I said a simple test case, not your entire application. :)

Before we begin, I need to state right off the bat: use strict and warnings and use CGI or die;

Here is the test case I used. The results are not consistent with the problem you're seeing. See if you can reduce your application down to something as simple as this and see if your problem persists.

#!/usr/bin/perl

use strict;
use warnings;
use Text::Wrap;

my $data;
{
  local $/;
  $data = <DATA>;
}

$Text::Wrap::columns = 60;

print "Before:\n";
print $data;
print "\n";

print "After:\n";
print wrap("", "", $data);
print "\n";

__DATA__
This is a block of text that will precede the URL that is being presen
+ted

THE URL    http://xxx.yyy.com/admin/more_grassroots/bigalerts/thefeder
+algovernment/oy_veit/email/the_email_template.html

This is the concluding block of text that will appear AFTER the URL.

If this block is NOT at the bottom of the email, then we need to fix t
+he wrapping algorithm!
[download]

This prints:

...
After:
This is a block of text that will precede the URL that is
being presented

THE URL
http://xxx.yyy.com/admin/more_grassroots/bigalerts/thefeder
algovernment/oy_veit/email/the_email_template.html

This is the concluding block of text that will appear AFTER
the URL.

If this block is NOT at the bottom of the email, then we
need to fix the wrapping algorithm!
[download]

As expected.

---

---

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