Magnetic Head Pulleys operate much the same as non-magnetic Head Pulleys, except that the metal pieces are discharged separately to the non-magnetic product stream.
As the product stream reaches the conveyor discharge point, ferrous metal is attracted to the pulleys magnetic field and held to the belt. As the belt moves around the pulley, the non-magnetic material is discharged in a normal trajectory, however, the ferrous metal is still held to the belt.
When the belt passes out of the magnetic field, the magnetic material drops off into a separate chute or bin to the rest of the product. A non-magnetic splitter may be installed to separate the two discharges.
Ferrous metals commonly extracted from the product stream include nails, nuts, bolts, wire, cans, screws, tools, and so on.
MSA can supply complete new Magnetic Head Pulleys or can fit Magnetic Lagging Strips to your existing Pulley.
The addition of Magnetic Lagging Strips to your existing Pulley is not only a cost-effective solution (as opposed to purchasing a complete new Pulley System), but also assists with conveyor belt tracking. The lagging will only cause a small increase in the weight and diameter of the existing pulley.
Foreign tramp iron and metal fragments in stock feed can cause injuries to farm animals and handlers, cause customer complaints, and can also damage expensive processing equipment.
MSA’s Stock Feed Magnet Retrieval Systems comprises of powerful Overbelt Suspension Magnets and Magnetic Head Pulleys. Used in combination, these two magnets have numerous advantages, some of which include:
- Help maintain and increase the value of the stock feed
- Increase product purity and final product protection
- Reduce liability
- Protect expensive processing equipment, such as chaft cutters
- Protect livestock from injury
The MSA Stock Feed Magnet Retrieval Systems have been known to reduce reject bales by 75-90% and customers have reported filling at least 1 x 44-gallon drum with recovered tramp metal within one month.
- Australian Made
- Engineered for use in stock feed production
- Scalping magnet easily discharged using proprietary stainless-steel draw system
- Cost-effective long-life option for steel separation
- High energy RE80 Rare Earth magnets
- Design assists with conveyor belt tracking
- Reduces belt damage
- Highly effective magnetic field design for maximum lower burden penetration
MSA Magnetics can supply complete new Magnetic Head Pulleys or can convert your existing Head Pulleys into Magnetic Head Pulleys.
For more information on how you can reduce tramp metal in your stock feed production, or to request a quotation, please contact the MSA team of engineers.
Let us help you find out.
MAGNETS FOR WASTE AND RECYCLING FACILITIES
The recovery of metal from waste materials is extremely important for the recycling industry.
The filtering out and extraction of metals has 3 main purposes –
- Resource Recovery – Metals can be reused. They are often remelted and reshaped into new products.
- Product Purification – Waste products such as timber and glass are more suitable for recycling after tramp metal has been removed.
- Plant Protection – Tramp metal can cause damage to expensive recycling equipment if not removed (e.g. plastic granulators).
METAL SEPARATION EQUIPMENT
Metal separation equipment such as Eddy Current Separators, Overbelt/Suspension Magnets, and Pulley Magnets are used in recycling and waste facilities to extract metal pieces from the products.
Commonly extracted metals include:
- Ferromagnetic particles such as iron, steel, and work-hardened stainless steel (SS). These are usually extracted by Overbelt Magnets or Pulley Magnets.
- Nonferromagnetic particles such as aluminium and copper along with inert materials. These are extracted by Eddy Current Separators.
Often a number of separators are installed in various strategic locations around a plant. This ensures that both types of metals are removed and the risk of metal contamination is minimized.
Overbelt and Suspension Magnets are installed above belt conveyors to magnetically lift ferrous metal pieces out of the product stream. Contaminants are held against the magnet until cleaned (manual and self-cleaning designs are available).
Click here for more information on overbelt magnets
Magnetic Head Pulleys operate at the discharge of belt conveyors. As waste is dropped off the end of the belt, the metal that may be on the belt, under the burden of material, is held by the magnetic energy of the pulley and dragged around by the belt underneath the conveyors and dropped off into another bin. Magnetic Head Pulleys are ideal as a secondary complimentary magnet downstream of overbelt/suspension magnets.
MSA can provide new magnetic head pulleys or can transform your existing head pulleys to a highly magnetic pulley using MSA’s patented magnetic lagging system.
Click here for more information on magnetic head pulleys
Eddy Current Separators are essential in material recycling facilities and other general dry waste processing plants. They are used for the removal of non-ferrous metals from dry waste streams. They are typically part of the final stage of the process, removing the non-ferrous materials from the remaining plastics and small fragments of paper/cardboard.
It is critical when dealing with unsorted recyclables to utilize magnetic screening upstream from the Eddy Current Separator (ECS). The ECS, unless it has an incorporated Drum Magnet, cannot remove ferrous materials. It is ideal to have magnetic screening upstream from the ECS to reduce load and wear and tear on the ECS.
RECYCLING AND WASTE APPLICATIONS
Magnetic separators are often used to filter out metal pieces from waste applications such as –
- Construction and demolition debris. Asphalt, bricks, concrete, plasterboard, timber, building waste, and other excavated demolition waste is often contaminated with metal pieces – from large pieces of concrete reo, wear plates, and bucket teeth, to smaller items such as nails, nuts, and bolts. These contaminants must be removed before the demolition material is processed to be used for pavements, earthworks, and drainage, amongst other uses.
- Material Recovery Facilities (MRF). All the stuff you’d find in a yellow recycling bin.
- Glass. Glass fines can be used as a replacement for virgin sand when manufacturing new glass objects, or for civil construction projects such as in the embedment of residential sewerage pipes and water mains – concrete aggregate and cement mix. It is essential that metal contamination is removed before it becomes an issue.
- Timber recycling such as utility poles, cable spools, and pallets. The need for high-quality timber products means that recycling timber is now more useful and viable than disposing it at landfill or using it as fuel. Wooden pallets are mostly recycled for poultry bedding. Timber products must be inspected for metal pieces such as nails and bolts before processing, otherwise, equipment is damaged easily.
- Tyres and rubber
- General waste
- Shredder floc
The Australian Government has committed to working with the Environment Protection Authority (EPA) over 9 years to assist in maintaining a clean environment and reducing landfill. Funding has been made available, through grants, to all sectors of the recycling industry to help improve best practice systems.
This includes funding for waste and resource recovery initiatives, such as improved recycling facilities. New and improved recycling infrastructure and equipment will allow waste processors to develop more innovative and efficient methods for processing materials.
A key target of the EPA is to increase the amount of waste processed and decrease the amount of waste sent to landfill by 75%. The EPA is aiming to increase the reuse, recycling, and reprocessing of materials such as timber, cardboard/paper, plastics, and packaging. Processed waste must therefore be high quality and free of any contaminants, such as metal pieces, that will have a negative effect on the recycling process and potentially damage plant equipment.
Between 2017-21, the NSW EPA initiative, ‘Waste Less Recycle More’ has allocated a total of $48 million to improving recycling infrastructure. Similarly, the Victorian Sustainability Fund has allocated $30.4 million to waste and resource recovery.
Magnets and Eddy Current Separators are critical components in any resource recovery application. Improvements to ferrous and non-ferrous metals sorting lines are able to be considered for partial funding under these current EPA grants.
Waste Initiatives have partnered with MSA to assist recycling companies’ with collecting unwanted tramp iron and metal pieces from their waste product lines.
Based in Singleton NSW, Waste Initiatives are leading suppliers of quality recycling solutions including balers, shredders, and compactors. They are also approved resellers of MSA equipment.
Magnetic separators are available direct through MSA, or from Waste Initiatives.
MSA Magnetics offers full-service support to all Waste Initiatives Magnet customers, so no matter who you decide to buy MSA products through you are covered!
MAKE AN ENQUIRY
Have a need regarding tramp iron and metal removal in your recycling facility? Contact us today for assistance and a quote on high-quality magnetic separation equipment.
Click here to contact us
DO THE LIFTING PRACTICES IN YOUR FACTORY GIVE UNNECESSARY STRAIN TO YOUR WORKERS?
A large Sydney-based bakery (name withheld) recently contacted MSA regarding a problem they had with lifting large metal billets out of lathe chuck jaws in their maintenance workshop. The heavy 18+ kg billets were being transported by slings, a method which held many WHS risks:
- Unnecessary strain on staff as they bent at uncomfortable angles to remove the heavy billets.
- Risk of billet falling out of the sling due to insufficient holding surface area.
- Damage and wear to the slings posed a huge safety risk if they unexpectedly broke.
- Risk of billet falling out of the sling cradle due to it not being designed to hold a workpiece offset.
These slings would often lift between 20 – 500 kg of weight and although tested every 3-6 months, were still not considered the ‘best practice’ as manual loading of weights into the sling was still necessary.
The bakery researched the various types of lifting methods and concluded that the MAGSWITCH MLAY1000x4 heavy lifting magnet was the answer to their problems.
The MLAY1000x4 is a switchable magnet that has been specially designed for use in workshop environments to aid in the lifting of heavy ferrous materials, with a holding strength of up to 591 kgs (1,300 lbs) with a 3:1 SWL. It is lighter and stronger than competitive shunting switchable magnets, eliminates the strain that the slings were causing the bakery workers and greatly reduces the WHS risks that the slings held.
The customer provided MSA with the justification document in which they highlighted the benefits the MLAY1000x4 held for their applications:
- “Far less prone to damage and failure
- Quick and easy setup and to operate
- Can lift vertically instead of horizontally
- Allow slings to be kept for machined work and non-ferrous handling, reduces wear and tear on the slings
- Latest Safety two press finger latch to activate/de-activate magnet arm (prevents unintentional switched off)”
After purchasing and installing their new Magswitch lifting magnet, the bakery workers now experience a much safer work environment, and it has increased productivity due to the decrease in time taken to lift the heavy billets.
They since have found use for the magnet loading/unloading raw materials from delivery trucks, again increasing their productivity while improving their WHS standard.
The Magswitch MLAY1000x4 is available for purchase from MSA Magnetics. Call (02) 4272 8180 or visit the MLAY1000x4 page on our website to find out more.