Getting Metal Out of Pet Food

A Guide to the Ideal Location for Magnetic Separators and Metal Detectors in a Pet Food Processing Plant

Ensuring Pet Food is metal free before it reaches the consumer is critical.  However, reports of foods being recalled due to metal contamination occur several times each year [Sainsbury warns of Metal in Bread, Jan 2016].  To assist processors and producers, Bunting has developed a series of typical plant flowsheets showing proposed locations for Magnetic Separators and Metal Detectors.  This blog reviews a flowsheet for a typical Pet Food Processing Plant.

BUNT-2910 Perfect Plants 5

The flowsheet shows material being fed into the plant through to packaging and shipment to retailers.  The type and location of the Metal Separation equipment is detailed as follows:

  1. Infeed Material
    • Dry Side – Dry materials are often fed into the plant from transportation via a pneumatic line.  To remove ferrous metals (eg nuts, bolts, nails, etc) then a Pneumatic Inline Magnet is recommended.  Additionally, after storage in the primary silo, the dry material is passed through a Plate Housing Magnet before being mixed with any other materials, such as meat;
    • Meat Side – After discharge from the transportation, material is commonly fed up a conveyor.  Positioned above the conveyor to lift and remove larger ferrous metal is a Suspended Plate Magnet and this is then followed by a Metron C Metal Detector to identify any non-ferrous metals such as stainless steel.  This ensures that no metal is fed into the grinder where is could damage equipment and also be fragmented into smaller parts that are more difficult to detect and remove;
  2. After 1st Stage Mixing
    • After mixing, when the material is now in a slurry form, a Magnetic Liquid Trap with high strength Rare Earth Magnets is ideal to remove any smaller ferrous metals and any metal that originates from the wear of processing equipment;
    • Bunting Magnetic Liquid Trap
  3. On the Wet Line prior to Canning
    1. To ensure a metal-free product prior to canning, a P-Tron-O Metal Detector can be used on the line to detect and remove smaller ferrous and non-ferrous metals;
  4. On the Dry Line prior to Bagging
    1. After extrusion and just prior to bagging or insertion into cartons or boxes, a Quicktron Metal Detector is ideal to detect and remove any smaller remaining ferrous and non-ferrous metals;
    2. As a final check, the filled and sealed bags are commonly passed through a Metron C Metal Detector which can detect metal inside a package;

The type and design of Magnetic Separator and Metal Detector and the recommended location has been determined following several decades of working with food producers and processors all over the world.  There are always variations to plant designs and layouts that mean different types of Metal Separation equipment is needed and an onsite review by a Bunting engineer will help ascertain the best solution.

For further information on removing Metal from a Pet Food processing plant using Magnetic Separators and Metal Detectors, please contact the Bunting technical sales team on:

Phone: +44 (0) 1442 875081
Fax: +44 (0) 1442 875009
Email: sales@buntingeurope.com
Web: http://www.buntingeurope.com

Plate Magnet Bunting Magnetics-9805.jpg

A View of the South African Plastics Industry

Dave Hills Reports on his return from the ProPak Exhibition

Before getting on the plane, I was really unsure of what to expect at the ProPak 2016 exhibition that was being held in Johannesburg in South Africa.  We had recently teamed up with local company Eder Design to develop business for Magnetic Separators and Metal Detectors in the plastics sector and the show gave me an opportunity to gain a first hand  appreciation and understanding of the market potential and challenges.

ProPak was a 4 day show focusing on plastics and attendance was excellent even with torrential rainfall and flooding in the general locality on day 2.

IMG_0473

Eder Design had one of the largest stands at the show and on display was equipment from Piovan (Italy), Rapid (Sweden), BM Silos (Denmark) and Bunting Magnetic Separators.

Whilst speaking with plastics producers on the stand, it became apparent that the Magnets and Magnetic Separators commonly being used in South Africa were of low magnetic strength.  Eder had already sold higher strength Drawer Magnetic Filters to several companies and could see the substantial difference in metal separation performance.  They now include them as standard for all new installations.

Customers visiting the stand also commented on a problem with non-ferrous metal contamination and this resulted in a great deal of interest in the Machine Mounted All-Metal Separators (MMS), which is used in conjunction with a Drawer Magnetic Filter.

Over the four days, there was excellent footfall and we have a number of high quality leads to follow up.  There is no doubt that South Africa is a challenging market and, even though there is always a focus on price, Eder has built their business and reputation on supplying high quality equipment, commonly from Europe.

Being in the country enabled to gain an understanding and appreciation of the market that would have been impossible sitting in my office in Berkhamsted.  It has been great to spend time with the team from Eder and I am sure that this is just the beginning of a very exciting partnership.

Dave Hills is the Head of Sales at Bunting Magnetic Europe.

For more information on Metal Separation, Magnetic Separators, Metal Detectors of to express interest in becoming one of Bunting’s growing number of distributors, please contact us on:

Phone: +44 (0) 1442 875081
Fax: +44 (0) 1442 875009
Email: sales@buntingeurope.com
Web: http://www.buntingeurope.com

 

Is Household Waste Recycling Economically Sustainable?

Councils Losing Income as the Price of Recycled Materials Falls

The slowdown in the global economy is impacting the viability of many recycling operations, reports the BBC.  Local authorities have seen falls in steel prices of 88% and a halving in the price of waste plastic.

Hanbury Plastics Bunting Overband Magnet-7954

The fall in the price of recycled materials comes at a time when the amount of waste being processed is continually increasing and as political pressure for increased recycling from the UK and European Parliaments intensifies.  And there does not appear to be any prospect of change in the near future.

The only way to potentially increase the value of the recycled waste is to increase the purity or further segregate.  Steel and Aluminium are two relatively easily recovered materials (by using Overband Magnetic Separators and Eddy Current Separators) but the value can be compromised if contaminated with paper and plastic.

Many waste recycling operations have targets that relate to throughput and not recycled material output and this often compromises quality.  Seeking advice from equipment suppliers to improve the purity of recycled products is one way to potentially recover a small part of the lost revenue from falling prices.

As the UK’s Chancellor of the Exchequer, George Osborne, demonstrated yesterday, predicting movements in the global economy is exceptionally difficult if not impossible and there is no short term expectation of a strong recovery or increase in the price of recycled materials.  Looking at increasing product purity and productivity are potentially the only ways to combat lost revenue.

For further information on equipment such as Magnetic Separators and Eddy Current Separators for metal recovery, please contact the Bunting Technical Sales Team on

Phone: +44 (0) 1442 875081
Fax: +44 (0) 1442 875009
Email: sales@buntingeurope.com
Web: http://www.buntingeurope.com

Bunting Vulcanis-1098

Expanding the Bunting Network into South Africa with Eder Design

 

Export Business Development in the African Plastics Sector

Eder Design in South Africa has joined the expanding Bunting distributor network and is presently exhibiting Magnetic Separators and Metal Detectors at a major packaging, processing and plastics exhibition called PROPAK Africa 2016 being held in Johannesburg between 15th and 18th March.

Bunting_at_PROPAK2016 3A

Dave Hills, Bunting Europe’s Head of Sales, is presently at the exhibition with Eder Design on stand Hall 5 stand E21 providing training and support for the exhibition and is really impressed by the level of interest.

“Our growth strategy for 2016 and 2017 is to develop business overseas and appointing Eder Design is an important step into the totally new geographical market of Africa.  Johann [Eder, Owner of Eder Design] has a great working knowledge of our key primary markets of plastics and processing.  Eder represent other key suppliers to those industries including Piovan [Italy] and Rapid Granulators [Sweden] and BM Silos [Denmark] our range of Magnetic Separators and Metal Detectors fir perfectly into their product portfolio.”

Bunting specialise in developing metal separation equipment, especially for the plastics sector.  Dave has been impressed by the level of interest.  “Metal contamination is a huge problem causing damage to process plant such as granulators and extruders as well as affecting end product quality.  So far, we have received a wide range of enquiries especially for FF Drawer Magnets, Inline Magnets and All-Metal Separators.  We have been working through the plastics flowsheet looking at the best location for the metal separation equipment.  Also, being here means that we can demonstrate the strength of our Magnets. It is always good to see people looking bemused by the sheer magnetic strength as a bolt is stuck onto a Grate Magnet.”

Johann is equally excited by the new partnership.  “The South African market is developing rapidly and we at Eder Design want to provide the best quality European processing equipment.  Hence working with companies such as Piovan, Rapid Granulators and, now, Bunting Magnetics Europe.  The vast majority of our customers have experienced or are experiencing metal contamination problems and we can now help provide cost-effective solutions.”

Johann was also pleased with Bunting’s commitment to developing business in South Africa.  “Having Bunting Europe’s Head of Sales on the stand is a huge statement of intent.  This is the kind of support we need and will be hugely beneficial for our sales team and customers.  It also gives Dave a chance to gain a greater understanding of the South African market and this will help when we are developing sales and marketing strategies moving forward.”

Bunting will be announcing additional appointments as they further expand their distribution network.  Companies interested in potentially joining Bunting’s growing network should contact Dave Hills (details below).

For further information on any Metal Separation issue, please contact the Bunting Europe technical sales team on:

Phone: +44 (0) 1442 875081
Fax: +44 (0) 1442 875009
Email: sales@buntingeurope.com
Web: http://www.buntingeurope.com

 

Where are Metal Separators Positioned in a Plastics Plant?

A Guide to the ideal location for Magnetic Separators, Magnets and Metal Detectors

Determining the best location to remove metal in a Plastics Processing plant can be difficult and so Bunting has released a series of Typical Plant Flowsheets showing ideal locations for different designs and types of Magnetic Separator and Metal Detector.

Perfect Plastics Plant

On the flowsheet, the Plastics plant is divided into different areas and each has potential locations to remove metal.  In many cases, a combination of Magnetic Separator and Metal Detector is recommended as the Magnet captures and holds ferrous metal (the vast majority of metal contamination in any plant) leaving the Metal Detector to focus on removing the more difficult non-ferrous metals whilst minimising product loss and production downtime.  The type and suggested location of Metal Separation equipment is as follows:

  1. On the primary feed into the Bulk Storage Silo to remove metal before it enters the process:
  2. From the Bulk Storage Silo to capture any metal from the storage silo:
  3. On the Moulding Line to protect processing equipment;
  4. On the 1st Extruder to protect processing equipment
  5. On the Hot Runner System to protect processing equipment
  6. Molding (just in time material handling) to protect processing equipment
    • Torpedo Magnet to remove ferrous metal;
    • Machine Mounted All-Metal Separator to remove all metals;
  7. On the 2nd Extruder to protect processing equipment
  8. On the Regrind Line to remove metal introduced during reprocessing
  9. On the Cleaning Station as a final metal removal stage
    • Duplex Separator

The type and design of Magnetic Separator and Metal Detector and the recommended location has been determined following several decades of working with plastics producers and processors all over the world.  There are always variations to plant designs and layouts that mean different types of Metal Separation equipment is needed and an onsite review by a Bunting engineer will help ascertain the best solution.

For further information on removing Metal from a plastics processing plant using Magnetic Separators and Metal Detectors, please contact the Bunting technical sales team on:

Phone: +44 (0) 1442 875081
Fax: +44 (0) 1442 875009
Email: sales@buntingeurope.com
Web: http://www.buntingeurope.com

AJ Solutions Working with Bunting in Belgium

Dave Hills Talks Magnetic Separation and Metal Detection at AJ Solutions Open Day on 10th March 2016

Bunting Europe’s Head of Sales, Dave Hills, is in Belgium with local distributor AJ Solutions for their 10th anniversary open days.  AJ Solutions has been working with Bunting since 2012, promoting metal separation equipment used in the plastics sector.

Dave_Hills_Alain_Janssens_AJ_Solutions
Dave Hills (Bunting Europe’s Head of Sales) with Alain Janssens (Owner of AJ Solutions)

 

Dave Hills is excited by the opportunity.  “We [Bunting] want to support our overseas distributors as much as possible and so I was thrilled when AJ Solutions invited me to give a presentation at their open day.  AJ Solutions has a great reputation in the plastics sector, one of our primary markets.  The range of equipment that they offer perfectly complements our range of Metal Separators.”

“Also, it is great to be here as AJ Solutions celebrate their 10th anniversary.  They have a 10 year history of providing excellent customer support and we hope to be working wiBunting_Magnetics_at_AJ_Solutions-th them and developing business in the region for the next 10 years and more.”

AJ Solutions Owner, Alain Janssens, added:  “We re really pleased that Dave could come over and give a presentation on Metal Separation.  Representing Bunting means that we can help all our customers in the plastics industry find solutions for metal contamination problems.  Bunting is a really good fit in our product range.”

The AJ Solutions open days are held over the 10th and 11th March 2016.  There are 23 companies exhibiting and over 200 people from the plastics industry have booked to attend.

For more information about Magnetic Separators and Metal Detectors used in the plastics industry or to enquire about becoming a Bunting overseas representative, please contact us on:

Phone: +44 (0) 1442 875081
Fax: +44 (0) 1442 875009
Email: sales@buntingeurope.com
Web: http://www.buntingeurope.com

AJ_Solutions-
AJ Solutions premises

Pros and Cons of the Inline Magnetic Separator

The Bunting Product of the Month for March

The Inline Magnet is one of the most versatile Magnetic Separators available.  There are 3 different models:

  1. Gravity Inline Magnets (GIM) – A Plate Magnet, positioned inside a fabricated tube, captures ferrous metal from gravity-flowing product;
  2. Pneumatic Inline Magnets (PIM) – Again a Plate Magnet is used, but the fabricated body is designed for use in pneumatically fed process lines;
  3. Centre Flow Inline Magnets (CFM) – The Plate Magnet is replaced by a Magnetic Cone positioned in the centre of the fabricated body;

In all cases, the Magnet supplied is either standard strength Ferrite or high powered Rare Earth Magnets.  The strength of Magnet is dictated by the type of ferrous metal that needs to be removed.

Bunting Magnetics In Line Magnet-24

Pros and Cons of the Inline Magnets

The versatility of the Inline Magnet means that it is used across a wide range of industries including Food Processing, Plastics, Recycling, Chemicals and Bulk Handling.  However, the Inline Magnet is not ideal for every metal separation application.

Pros of the Inline MagnetBunting Magnetics In Line Magnet-17

  1. There is limited restriction to the product flow, reducing the chance of any blockages;
  2. The deep magnetic field reaches right across the product flow to drag ferrous metal into the capture zone;
  3. The strong magnetic field ensures that any captured ferrous metal does not get knocked off by product flow;
  4. By opening a sealed side door, the Plate Magnet or Magnetic Cone can be easily cleaned of captured ferrous metal;
  5. Easy to install into existing process lines;

 

Cons of the Inline Magnet

  1. Only suitable for dry material processing.  For processing slurries and liquids, the Liquid Magnetic Trap is required;
  2. There is a limit to the distance between the Magnet face and opposite side of the fabricated body, otherwise metal may be missed.  The Magnetic Hump, with two Plate Magnets, is often used for larger apertures;

For further information on the Bunting Inline Magnetic Separator, please contact our technical sales team on:

Phone: +44 (0) 1442 875081
Fax: +44 (0) 1442 875009
Email: sales@buntingeurope.com
Web: http://www.buntingeurope.com

Bunting® Magnetics Co. Names Robert Bunting General Manager, Magnet Materials Division

Bunting® Magnetics Co., announce the promotion of Robert Bunting to General Manager, Magnet Materials Division, effective March 1, 2016.

HiRes_BuntingMagnetic-40

Bob Bunting, President and CEO, Bunting Magnetics, made the announcement.

“Robert’s aptitude, experience and contributions have been invaluable. I am confident his innovative thinking, sales and management skills will enhance this division’s growth, profitability and long-term strategic direction,” commented Bunting.

Throughout high school, Robert worked at the company’s Newton, Kansas Global headquarters in both manufacturing and engineering.  Soon after his graduation from Rockhurst University, he became a member of the internal sales team at the Magnet Materials Division. His sales experience grew as an outside sales representative for the Standard Product Group, where he was recognized as one of the company’s top sales producers. Robert was most recently Product Manager for the Metal Detection Product Group where he assumed all responsibility for sales and profitability for Metal Detection equipment.  In 2014, Robert earned the Product Manager of the Year Award.

The company’s Magnet Materials Division comprises of thousands of products sold through its recently revamped website, buymagnets.com, as well as inside and outside sales initiatives. The magnets and magnetic products are shipped around the world from its warehouse located in suburban Chicago. The division has a staff of seven in sales, shipping, manufacturing and distribution.

For further information on this announcement or any Magnet, Magnetic Separation or Metal Detection project, please contact the Bunting Magnetics Europe team on:

Phone: +44 (0) 1442 875081
Fax: +44 (0) 1442 875009
Email: sales@buntingeurope.com
Web: http://www.buntingeurope.com