FF Drawer Grate Magnet Gets Metal Out of Plastic

The Bunting Product of the Month for April

A FF Drawer Magnet is one of the most versatile and widely used Magnetic Separators in the plastics industry.  Companies producing plastics and plastic products use the Magnetic Separator to capture and remove problematic and potentially costly ferrous metal Bunting Grate Magnetcontamination.

Inside the FF Drawer Magnet housing are 2 or more rows of carefully spaced and highly-powered Tube Magnets.  In operation, plastic beads or flakes flow under gravity through the FF Drawer Magnet and over the Tube Magnets.  The Magnetic Field attracts and then holds any ferrous metal contamination, ensuring the plastic product continues through the process metal-free.  Periodically, the Tube Magnets are manually cleaned of captured ferrous metal by an operator, although self-cleaning models are also available.

Magnetic Specification

  • Magnet type:  High strength, permanent, Neodymium Iron Boron Rare Earth Magnets;
  • Temperature rating:  Unlike standard Rare Earth Magnets, the FF Drawer Magnets are suitable for high temperatures (up to 80 deg C).  This enables the Magnets to maintain performance when positioned on or close to extruders, and injection and blow moulding machines;

Bunting Magnetics Europe Ltd FFS Magnet-0088

Housing Design

  • Housing construction:  11 gauge stainless steel;
  • Compression load:  Designed to handle symmetrical compression loads of 4,500kg;
  • Drawer gasket:  Ethylene Propylene Diene (EPDM) and designed to resist heat aging and compression;
  • Transition connection:  Both square and circular are available;

Options

Depending on the process, there are a number of other design options available including:

  • No-Spill Side Gate, which effectively switches off the product flow. When the Magnets are then removed for routine inspection or cleaning there are no concerns regarding health and safety or spillages;
  • Purge Hopper, which is ideal when there is a change of the product being processed (eg colour or compound) and enables the equipment to be cleaned without the need to empty the hopper or compromising magnetic protection;
  • Dump Tube, which is designed to totally empty the housing and the material hopper once a plastic run has been completed;
  • Liquid Port, which is a port with dual purpose. It can hold a temperature probe but primarily it provides a means to inject liquid colour additive into resin;
  • Powder Seal Kit, which limits any leaking of powdery materials by putting a compression seal around the slide gate;

Low Profile Designs

Often space is limited and headroom is at a premium.  To suit such locations, the Low Profile Design of FF Drawer Magnet was introduced.  The lower profile means that there is only one row of Tube Magnets, which does reduce the effectiveness of metal separation.  However, one row of Tube Magnets is better than none at all.  Bunting installed a number of Low Profile FF Drawer Magnets into BPI Minster Films.

Bunting Drawer Magnet in a Plastics Operation

A guide on the best location for both Magnetic Separators and Metal Detectors in a Plastics Production and Processing plant can be found in the blog ‘Where are Metal Separators Located in a Plastics Plant‘.

For further information, 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

Imports Rise, But What About UK Manufacturers?

Plastic Machinery Imports Strongest for 11 Years

PRW featured the PMMDA report stating that 643 injection moulding machines were imported into the UK in 2015, the strongest numbers since 2004.  This is really positive news for the UK plastics sector and an indication of strong investment.

However, is this just another indication of the demise of manufacturing in the UK?

Having a strong manufacturing sector is vital to the success of any economy and there are many successful and growing UK machinery manufacturers.  At Bunting Magnetics Europe, we manufacture magnetic separators that are sold into many different industry sectors including plastics.

F33A6146

If this increase in the purchase of equipment overseas is an indicator of sustained growth and investment in the plastics sector, are there opportunities for new UK manufacturing companies to emerge?  The competition is very stiff, especially when imported from low cost manufacturing regions and countries such as China, but there are advantages.

This year’s uncertainty about the EU and the reported steel dumping by China has made many people sit up and think that supporting local business and manufacturing may be the way forward.  Dependence on purchasing overseas introduces a number of additional uncontrollable risks (eg political, economic, etc).  There needs to be a will and desire to change from business and Government.

An expanding UK manufacturing sector would be fantastic, but are the hurdles too frightening to face at this present time?

Bunting Magnetics Europe Ltd manufacture a wide range of Magnetic Separation equipment at their European manufacturing headquarters in Berkhamsted.  For further information on any metal separation issue, please contact the Bunting sales team on:

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

Welding at Bunting Magnetics Europe-4

New Magnetic Separator Recovers Printed Circuit Boards

Separating PCBs from Shredded Plastic and White Goods

Bunting Magnetics has developed a new Magnetic Separator that separates and recovers Printed Circuit Boards (PCBs).  The High Intensity Separation Conveyor (HISC) has an exceptional strong magnetic head pulley and was originally designed to separate very weakly magnetic materials such as abraded and shredded stainless steel.  During on-site tests at a UK plastics recycling company, the HISC was also found to efficiently separate and recover PCBs.

Bunting HISC Stainless Steel Separator-13

The separation of Printing Circuit Boards is an issue for many recycling companies, especially those involved in WEEE (Waste Electrical and Electronic Equipment).  PCBs contain a number of components mounted on a non-conductive substrate including capacitors, resistors and active devices.  A PCB will contain gold, palladium, silver, copper and different hazardous materials, and cannot be disposed of in landfill.  Once recovered, there are companies who specialise in recovering the precious metals from the PCBs, but firstly, these need to be recovered from a waste stream.Bunting HISC Stainless Steel Separator-2

Bunting’s HISC Magnetic Separator is commonly installed after primary Magnetic Separation and Eddy Current Separation and is used to either remove weakly magnetic materials from the primary product to produce a clean recycled material (eg UPVC window frames, recycled plastics, etc), or recover valuable materials (eg stainless steel and PCBs).

The strength of the magnetic field is far greater than standard magnetic separators, extending the separation capabilities from just removing ferrous and strongly magnetic materials to materials that have a very low magnetic susceptibility.

For further information on the High Intensity Separation Conveyor for PCB separation or any Magnetic Separator for the recycling industry, please visit contact our technical sales team on:

More Concerns for UK Manufacturing?

1.8% Drop in Manufacturing Year-on-Year in February

As reported in PRW, the latest performance data for the UK’s manufacturing industry raises a number of questions and concerns.  A drop in production output of 1.8% on February 2015 is significant and must concern the UK Government.  Whilst the arguments and discussions surrounding the UK retaining steel manufacturing capabilities rumble on, this latest data highlights the delicate and fragile nature of the economy.

From a manufacturer’s perspective, there is no point in dwelling on the past, but instead assess ways to forge the future.  The UK has an excellent manufacturing industry that leads the world in many areas.  Yes, the global economy is delicate and it is a far bumpier ride than prior to 2008, but there are still great opportunities for successful, creative and dynamic manufacturing companies.

Developing business overseas has always been challenging, but is a vital part of most manufacturing companies businesses.  At Bunting, this was identified as a key part of our growth and so far this year we have:

Appointed New Representatives

Dave_Hills_Alain_Janssens_AJ_SolutionsWe are presently working on appointing new representatives in many other countries and if you are interested in joining the Bunting sales distribution network, then please contact us.

Plan to Exhibit in the UK and Overseas

Exhibiting our range of Magnetic Separators and Metal Detectors overseas has always proven successful and this year Bunting will be exhibiting at:

  • Waste 16, AJ Bell Stadium, Salford (9th June 2016) – Bunting is the headline sponsor of Waste 16, an exhibition organised by Skip Hire Magazine.  Focusing on the waste and recycling sector in the Northern part of the UK, the exhibition continues to grow and is a key show for the sector.Waste 15-0105
  • RWM 2016, NEC, Birmingham (13th – 15th September 2016) – Following a very successful show in 2015, on stand 5T152-V153 Bunting will be demonstrating metal separation equipment for recovery and removal of metal from a wide variety of recycled and reclaimed materials.
  • K-Show, Dusseldorf, Germany (16th – 26th October) – On stand C11 in Hall 10, Bunting is displaying Metal Separation equipment including a range of Magnetic Separators and Metal Detectors.

Developed and Launched New TechnologyBunting HISC Stainless Steel Separator-13

The new High Intensity Separation Conveyor (HISC), which is designed to separate weakly magnetic materials such as Stainless Steel and even Printed Circuit Boards, has proved to be a great success in the recycling industry (news as featured in HUB4 online).  Despite the recycling industry suffering from low material prices, the HISC has enabled companies to recover more and cleaner metal, adding value.

What does the Future Hold?

There are many aspects of the Marketing Environment that remain outside the control of any company like the UK’s membership of the EU or dumping of low cost goods and materials by low cost manufacturing regions.  By molding and changing those aspects within our control, UK manufacturing can continue to be a key part of the UK economy despite the future remaining challenging.

Comments and feedback from other UK manufacturing companies would be welcomed.

For further information, please contact Bunting on:

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

 

Bunting Eddy Current Separating Metal from Plastic

Video Showing Metal Being Propelled Out of Shredded Recycled Plastic

Getting the metal out of reclaimed plastic to enable efficient recycling is vital and Bunting has installed a complete Metal Separation Module in a plastics recycling plant to achieve this basic objective.

The Metal Separation Module comprises of a large Vibratory Feeder that controls and regulates the flow of shredded plastic onto a high strength Rare Earth Drum Magnet.  At this stage, ferrous metal is removed.

The ferrous metal free plastic then flows onto the moving conveyor of an Eddy Current Separator, when non-ferrous metals (eg aluminium, copper, zinc, etc) are propelled out of the material flow by a strong, rotating magnetic field produced by a large Magnetic Rotor.

Separation on the Eddy Current Separator is optimised by adjusting the speed of the conveyor belt and position of the splitter.

Simple and efficient and the Bunting Metal Separation Module ensures that the client Gets All The Metal Out!

For further information on Magnetic Separators and Eddy Current Separators for recycling operations, 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

Getting Metal Out of Recycled Tyres and Rubber

A Guide to the Ideal Location for Magnetic Separators and Metal Detectors in a Tyre and Rubber Recycling Plant

Successfully removing the metal banding from rubber when recycling tyres is critical as rogue metal can cause injury to horses and children who run and play on the rubber crumb.  Although each tyre recycling plant is different, here is a guide to the types and location of Magnetic Separators to remove the steel.

The biggest challenge with removing all the steel wire from shredded tyres is to maximise separation whilst minimising product (rubber) loss.  This means that multi-stage Magnetic Separation is required.

Tire_Recycling

As shown in the typical plant layout, the primary objective is to liberate the rubber from the metal and this is commonly achieved with a 2-stage shredding set-up.  This achieves optimum size reduction whilst also producing a rubber crumb material that is well liberated.  After the 2nd stage of shredding, it is then possible to focus on the separation of the steel.

Step 1 – Primary Magnetic Separation after the 2nd Shredder

At this stage, the objective is to separate the bulk of metal and this is achieved using a high strength Twin Pole Overband CBS Magnet.  The Twin Pole Overband produces a deeper and stronger Magnetic Field to lift and separate small wires and wire still entrapped in rubber (as explained in the blog The Benefits of a Twin Pole Overband Magnet);

Bunting Overband Single and Twin Pole Magnetic Field

Step 2 – Magnetic Separator Treatment of the Separated Metal Fraction

As there will be clean rubber product carried over into the separated metal fraction, the material can be passed over a Magnetic Drum Separator or Magnetic Pulley or the High Intensity Separation Conveyor (also known as the Stainless Steel Separator), all using high strength Rare Earth Magnets.  It is important that either of these has an Axial magnetic field (one that runs along the length of the Magnetic Separator) as this causes the material to tumble and release entrapped rubber.  If a Magnetic Drum is uses, then consideration is needed for either a manganese steel shell or wear cover as the strong magnetic characteristics of the steel wear can result in heavy wear;

Step 3 – Secondary Magnetic Separation

A second stage Magnetic Separation treatment of the primary rubber product prior to storage is recommended to remove any stubborn metal left after the first stage separation.  This is achieved using a second Twin Pole Overband CBS Magnet;

Step 4 – Magnetic Treatment of the Rubber Powder

For fine rubber material, that is fed onto a powder grinder, a final stage Magnetic Separator is needed to remove small fragments of wire.  As the volume of metal is low, a Plate Magnet suspended close to the product over the conveyor will lift and remove the fine wires;

Plate Magnets Bunting Magnetics

The 4 steps outlined are generalisations in line with work Bunting has conducted with tyre recyclers around the world, but each plant is often unique.  When considering metal separation, either from the start or to improve on the level of metal separation presently being achieved, a review of the plant by one of the Bunting or Master Masters Application Engineers will enable the recommendation of the optimum design and location of a Magnetic Separator.

For further information on removing Metal from Recycled Tyres using Magnetic Separators, 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

Metal Separation from Rubber Crumb