The biggest issue you are going to get into is the fact that re-baled straw is not going to look right no matter how you fluff it. I have fluffed it back up by hand and re-baled it and it is still broken up. Your customer wants it to look like small square bales for retail sales because it is worth much more in small squares than big squares.
The mechanical or physical issue is the fact that unbaled straw stems are round like pop straws. When it is baled in any manner it flattens the straw stem. So when you go to re-bale it you get a percentage of the individual straw stems turned from the original way they where baled. This makes another break in the stem so it will not fluff up like single baled straw. Hay is much the same way. So your biggest issue is kind of a rule of physics and you are not going to be able to change it. So you can get a machine to break the bale back up into individual straws and it still will not look like single baled straw.
A buddy and I spend about two years and a good bit of money making a re-baler to re-bale round bales of hay. We got a machine that would work but the end result was never very good even in hay unless you found real loose baled material. Then that defeated the hauling of the original hay/straw at a reasonable cost. The biggest stopping problem was that the leaf lose in hay was so great that you lost about 10-20 percent of your original weight. The better and drier the hay the larger the loses.
The best way is to have the first baling be with a small square baler. Then make those bales into an easily handle product. There are several machines that do that. The one I have seen in person is the Bale Bandit. here is a link to there site.
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Today's Featured Article - Upgrading an Oliver Super 55 Electrical System - by Dennis Hawkins. My old Oliver Super 55 has been just sitting and rusting for several years now. I really hate to see a good tractor being treated that way, but not being able to start it without a 30 minute point filing ritual every time contributed to its demise. If it would just start when I turn the key, then I would use it more often. In addition to a bad case of old age, most of the tractor's original electrical system was simply too unreliable to keep. The main focus of this page is to show how I upgr
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