EcoVyn Reduce Waste by 94% with Bunting Drawer Magnets

Magnetic Separators Remove Contamination from Plastic Waste

EcoVyn Ltd has installed two Bunting Drawer Filter Magnets to remove ferrous metal contamination from plastic waste.  Since the installation of the magnetic separators, EcoVyn has reduced their waste by 94%.

Bunting Magnetics Drawer Magnets at Ecovyn
Bunting Drawer Filter in situ at EcoVyn

EcoVyn Ltd is at the forefront of PVC compounding and brings pioneering new technology to the market place.  They offer one of the most advanced and innovative production processes in the UK producing reprocessed, blended and virgin compounds for a variety of applications.

EcoVyn first met Bunting at the Interplas international plastics exhibition in September 2017.  The company use a high proportion of plastic waste, of which 80% is post-consumer.  Presently, EcoVyn processes 1000 tonnes per month of good quality reclaimed plastic waste, which they plan to increase to 16,000 tonnes per annum.  The cleansed plastic waste is blended into virgin material, resulting in a 90% output of grade A product.  Waste generated during the manufacturing process is also recycled leaving less than 1% being discarded.

Bunting Magnetics Drawer Magnets at Ecovyn
Granulated plastic waste

However, plastic waste is often highly contaminated with metal.  Metal Detectors were already installed to remove the metal contamination, but the reject rate was very high with over 60 tonnes of waste being generated, of which a high proportion was good quality plastic.

At Interplas, EcoVyn explained the problem to the Bunting team who agreed to conduct a site review.  During the review it was concluded that easily removable magnetically-susceptible metal could be removed, leaving the metal detectors to detect and separate non-ferrous metals.  This would then significantly reduce the number of metal detector rejections and, therefore, the amount of waste generated.

After a review of the process, Drawer Filter Magnets were recommended to be installed between the screw conveyor transporting the 8-10mm sized infeed material and the metal detector.  The metal-cleansed material would then pass onto a pulveriser before continuing through the process.

The Bunting Drawer Filter Magnet is used widely in the plastics industry and enables the simple and effective removal of ferrous metal from free-flowing materials.  The Drawer Filters installed at EcoVyn have two rows of high strength Rare Earth Neodymium Magnets.  The top row has two Tube Magnets with three in the second row aligned to sit below the gap in the top row.  This ensures that all the product strikes at least one of the Tube Magnets, where ferrous metal is attracted by the strong magnetic field and captured.

Bunting Magnetics Drawer Magnets at Ecovyn
Ferrous metal captured on the surface of the Tube Magnets

After the installation of Drawer Filter Magnets, the amount of waste was reduced from 60 tonnes to 4 tonnes.

Since installing the Drawer Filter Magnets, EcoVyn has established that a 20 minutes cleaning frequency is required, highlighting the high level of metal contamination commonly found in plastic waste.  The ferrous metal found captured on the Tube Magnets ranges from small fine ferrous dust to nails, washers, steel sheet shards and electrical capacitors.

Bunting Magnetics Drawer Magnets at Ecovyn
Ferrous metals captured by the Bunting Drawer Grate Magnet including nails, a capacitor, washer, wire and steel sheet shard

Following the installation of the Bunting Drawer Filter Magnets, controlled laboratory tests have been conducted at Bunting’s Master Magnets facility in Birmingham which indicated that 99.9% of all ferrous metals had been removed.

The final plastic product produced by EcoVyn is then used to manufacture products such as pipe, internal windows, beading, picture frames, and shoe soles.

For further information on separating metal from plastics during the production of the virgin product or during the recycling process, please contact the Bunting team on:

Hillhead Attracts Bunting Europe

Bunting Europe Exhibit at Hillhead for the First Time

Magnetic Separators and Metal Detectors for the quarrying, mining and recycling industry will be on show on stand C9 at this year’s Hillhead exhibition (Hillhead Quarry, Buxton, 26-28 June 2018).

Bunting Master Magnets at RWM17

The joint Bunting Europe and Master Magnets stand will feature Permanent Overband Magnets (self and manual clean designs) and two different types of Metal Detector (the TN77 and QTA).

“Hillhead has always been a really important exhibition for Master Magnets,” said Dave Hills, Bunting’s Head of Sales.  “The Master Magnets Overband Magnets and Metal Detection Ltd range of detectors are widely regarded as industry standards for both quarrying and recycling.”

Held in a limestone quarry in the heart of the Derbyshire countryside, Hillhead is the largest exhibition of its kind anywhere in the world. Continually adapting, it provides a spectacular and unique setting for exhibitors and visitors alike to do business amongst live working demonstrations and static displays.

aggregate-industries-tn77-e1528271468785.jpg

Many quarries use the combination of a Permanent Overband Magnet and Metal Detector to protect processing equipment such as screens, crushers and conveyor belts.  The Overband Magnet removes any magnetic tramp metal leaving the Metal Detector to identify non-magnetic metal parts such as manganese steel digger teeth.

“The recycling of construction waste continues to grow in importance and features strongly at Hillhead,” said Dave.  “With equipment such as the Mastertrax Mobile Eddy Current Separator, we have practical solutions for removing ferrous and non-ferrous metals.”

May through to July is a very busy exhibition period for Bunting Europe and Master Magnets.  Hillhead is just over one month after the very successful IFAT waste and recycling show in Germany and is followed by the Waste ’18 exhibition (Warwickshire Exhibition Centre, 5 July) and CARS (NAEC Stoneleigh, 11-12 July).

“Exhibiting at these events is so important,” explained Dave.  “We meet both existing and potentially new clients and can also show them what our equipment can do.”

For further information on the Magnetic Separation and Metal Detection equipment on display at Hillhead, please contact Dave Hills on:

Phone: +44 (0) 1442 875081
Email: dhills@buntingeurope.com
Via the website

Master Magnets Mobile Eddy Current Separator (1200)

59 Pastry Products Potentially Contaminated with Metal

Tesco, Aldi and Nisa Recall Pastry Product Due to Potential Metal Contamination

On the 2nd June 2018, the Food Standards Agency announced that the Addo Food Group was recalling batches of chilled pastry products, including sausage rolls, pasties, pastry pies and slices because of potential contamination with small pieces of metal wire.  This is the latest food safety recall due to metal contamination and the announcement comes seven days before the start of National Food Safety Week.

Addo Food Group manufacture the chilled pastry products as own-branded products for major UK supermarkets Tesco, Aldi and Nisa, as well as those produced under the Walls and Millers brands.  The extent of the recall is substantial, with 59 products being recalled.

How Does Metal Get Into Food?

Unfortunately, food product recalls due to metal contamination are relatively common with 6 Food Safety Scares reported by the UK Food Standards Agency in 2017.

Metal In Food-1127

However, with the correct combination of Magnetic Separators and Metal Detectors, such disastrous and costly product recalls should not happen.

Metal can enter the food production process at a number of stages:

  1. Metal can be present in the foodstuffs being delivered.  To prevent such an introduction of metal into the process, many food processors pass the in-feed material over Magnetic Separators and through Metal Detectors;
  2. Processing equipment wear and failure (e.g. screen break, pump collapse, etc) can cause metal to enter the process stream;
  3. Accidental introduction by people on site;

However, with the right combination of metal separation and detection equipment, such metal can be found and removed before any finished product leaves the production facility.

How To Prevent Metal Contamination

The vast majority of food processing plants have Magnetic Separators and Metal Detectors installed.  Many of these have been in operation for many years which, in some cases, can be decades.

Bunting Magnetics Pull Test Kit
Demonstration of how to use the Bunting Magnetics pull test kit to measure the strength of Tube Magnets and Plate Magnets

During some recent Magnetic Separator Audits at UK food processing plants, we have found Magnetic Separators that have been:

  • Damaged and no longer have any magnetic strength;
  • Moved and are positioned in such a way that it is very unlikely to capture any metal contamination;
  • Cleaned too infrequently, resulting in a substantial build up of captured metal until the magnet face is full and the Magnetic Separator no longer operates;
  • Purchased and installed without any check of the magnetic strength, which subsequently turns out to the very weak;
  • Installed many years previously and now provides limited protection due to the poor magnetic strength;

To prevent metal contamination problems, it is advisable to have an annual audit by an external third party.  This audit then forms part of the quality and safety management system.

It will be interesting to determine the cause of the latest food recall due to metal contamination, but it will take longer to damage the reputation of the manufacturer Addo Food Group and consumer confidence in the affected products.

For more information on the issue of Metal Contamination and Metal Separation, or to arrange a free onsite survey and audit of a particular plant or process, please contact the Bunting team on:

Phone:  +44 (0) 1442 875081

Email:  sales@buntingeurope.com

Via the website