24 Drawer Filter Magnets Destined for France

Metal Removed From Plastics

24 Drawer Filter Magnets are under manufacture at our European HQ in Berkhamsted, UK.  The Drawer Filter Magnets are destined for installation in a plastics production operation in France.

Bunting_Drawer_Filter_Magnets-8
Drawer Filter Magnets at an early stage of manufacture

“The Drawer Filter Magnet is one of our most popular magnetic separators,” said Dave Hills, Bunting’s Head of Sales.

The order for the Drawer Filter Magnets was secured by Bunting’s local representative in France, BMS.  BMS specialise in providing technical support to the plastics sector.

Drawer Filter Magnet Specification

All 24 Drawer Filter Magnets have the same specification:

  • Model:  LP-1600-PL: Low Profile Drawer Filter Magnet
  • Magnets:  Three (3) high strength Neodymium Rare Earth Magnets;, three 25mm diameter stainless steel
  • Dimension of the opening:  150mm square
  • Height:  180mm
  • Rows of Magnets:  One
  • Flanges:  Bottom and top included, 6.35mm thick
  • Slide gate:  6.35mm thick
  • Viewing port:  Unit features a 9.5mm thick clear polycarbonate drawer front

Application

During the manufacturing process of any plastic or plastic product, it is possible for metal to be introduced into the process.  This could be from a wide variety of sources including the wear of processing machinery.

Bunting_Drawer_Filter_Magnets-0346

If metal contamination is not removed, it can damage processing equipment and result in increased final product rejects.  The Drawer Filter Magnets are used to attract, hold and thus remove any magnetically susceptible metal contamination.

Another Export Order

“This is another great export order for Bunting,”said Hills.  “Despite all the concerns about BREXIT, we continue to work hard supporting our regionally based distributors.  This is paying dividends as our sales overseas continue to rise.”

For further information about metal separation equipment designed for removing metal during the plastic or plastic product manufacturing process, please visit our website or contact us on:

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

Other Plastics Industry Articles

 

Magnetic Separator Audit for Jordans Dorset Ryvita

Inspecting Magnet Strength

Bunting engineers have conducted a thorough review of all the Magnetic Separators installed at the Jordans Dorset Ryvita plant in Poole, Dorset.  The audit was completed over three days, including attending site on Saturday to prevent any loss in production.

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Master Magnets Grate Magnet

Jordans Dorset Ryvita has a strong heritage of making whole grain foods and working with farmers to protect the countryside.  Ever since the brands first came together, they have continued to act on these values.

A Magnetic Separator Audit involves the inspection and test of Magnetic Separators to confirm their magnetic and physical integrity.  Commonly, such tests are conducted annually, with the final report forming part of the company’s quality audit process.

The tests in a Magnetic Separator Audit are conducted in two stages.  Stage one involved the inspection of the physical integrity of the Magnetic Separator.  This includes checking welds, and assessing any wear and damage to the surface.

Bunting Magnetics Pull Test Kit
The Spring Balance

Stage two involves testing the magnetic strength of the Magnetic Separator.  These tests are conducted by placed a magnetic ball or plate into the magnetic field and then measuring the force (in kgs) needed to remove that object from the surface of the magnetic separator.  The actual ‘gauss’ reading of a Magnetic Separator is not checked as measurement is difficult and often inaccurate.  Gauss is the is the cgs unit of measurement of magnetic flux density (or “magnetic induction”, but can be difficult to measure accurately.

Bunting Magnetics Pull Test Kit
The Magnetic Test Piece

The metal test piece is attached to the end of the Spring Balance and then placed into the magnetic field, being attracted to the magnetic pole.  The metal test piece is then pulled off the surface of the magnetic separator whilst holding the other end of the spring balance.  The amount of force needed to remove the metal test piece from the surface is recorded (in kgs).  The test is repeated three times and an average reading taken.  Similar techniques are used to test other designs of Magnetic Separators such as Plate Magnets.

Bunting Magnetics Pull Test Kit
The magnetic test piece on the surface of the Magnetic Separator

There were a wide range of designs, strengths and ages of Magnetic Separators in the production process at Jordans Dorset Ryvita.  The company had not experienced any problems due to metal contamination and requested the audit as part of their continued improvement plan.

Day one was spent assessing the location and recording the customer identity numbers of all the Magnetic Separators.  Checking the location also highlighted any health and safety issues that needed to be considered for the audit, such as working at heights.  The review identified 52 Magnetic Separators.

The physical checks of the Magnetic Separators were conducted on day two and three, on the weekend to minimise any production downtime.  Each Magnetic Separator was removed from its location and visually inspected.  Then the magnetic strength was checked using the pull test technique.  The data was recorded and presented in a detailed report with recommendations following the audit.  This report can then be used as part of the quality management system.  It also provides base data for comparison on future audits.

 

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Master Magnets Grate Magnet

Following the audit, the engineering team at Jordans Dorset Ryvita have made several changes to improve the removal of metal during the production process.

“Having an external review of the Magnetic Separators really helps the client,” explained Mark Harris, Bunting’s Engineer.  “We conducted the audit without any assumptions and this freedom enabled us to highlight the areas where protection was good and also focus attention where they could be improvements.  We are looking forward to working with the team at Jordans Dorset Ryvita for the long-term and providing our technical support when needed.”

For further information on measuring the strength of a Magnetic Separator, please visit our website or contact us on:

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

Photographs taken and videos produced by Paul Fears Photography

Bunting Awarded ISO 45001 Standard

Priority Given To Health and Safety

In October 2018, Bunting Magnetics Europe successfully achieved the new ISO 45001 international standard for occupational health and safety (OH&S).  This relates to all activities on their European manufacturing headquarters in Berkhamsted, United Kingdom.

iso45001_infographic

To combat injuries in the workplace, ISO has developed a new international standard, ISO 45001, published in March 2018.  This covers occupational health and safety management systems.  ISO 45001 provides organisations with a framework for employee safety, reducing workplace risks, and creating better and safer working conditions all over the world.

Bunting has achieved the new standard directly and in a short period of time.  This was achieved without modifying and migrating from existing processes.

“As a team, we felt that it was important to have a fresh review of the whole process,” explained Denis Elkins, Bunting’s Health and Safety Manager.  “By effectively starting from scratch, we were able to implement processes without compromise.”

Bunting is the first company of their kind to be awarded the ISO 45001 standard.

“We are very proud of our achievement,” explained Simon Ayling, Bunting’s Managing Director.  “From the outset, we knew that this would be a challenging objective.  However, our newly formed Health and Safety committee has been outstanding.  I wish to thank everyone for their hard work in making this happen.”

Bunting Europe Health and Safety Committee
David Lewis, Denis Elkins, Nigel Thorne and Caroline Rasura outside the Bunting Europe manufacturing HQ in Berkhamsted

All areas of the company were represented on the Health and Safety committee:

  • David Lewis – Production manager (ISOH trained)
  • Nigel Thorne – Design Engineer (ISOH trained)
  • Caroline Rasura – Customer services (Fire Marshall and First Aider)
  • Andrea Geddes – Production
  • David Pollard – Production (First Aider)
  • Denis Elkins – Health and Safety Manager (ISOH trained)

With the ISO 45001 accreditation, Bunting Magnetics Europe has clearly stated that the company is committed to providing the best possible safe and caring culture within a world organisation.

For further information on Bunting Magnetics, please visit our website or contact us on:

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

Practically Measuring Magnetic Separator Strength

Technically Assessing Magnetic Separator Power

A Magnetic Separator is designed to attract, capture and hold magnetic particles.  The magnetic strength needed to successfully achieve that design objective is commonly stated in a magnetic separator supplier’s quotation or specified in the tender.  This ‘Magnetic Strength’ is usually referenced in terms of ‘gauss’, a unit of measurement.  However, the ‘gauss’ value can be very difficult to accurately measure.

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Fine iron contamination captured on Tube Magnets

There is a more practical method of assessing the magnetic strength.  This removes any ambiguity whilst providing simple, repeatable, and comparable data to assess most Magnetic Separators.

Measuring Magnetic Strength

The magnetic strength of a Magnetic Separator is often referenced in terms of ‘gauss’.  Gauss (symbolized G) is the centimetre-gram-second (cgs) unit of magnetic flux density. A flux density of 1 G represents one maxwell per centimetre squared (1 Mx ­ cm -2 ).  It is named after the German scientist Carl Friedrich Gauss.

Gauss can be measured using a Gaussmeter.  However, it is important to note that the Gauss rating on its own does not fully indicate the strength of a magnet.  Additionally, gaussmeters can give a range of readings dependent upon the orientation of the probe and several other variable parameters.

Proposals for Tube Magnets often include details of length, diameter and the gauss reading.  With the gauss reading being so difficult to test and prove, purchasers and users are unable to check that the Tube Magnets supplied actually meet the specification of the quote and the order.

However, in terms of Magnetic Separation the objective for the user is simple; the magnetic force must enable the attraction and capture of any magnetically susceptible metal.  That ability can be measured as a function of the effort needed to remove a specific steel item from the surface.

The Method

Measuring the effort needed to remove a steel item from the face or surface of a Magnetic Separator is achieved using a spring balance and is commonly called a ‘Pull Test’.  The magnetic test piece (e.g. a 6mm ball bearing welded onto a non-magnetic attachment ring) is clipped onto the end of the spring balance.

Bunting Magnetics Pull Test Kit
A Pull Test Kit ‘Spring Balance’

The magnetic test piece is placed on the surface of the Magnetic Separator and force applied at the other end of the spring balance until it is detached.  The force required to remove the magnetic test piece (measured in kgs) is recorded on the measurement scale of the spring balance.

Measurements are taken in the centre of the Tube Magnet and on the end poles.  They are repeated three times and the average recorded as the force required to remove the magnetic test piece at each point.

The following video explains the Pull Test technique.

This simple but effective method does not record or provide any indication of the gauss, but accurately provides data that can be used to compare the condition of a Magnetic Separator over time and compare the performance with other similar designs.

Pull Test Experiments

Magnetic Separator designs vary considerably depending on the application.  The Pull Test technique is suitable for measuring the magnetic strength of smaller Magnetic Separators such as Tube or Cartridge Magnets and Plate Magnets.

Tube or Cartridge Magnets are often used stand alone or as part of a Magnetic Separator configuration (e.g. Drawer Filter or Liquid Trap).

Bunting Magnetics Pull Test Kit
Magnetic Test Piece

A small steel ball is used as the magnetic test piece when measuring the magnetic strength of a Tube or Cartridge Magnet (the photograph shows a 6mm diameter ball)

The metal test piece is attached to the end of the Spring Balance and then placed into the magnetic field, being attracted to the magnetic pole.

Bunting Magnetics Pull Test Kit
Magnetically Attracted Metal Test Piece

In a series of experiments, we used the Pull Test technique to assess the magnetic strength of Tube Magnets with Ceramic (Ferrite), Standard Neodymium Rare Earth, and High Strength Neodymium Rare Earth Magnets.

The tests were undertaken using three different sizes of steel ball in the magnetic test piece (6mm, 12mm and 25mm) and introduced non-magnetic spacer to assess the magnetic strength at specific distances away from the surface (3mm and 6mm).  All the recorded measurements are in kilograms (kg)

Ceramic (Ferrite)

Gap 6mm Ball 12mm Ball 25mm Ball
None 1.25 1.75 2.5
3mm NR NR 1.2
6mm NR NR NR

Graph - Ceramic Tube Magnet

Note:  all measurements are recorded in kilogrammes.

Standard Neodymium Rare Earth

Gap 6mm Ball 12mm Ball 25mm Ball
None 2 4.25 9
3mm 1.2 1.6 2.45
6mm NR 1.25 1.5

Graph - Std Neo Tube Magnet

Note:  all measurements are recorded in kilogrammes.

High Strength Neodymium Rare Earth

Gap 6mm Ball 12mm Ball 25mm Ball
None 3.75 9 14.5
3mm 1.5 2.5 4.6
6mm 1.1 1.5 2.25

Graph - High Strength Neo Tube Magnet

Note:  all measurements are recorded in kilogrammes.

In all cases, the drop off in magnetic strength as you move away from the surface of the Tube Magnet is significant and this highlights the need for metal contamination to come into contact with the surface.  Arrangements where the Tube Magnets are configured as a Grate (i.e. are lined up and equally spaced) commonly have a deflector above the gap between the Tubes that directs material in the area of maximum magnetic strength.

Comparison

The tests highlight the difference in magnetic strength on the surface, with high strength Rare Earth magnets producing nearly 3 times as much pull as Ceramic magnets.

Findings During Magnetic Separator Audits

Magnetic Separator Audits often highlight issues that had previously gone undetected.  The first check focuses on the physical integrity of the Magnetic Separator, inspecting welds, and assessing wear and damage.  Once these have been completed, the measurements are taken.

The most common findings when undertaking magnetic separator audits are:

Weld Failure

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Consequence of weld failure on a Liquid Magnetic Filter

Magnetic Liquid Filters, fitted into pipelines, have Tube Magnets that are welded to a lid and project down into the product flow.  Metal is attracted and captured on the surface of the Tube Magnet.

In cases where the welds have failed (e.g. poor manufacture, eaten away by acidic or alkaline liquids), liquid will seep into the tube and onto the magnets.  The magnets then swell and lose magnetic strength, ultimately splitting the outer stainless-steel casing.

Tube Magnet Wear

When material falls directly onto the surface of a Tube Magnet, over time the surface can be worn.  Wear usually occurs on the poles where magnetic particles have been captured.  Once the outer stainless-steel casing has been breached, the Tube Magnet should be replaced.

Weak Tube Magnets

Magnetic separation audits highlight the variance in magnetic strength of Tube Magnets.  Often, the Tube Magnets have been installed for some time and details of the original specification have been lost.  When testing the magnetic strength, some Tube Magnets are found to have very poor strength and provide little if no metal separation protection.  This is of great concern when the Tube Magnet is positioned to protect a particular item of processing plant where metal contamination damage could result in production downtime and costly repairs.

Conclusion

The Pull Test Experiments highlights the importance of physically checking the real magnetic strength of a Tube Magnet and not only replying on the stated gauss.  Including details of the force needed to detach a 6mm steel ball from the surface of the Tube Magnet in the request for quotation and the order, protects the user and ensures that the supplied equipment is as exactly as stated.

This ‘Pull Test’ measurement technique also enables a regular comparative test that will immediately highlight any drop in magnetic strength.  This can be used in annual audits or inspections as part of a plant’s quality management system.  A change in ‘pull’ strength may be the result of physical (e.g. failed weld, broken magnets from being dropped) or excessive heat.  The reduced magnetic force may result in the magnetic separator no longer being fit for purpose.

For further information on measuring the strength of a Magnetic Separator, please visit our website or contact us on:

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

Photographs taken and videos produced by Paul Fears Photography

Master Magnets Brand Celebrates 40 Years

Celebrating Long Term UK Manufacturing Success

In October 2018, the Master Magnets brand celebrates its 40th anniversary.  In that time, the Birmingham based Magnetic Separator and Metal Detector manufacturer has developed a reputation as one of the leading technology companies in the recycling, mining and mineral processing industrial sectors.

Adrian Coleman (left) and Simon Ayling (right) on the Bunting stand at RWM18 exhibition

Since January 2017, the Master Magnets brand has been owned by Bunting Magnetics.  Bunting Magnetics is one of the world’s leading suppliers of Magnet related technology.  The European manufacturing headquarters are based in Berkhamsted in Hertfordshire, UK and they have an extensive overseas network of distributors and marketing agents.

Master Magnets was founded in 1978 by Geoff Worley, a qualified engineer with fifteen years’ experience in the magnetics industry.  The company grew steadily throughout the 1980s despite the economic challenges and was perfectly positioned for the increased demand in the early 1990s.

At the time, there was high levels of investment in the UK coal industry and globally located mineral processing projects.  Using his considered knowledge, Geoff and his team of engineers developed a range of magnetic separators specifically for those key industries.  For the coal and mining industries, they developed large Electro Suspension Magnets which would be suspended over conveyors to remove large tramp metal such as pit props and bars.  The drive in Mineral Processing was for higher purity non-metallic minerals.  The team designed the Induced Roll Magnetic Separator (IMR) and established a laboratory where clients could test materials.

As demand increased, the company expanded and made investments in new manufacturing technology including heavy-winding gear for ever-larger Electro Suspension Magnets.  A bespoke super-strength magnetiser, weighing over 14 tonnes, was acquired, one of the largest of its kind in the world.

Master Magnets Overband Magnet on a mobile shredder

Master Magnets also developed a reputation for manufacturing Permanent Overband Magnets.  Recycling was in its infancy, but several UK businesses were developing large mobile screens and crushers for construction and demolition sites.  Master Magnets worked with the companies to develop a compact but powerful Overband Magnet that needed limited power (the only power required is to operate the belt which can be done hydraulically or electrically).  Master Magnets continue to be one of the world’s largest producers of the Permanent Overband Magnet.

The Master Magnets brand became globally recognisable as export sales increased.  In 2003, Master Magnets acquired the company Integrated Recycling Systems and relocated to Redditch.  Further acquisition took place in 2005 with the purchase of the Metal Detection business.  This further expanded their manufacturing portfolio.  Customers were now able to purchase their metal separation and detection solution from one supplier.

Master Magnets continued to evolve and expand.  Worley took partial retirement and handed the reigns of the business to Adrian Coleman.  Coleman had started his career at Master Magnets in 1984 as an apprentice and witnessed the evolution of the company.

Adrian Coleman with Geoff Worley in 2008

“Master Magnets gave me the opportunity to develop my engineering career,” explained Coleman.  “In 1988, they supported me through a four year Mechanical Engineering course at Birmingham University.  This gave me the necessary engineering skills to join the design office.  As the company grew, I took up the position of Production Manager, before becoming Managing Director in 2008.”

In 2017, Worley agreed to sell the Master Magnets business to Bunting Magnetics.  He foresaw the investment needed to maintain Master Magnets’ reputation as a global leader and identified Bunting as the ideal partner.  Coleman was appointed as the General Manager, an important step that ensured business continuity.

The joint Bunting and Master Magnets team on the stand at RWM18

“Master Magnets has developed a long-standing strong identity and reputation as a leader in metal separation technology,” said Simon Ayling, Bunting Magnetics Europe’s Managing Director.  “The acquisition means that we can invest in their manufacturing facility in Birmingham and in the development of new separation technology.  When Geoff [Worley] founded the company, his aim was to produce well-engineered equipment to solve metal contamination and separation problems.  That challenge has been passed onto us and we are excited by the future.”

For further information, please visit our website or contact us on:

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

Photographs 1, 2 and 4 taken by Paul Fears Photography