Wayne, I feel your dilemma: it must be simple and cheap, yet effective and efficient. Fully concur on your idea of using off the shelf parts or even machinery. Shredding the bale is no option, I understand. Would cutting 6 inch thick slices (like slicing bread) off the bale and feeding the slices through a tedder help? May be looking at some pics may help; try: http://www.google.nl/search?q=fluffer+hay+OR+straw+OR+cotton&hl=nl&as_st=y&tbm=isch&ei=E1lgT9fdHojOhAed4rDCBw&start=168&sa=N Would such a machine help: http://www.rowserakes.com/fluffer2.html
Usually, poor quality hay will be difficult to "fluff", especially when baled wet. But then, this hay is no good for horses(?) anyway, so there is no money to be made there and you should not try to devise a process/machinery able to rebale poor hay.
I've seen processing units for making boards of a mixture of wood wool and cement (wood wool cement board). Wood wool is nasty stuff and distributing it evenly is comparable to the process you are looking at. Large rotating drums are used to pull the wood wool onto wide conveyor belts. On the outside of the drum "shark fins" are welded. The rotation of the drum is such that the wool is "stroked" by the hypotenuse of the triangles (shark fins) rather than "pulled". Hope this helps; may have more ideas/suggestions later. Hendrik
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