Magnetic Separation
Precision-crafted magnetic solutions tailored for industrial excellence.
MAGNETIC SEPARATION
Safeguard your product quality and protect your processing equipment with Bunting’s line of magnetic separation products. Separation of metal contaminants is an essential step in the production of food and pharmaceutical products. Bunting manufactures an extensive line of magnetic separation equipment that removes contaminants from avariety of material consistencies, including dry particulates, liquids, and slurries. We offer units designed to remove metal contamination from gravity, mechanical, andpneumatic conveying systems. Metal contaminants in a production line present not only a risk to a consumer who may bite into a sharp piece of scrap metal, but also to the other equipment in your facility. Our magnetic separation equipment pulls contaminants out of the production line quickly and efficiently, sparing you the costs of repairing or replacing equipment such as grinders that could be seriously damaged if a piece of metal scrap were to pass through. In addition to causing harm to the consumer and to other equipment within a facility, metal contamination found in a product can seriously damage a manufacturer’s brand and reputation. We are proud to be the first company in the metal separation industry to have earned USDA and AMS acceptance for our sanitary-grade metal separators. Bunting engineers have made it a priority to stay on top of the constantly changing marketplace and government requirements regarding the safety and purity of food and pharmaceutical products. We welcome the challenge of ever more stringent guidelines as we are driven to continuously improve our product offerings
Plate Magnets
Bunting supplies various types of plate-based magnetic separators that can be implemented into a broad range of applications, and can be used with an equally wide range of materials. All plate magnets are designed for the capture of tramp metal in gravity free-fall applications. Metal-detectable gaskets and grommets are standard features in housing of plate magnets.
STANDARD PLATE MAGNETS
Standard Plate Magnets are available with permanent ceramic magnets or with high-intensity permanent rare earth magnets. Both types of magnets work efficiently to capture fine metal particles and slightly magnetic debris from powdery, moist, clumpy, or abrasive materials that might choke or wear cartridge-based separators. Plate magnets install easily in chutes to remove ferrous fine particles and larger pieces of tramp iron from many types of free-flowing and pneumatically conveyed material. They can also be installed above conveyors or below conveyor drive pulleys to capture contaminants as material drops from open belts. Standard installation kits include a pre-drilled hinge, latch, and other hardware to ensure easy mounting. The tapered magnetic face is designed to prevent contaminant wipe-off in rapid product flow. Standard plate magnets are available in widths from 10 to 150cm.
- Ideal for 30° to 60° inclines, allowing contaminants to be trapped as material flows over the plate magnets.
- Food and sanitary available to fit your production safety regulations
- Hinged plates swing out for easy cleaning.
- 300 series SS construction. 316 stainless steel available when required. Tapered step face to prevent product wipe off in rapid product flow is standard with 400 stainless steel.
- Rare earth magnets are available to provide maximum strength and reach out.
- Optional replaceable grain face available for dealing with abrasive materials.
PLATE HOUSING MAGNETS
Plate Housing Magnets resist bridging and choking to remove tramp iron and ferrous fine particles from flow resistant bulk materials. The stainless steel housings mount easily to enclosed spouting or directly on processing equipment. Optional square, rectangular, and round adapters can be supplied or designed to your specifications for ease of installation. A baffle at the top of the housing helps break up clumps and directs product flow over the unit’s two powerful plate magnets
- Excellent for separation of coarse, fluffy, and other flow resistant materials that bridge in grates and drawer magnets.
- A diverter at the top of the housing helps break up clumps and directs product flow over the unit’s two powerful plate magnets. Additional removable/replaceable diverters are available.
- Custom transitions for round, square, or rectangular spouting are available to fit any application.
- Economical ceramic and powerful rare earth magnets are both available based on your production needs.
- A self-cleaning option is available for increased efficiency.
- Compact design fits easily into limited spaces, which allows for mounting on processing equipment or on spouting.
- Rugged stainless steel construction resists wear and extends life of equipment.
SUSPENDED PLATE MAGNETS
Bunting suspended plate magnets are designed to be suspended above open conveyors to remove ferrous objects and fines found in grains, feedstuffs, raw and processed food products, dry powders, and other particulates.
- The stainless steel design complies with food and sanitary grade requirements.
- The magnet suspends over a conveyor belt or drop-off point to remove contaminants from dry powders, grains and particulates without interrupting the product flow.
- The magnet suspends over a conveyor belt or drop-off point to remove contaminants from dry powders, grains and particulates without interrupting the product flow.
- The powerful ceramic magnet field reaches deep into conveyed material to pull ferrous tramp from flat-belt and trough conveyers. Rare earth magnet models are available for applications that require greater magnetic power.
- Sturdy, free-standing, bolt-together support frames enable convenient mounting.
- Optional stripper plate slides out for fast, easy, out-of-the-way cleaning.
Benefits of the Oil Cooled
- Strongest option available.
- Maintains optimum working temperature.
- Maximum protection for your processing equipment.
- Holds extracted ferrous material in place until power is turned off.
- On/Off switching simplifies removal of collected ferrous.
- Comes standard with suspension chains and hardware.
- Works on burden depths up to 760mm depending on the material being separated.
Metal Detection: Custom Designed for Aggregate and Mining Applications
TN77 CONVEYOR BELT METAL DETECTOR
- Metal Detection for the Aggregate, Mining, and Minerals Industry The electronic TN77 metal detector is a tunneltype unit that is generally installed onto conveyor systems. The TN77 enables a continuous inspection to be made of any non-metallic or non-conductive materials. The unit is used for the detection of tramp iron and manganese steels where their presence would prove damaging to processing equipment or a clients’ end product.
Product Features:
- Reliable protection against machinery damage
- Detection of tramp iron & manganese steel, including non-magnetic digger teeth.
- Easy installation into a customers’ existing conveyor system.
- Simplicity of operation with fully adjustable sensitivity/detection levels.
- Capable of indicating if one or two pieces of tramp iron are simultaneously detected.
- Capable of overlooking non-magnetic, copper-alloy belt fasteners
EDDY CURRENT SEPARATION CONVEYOR
These units can be designed into a complete custom system for maximum product purity. The system could include: Transfer Conveyor into and out of the system; HISC® High Intensity Separation Conveyor® or SSSC® Stainless Steel Separation Conveyor™ for stainless steel separation; Magnetic CrossBelt™ Separation Conveyor for larger ferrous tramp; and Vibratory Feeder Trays. Bunting Engineers will provide full 3-D System CAD Models and 2-D drawings for system review analysis when orders are placed.
Product Features:
- Designed to provide the optimal eddy current fields to achieve the maximum separation of small non-ferrous metals from other materials
- Low maintenance conveyor with extremely tough urethane belts to allow longer wear.
- Cantilever frame weldment design allows easy belt change within minutes.
- Double VFDs for optimising relative belt speeds.
- Available in varying widths with four rotor options available based on your application needs
- Units can be designed into “custom systems” in combinations with equipment.
High Intensity ECS Units:
The High Intensity ECS units are specifically designed to handle the separation of small and difficult non-ferrous particles that require high repulsive forces for an accurate separation. This type of unit has a 300mm diameter, 24 pole rotor and is available with operating widths of up to 2 metres
Optional extras include:
- A high powered rare earth drum magnet to be utilised in applications with high ferrous content to remove small particles of ferrous materials, which may damage the rotor cover if caught underneath the belt.
- Rotary or static belt cleaning brushes for use in applications where the product may be wet or sticky.
- Mobile chassis
- Power plant.
Standard Drum Magnet
Designed for separation of ferrous from high volume loads. Drum magnets provide an efficient method for
removing ferrous material from heavy-flow applications. They are self-cleaning and install easily.
- All drum magnets are available in electromagnetic or permanent designs, as well as including the option to be made with a high intensity rare earth magnetic system (ideal for separation of exceptionally small contaminant particles).
- Ideal for high-flow, heavy-contamination applications.
- Optional manganese wear plates for abrasive materials.
- Multiple drums can be used sequentially for heavily contaminated product
- Direct drive with an optional variable speed control based on your application needs.
- Open style design (free of housing) is ideal for installing at the end of conveying machines, such as chutes, for removal of ferrous contaminants.
- Totally enclosed design (equipped with housing) is ideal for applications where product must be kept free from external contamination, as well as protecting your employees from inhaling any dust being given off from the product
Magnetic Separation Pulleys
Offering superior continuous removal and discharging of ferrous contamination, such as nails, staples, bolts and wire from conveyors, all with maintenance-free operation. OEM Separation Pulleys are economical magnetic separation pulleys that can be used to transform your standard material handling conveyor into a material separation conveyor. Being able to combine the transport of your mate rials and the separation of contaminants into one simple step increases the efficiency of your operation
- Manufactured for maximum reach-out, holding force and separation effectiveness.
- Available in both economical ceramic and the high-intensity neodymium rare earth magnets for maximum separation
- Pulleys are 100-1200mm in diameter depending on your application needs. These pulley systems offer maintenance-free operation.
- Widths from 100mm up to 2100mm wide
- Available in all-stainless-steel construction with food, sanitary, and USDA finishes available to fit your production safety regulations.
- Pulleys are offered with economical stepped crowned face, machine crowned face, flat faced and provide an assortment of rubber vulcanised crowned covers. These pulleys can be provided with the same shaft your existing conveyor has, making the switch from a standard to a magnetic pulley system quick and easy.
- We offer an assortment of taper lock or QD hubs for any shaft diameter you need or welded in shafts to slip into the end of your conveyor and match up perfectly
High Intensity Separation Pulleys
Built with high-intensity neodymium rare earth magnets, these pulleys are designed for the toughest jobs that require maximum separation. High-intensity separation pulleys are ideal for separating materials that are difficult to magnetically attract and separate from a material flow using standard methods, such as paramagnetic fine particles, stainless steel scrap, and work-hardened fasteners.
- Deep reach rare earth field pulleys are ideal for installation in high volume processing lines to ensure all ferrous metals are removed from deeper burden streams before they reach other equipment.
- Pulley units can be incorporated on OEM conveyors, providing reach outs of 10″ to 12″ with unmatched field intensity.
- Low reachout rare earth field pulleys are available, designed to have high gauss, super high-intensity fields while maintaining a low reachout in order to suit low volume applications.
- Low reachout pulley units can be easily incorporated on OEM conveyors to create an all-in-one system for conveying and separating materials.
- Electro Pulleys available with variable flux control for selective separation of materials with different magnetic properties
Rare Earth Roll Separator
The Rare Earth Roll Separator is ideal for handling dry material, whether fine or coarse, and purifying it of ferromagnetic and paramagnetic particles. Within the production line, a vibratory feeder loads material to be treated onto a short centered thin conveyor belt, allowing for material to be fed evenly onto the magnetic roll. Any magnetic elements present in the greater non-magnetic material are securely held onto the belt by its powerful magnetic force, a result of the neodymium magnets this equipment incorporates. These magnetic contam inants are discharged down a rear chute once the belt exits the magnetic force area present on the underside of the roll. This system efficiently traps magnetic contaminants while allowing non-magnet ic material to be discharged in front of the roll, following its normal trajectory in the production line.
- Composite high-intensity magnetic head pulley utilises neodymium magnets, the most powerful permanent magnets available
- Magnetic rolls are available in 75mm, 150mm, and 200mm diameters, up to a width of 1 metre
- Multiple configurations of rolls are offered, giving the non-magnetic fraction a further pass for improved product purity. Material from 100 micron to 5mm can be treated
- Varying separation trajectories can be set by adjusting the conveyor speed using the inverter control setting on the control panel and adjusting the splitter chutes.
- Can be used in a variety of applications, including ceramics, granulated slag, iron ores, plastics, silicones, ilmenite, mica, crushed glass, refractory material, high purity quartz, granite, talc, and battery recycling.
Laboratory Testing
To arrive at the best separation criteria, Bunting uses a fully equipped laboratory for material testing to en sure optimum equipment selection. Customers are in vited to submit samples for testing and evaluation, to ensure that separation performance can be measured, with all the results and process recommendations being submitted for the client’s approval. Initial trials are normally carried out free of charge and customers are encouraged, if practicable, to participate in the testing and processing procedure.
Induced Roll Separator
The induced roll magnetic separator provides mineral purification for a wide range of mineral and ceramic processing industries. It works to perform the continuous extraction of small magnetic particles from within material, resulting in an end product free of contamination.
- High intensity magnetic roll causes magnetic material to attach itself onto the roll face or be deflected towards the roll.
- Brush accessory assists in discharge of magnetic material, with a splitter plate interposed to separate material streams, ensuring no separated contaminants will find their way back into the product stream.
- Available in 1, 2 or 4 roll configurations. The roll arrangements can also vary depending on the application and requirements. We manufacture a range of sizes to suit your application.
High Intensity Electro Magnetic Filters
High Intensity Electromagnetic Filters are designed for the continuous removal of ferrous particles from many liquid based applications, particularly ceramic, slips and glazes and are designed to handle from 45 litres per minute to 900 litres per minute. Filters are fitted with an auto backflush system on a timed cycle to enhance performance and to prevent clogging. This feature proves to be particularly successful where superior quality ceramics are required, outperforming competitor units. The Filters enable companies to overcome the perennial problem faced by the ceramic industry of eliminating iron contamination in the glaze and slip processes, dramatically reducing structural and cosmetic defects in the manufactured product, resulting in costly rejects.
Disc Separators
Disc separators are widely used to ensure accurate separation of materials that have varied magnetic susceptibilities. With their original design dating back to the early 1900s, they have a long history of usage in separation applications. Today, the discseparator has been updated to accommodate modern manufacturing demands and incorporate new innovations in technology
- Material is continuously transported beneath rotating discs where magnetic particles are attracted to the high gradient magnetic zones on the disc. Powerful magnets allow for strong attraction of contaminant particles and ensure they are held securely to the disc before being released at the discharge chute.
- Scrapers mounted on chutes ensure the total discharge of magnetic particles.
Wet Drum Permanent Separators
Wet Drum Separators are mainly used for the recovery of magnetic/ferrosilicon in dense media plants and iron ores. Wet drum separators work on a similar principle to our other existing drum separators. A stationary magnet system with several radial poles attracts the magnetic material to the drum face. The rotating cover then carries the magnetics from one pole to another, at the same time rotating the magnetic particle to allow trapped non magnetics to free fall. This should then produce a clean magnetic product completing the magnetic separation process. Wet drum separators have three basic designs that work with 3 different types of application, they are concurrent, counter flow and counter current. The purpose of this is to ensure that we can meet recovery figures of 99.9% when dealing with different solid to liquid ratios