Aggregate, Mining, and Minerals

Precision-crafted magnetic solutions tailored for industrial excellence.

Advanced Magnetic Solutions for Heavy Industry Efficiency

Aggregate, Mining, and Minerals

Bunting is committed to helping customers across many industries “break ground” as our equipment assists them in solving challenging problems. We “dig down” to find the root cause of their problems and use specialty software to custom-design the best solutions to fit the customer’s needs. We offer exceptionally rugged magnets and heavy-duty magnetic separation equipment specifically to cater to customers in the aggregate, mining, and mineral industries. Working with these materials is tough, but Bunting equipment is even tougher. Our magnetic equipment will protect the other equipment utilised in your facility and allow you to deliver the highest purity product to your customers.
Bunting provides equipment to help aggregate, mining, and mineral companies by using magnetic separation technology to remove metal contaminants from product streams and providing metal detection equipment to alert operators of ferrous and non-ferrous metal hazards trapped within greater product mass. All of our equipment is designed to be low-maintenance and operator friendly to increase efficiency and decrease downtime in your production. Bunting protects your products from damage and increases the overall efficiency of your operations. All of our products are custom designed according to the customer’s specifications, allowing for them to integrate seamlessly into the existing production environment. Our team of engineers works with each customer to deliver a personalised piece of equipment with the physical dimensions to best fit your space and the magnetic components that best suit your separation and detectionneeds. Our ruggedly built magnets and magnetic separation equipment is designed specifically for the ag gregate, mining, minerals, and quarrying industries to protect your belts, crushers, and other expen sive equipment from tramp metal. This allows you to experience more productivity, more reliability, and more savings

SELF-CLEANING OVERBAND MAGNETS FOR HEAVY-DUTY APPLICATIONS

Our self-cleaning overband magnets have earned a reputation as being the most effective units for the continuous removal of ferrous tramp contaminants from a product stream. Most commonly used on mobile crushing and screening machinery, overband magnets are available in permanent and both oil-cooled and air-cooled electromagnetic configurations. These separators are popular in the concrete recycling and quarrying industries, as they are highly effective at protecting, cleaning, and separating
materials. Their heavy-duty construction and powerful magnetic force allows them to handle even the toughest, most challenging applications

Permanent Magnetic Overband Separators

General Benefits of Overband

Magnetic Separators:

Overall low operating costs, allowing for a cost-effective equipment upgrade.
Designed to be low maintenance and operator friendly, with advanced safety features to protect operators and equipment in your facility.
System is designed to be durable and capable of operating in challenging environments. The powerful magnet block is mounted in a heavy-duty steel frame and traversed with a heavy-duty, vulcanised, cleated belt that runs on two crowned pulleys
Electric or hydraulic motor options are available depending on your application needs.

Self-cleaning system minimises downtime and improves operational efficiency
Standard designs operate over 120mm to 2 metre con veyor belts and up to 400mm above a conveyor. Systems can be custom designed to fit large conveyor belt widths
Can be positioned either inline over a conveyor head pulley or suspended across a conveyor belt. These versatile mounting options allow equipment to easily integrate into various configurations of existing equipment in a facility.
Available in permanent and electromagnetic configurations.
Available inWhen a deep reach or a stronger field is required, Bunting offers an optional Tri-Polar design. This unique design uses two massive side poles to concentrate and intensify the magnetic field to the center of the magnetic block. permanent and electromagnetic configurations.

ElectroMax Air Cooled Overband Magnetic Separator

The new ElectroMax Overband Magnet is 185% stronger than equivalent permanent overband magnets. The ElectroMax provides customers with a smaller, lighter and more compact system without any compromise in separation performance. The ElectroMax Overband Magnet is ideally suited for applications where there are weight and size
suspension limitations. It provides additional magnetic power for more difficult tramp metal separation applications, achieving a boosted separation force while still remaining compact and light. The electromagnetic coil produces a high gradient magnetic field that is up to 185% more powerful than comparable equipment. This enables the removal and separation of smaller and more challenging shapes of iron contaminants often missed by other magnetic separation systems. The additional magnetic strength
also aids the lifting and removal of heavier tramp ferrous metals.

General Benefits of Overband

Half the weight of an oil cooled magnet.
Lower profile (46cm), than an oil cooled magnet
Substantially less maintenance than an oil cooled magnet.
Air cooled transformer rectifier included
Armor cleated belt optional
Durable construction ensures longevity of equipment and keeps maintenance to a minimum
Dual-pulley system drives self-cleaning belt, reducing overall weight and size of equipment.
Air cooling system eliminates need for any oil or conservator tanks.

Switching off power to the ElectroMax deactivates its magnetic field, allowing for easier, more convenient maintenance in between operations.
Four standard models are designed for suspension at a height of 450mm over conveyors with widths of 1, 1.2, 1.4 and 1.5 meters
Average comparisons between the new range of ElectroMax equipment and the permanent overband equivalents show a 185% increase in magnetic power.

Oil Cooled Electro Overband Magnetic Separator

A powerful Overband Separator for deep & heavy ferrous extraction

The Heavy-Duty electro Overband Separator is the most powerful in the Bunting line, and available in sizes to fit any aggregate, mineral, and mining operation. Due to its high magnetic strength, this Overband Separator is able to work at an increased operating gap, enabling it to extract ferrous from the deepest troughed conveyors.Electro Overband Separators are commonly positioned either inline over the head pulley, or across conveyor belts as little as 60cm wide to 210cm. For even larger belt widths, our engineers can custom design and add additional support structures as required.

To give the Overband Separator a longer belt life (especially when handling abrasive materials) an optional armored belt is available. In addition, heat-resistant belting is available to allow the heavy-duty Overband Separator to operate at higher ambient temperatures

Suspension Magnets

Permanent suspension magnets are designed to extract occasional tramp iron from material being processed by means of a vibratory feeder, gravity chute, or conveyor belt. They are exceptionally efficient in removing tramp iron from coal, stone, fertilisers, recycled asphalt, slag, gypsum, ores and similar materials. Removing tramp metal contamination helps protect the other equipment in your facility from being damaged and maintains higher purity in the materials you are processing through your operation

Benefits of the Permanent Magnet Design

Constructed using non-deteriorating, high power ceramic components
Optional Rare Earth models available
Intensely durable construction resisting moisture, corrosion, and heat.
Inexpensive to operate with no cables or wires required
Ferrous material is extracted and held in place until manually ceaned of
ber wiper assists in removing the collected ferrous
Optional stainless steel slider plate simplifies clearing of f
Optional Tri-Polar design increases field strength and reach.
Suspension magnets come standard with suspension chains and hardware .
Can be suspended horizontally or on an incline
Available sizes cover a full range of conveyor widths.

Benefits of the Air-Cooled ElectroMax Suspension Magnet

Lighter than oil-cooled electro suspension magnets.
Less maintenance than oil-cooled electro magnets
Durable construction ensures longevity of equipment.
Ferrous material is extracted and held 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 600mm depending on material being separated

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

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

Tailored Magnetics Engineered to Fit Your Unique Application

Custom Magnetic Solutions

At Doon Magnetics, we understand that every industry and application has specific challenges—and off-the-shelf solutions aren't always enough. That's why we specialize in custom magnetic solutions designed to meet your exact technical, dimensional, and performance requirements.

From magnetic separation systems to custom-shaped magnets, assemblies, and enclosures, our team works closely with you to design, prototype, and deliver application-specific magnetic components that ensure optimal functionality, safety, and efficiency.

Doon Magnetics