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In Brief
- Two Cross Wrap Bale Dewiring Machines installed in 2019 and 2023
- Safer wire removal with significantly less manual handling
- Smoother pulper infeed at up to approximately 40 bales per hour
- Second investment confirms proven performance and customer trust
- Service agreement and on-site original spare parts support long-term reliability
"We saw the improvements for our process straight away when we started to use the Dewiring Machine."
Ruud Rijks, Production Coordinator, Papierfabriek Doetinchem BV
Papierfabriek Doetinchem BV produces lightweight machine-glazed papers from 100% recycled fibre at its mill in the Netherlands. Like many paper producers working with recovered material, the company must handle considerable variation before the fibre even reaches the pulping process.
Bales can differ in size, material quality and tying method. At the same time, stock-preparation areas are often compact, leaving limited room for new equipment or major line modifications. In this environment, the way bale wires are removed has a direct effect on operator safety, material flow and process reliability.
To improve this first stage of production, Papierfabriek Doetinchem invested in two Cross Wrap Bale Dewiring Machines. The first was installed in 2019, followed by a second machine in 2023.
Replacing a difficult manual task
Before automation, bale wires were removed manually. Cutting tensioned wires by hand is physically demanding and difficult to standardize, especially when operators must manage bales of different dimensions and tying styles.
The work also exposes employees to risks from wire snapback, sharp wire ends and the movement of dense, compressed material after the bale is released. In addition to the safety concerns, manual cutting requires continuous labour and can create variation in the rate at which material is supplied to the pulping process.
For Papierfabriek Doetinchem, the challenge was therefore not limited to removing the wire itself. The mill needed a safer and more predictable way to prepare bales in a space-constrained stock-preparation area.
A modular solution for a limited space
In 2019, the mill installed its first Cross Wrap Bale Dewiring Machine. The modular system was retrofitted into the existing production environment, where available space was very limited.
The solution was configured with the essential functions required by the application, keeping the investment lean while automating the complete wire-removal process. The machine cuts the bale wires, separates them from the material and coils the removed steel into compact bundles.
Once the wires have been removed, the bale is pulled through the machine in slices. This supports more controlled material feeding and makes the bale easier to process in the following stock-preparation and pulping stages.
The compact wire coils also simplify storage and recycling compared with loose, manually cut wires, which can occupy significant space and be difficult to handle.
A second investment based on operating experience
The performance of the first installation encouraged Papierfabriek Doetinchem to continue automating its stock-preparation operations.
In 2023, the mill installed a second Bale Dewiring Machine on another line. The decision reflected the production team's practical experience with the first system and the immediate improvements observed in everyday operation.
Manual work was significantly reduced; material preparation became smoother and the consistency of the infeed improved. The system now processes up to approximately 40 bales per hour, depending on the operating conditions and bale characteristics.
The result is a more controlled start to the recycling process. When bales are opened and wires are removed before pulping, less steel enters the downstream process. This can contribute to cleaner pulping, lower maintenance requirements and fewer wire-related production interruptions.
Reliability extends beyond machine delivery
Long-term performance depends on more than the initial investment. To support reliable operation, Papierfabriek Doetinchem signed a Cross Wrap service agreement for its second machine and keeps original spare parts on site.
Regular service visits help identify wear early, plan maintenance and reduce the risk of unexpected downtime. Depending on the customer's need, Cross Wrap's Lifecycle Services can include machine checks, preventive maintenance, technical support, operator training, spare parts, upgrades and modernizations.
Finnish engineering with a practical approach
Rooted in Eastern Finland, Cross Wrap has combined practical engineering with in-house mechanical, automation and electrical expertise for more than three decades.
The two Papierfabriek Doetinchem installations demonstrate this approach in practice. The first Bale Dewiring Machine was successfully integrated into a highly space-restricted area, while the second investment reflected the mill's positive experience with the technology and its continued confidence in Cross Wrap.
The result highlights a simple principle: safer bale handling, smoother material infeed and long-term reliability are closely connected. The mill's decision to invest in a second Bale Dewiring Machine also reflects its positive experience with the first installation and its continued confidence in the Cross Wrap´s technology.