When I visited the WLT warehouse in Akron, Ohio, some years ago, what I observed was that clumps of leaf were pried from a purchased bale, sprayed with water, then allowed to soften a bit. It was then separated and flattened by hand. This was allowed to dry-down, then weighed and slipped into their bags. Nothing magical.
Bob
EDIT: Another point is that frog-legged leaf was frog-legged prior to the seller packing it into bales, since the import taxes are based on weight. The frog-legging served to reduce the tax per leaf.