. I can highly recommend Cross Wrap, and when our capacity grows, we will definitely be in contact with them again." - Brian Bailey, Pabco Paper