Our 2018 Review

A Look Back at Our News & Blogs from 2018

BREXIT and concerns about plastic waste have dominated the news in 2018.  Despite the BREXIT pessimism, UK exporters continue to export and the plastics industry is working hard to pacify environmentalists.  2018 has been another great year for Bunting Europe and we look back on the past twelve months of our news and blogs.

January

WEEE E Waste2018 started with the announcement of our attendance at the 17th International Electronics Recycling Congress (IERC) in Salzberg, Austria.  After the event, we write a review highlighting that the congress recognised that changes in e-waste management are needed.  Secondary electronics continues to be a source of many valuable and precious metals.  With technology such as the Stainless Steel Magnetic Separator, it is possible to recover printed circuit boards (PCBs) from waste.

Towards the end of January, we listed the record number of exhibitions and conferences being attended in 2018.  It was going to be another busy 12 months.

We also announced of search for a representative in German to help develop business in the recycling sector.  This search remains ongoing.

February

The UK Government had announced that 2018 was going to be the Year of Engineering.  We announced our support, highlighting the need to encourage young people to seek a career in an exciting and ever-changing industry.

RWM Digital Masterclass 2018_02_06In February, we were invited to attend a RWM digital masterclass at the Google headquarters in London.  The RWM exhibition had been acquired by PRYSM Media and they wanted to show how they were going to breathe new life into the struggling event.

A week later we announced our continued support for RWM with confirmation of exhibiting in 2018.  We had taken the opportunity to book one of the premier stands, immediately opposite the entrance to the show.  With our extensive range of Bunting and Master Magnets metal separation equipment, we wanted to demonstrate that we are now one of the major suppliers to the recycling industry.

One of our large ongoing export orders is supplying In Line Magnets to a baby food producer in Germany.  By February 2018, we had supplied 42.  The In Line Magnets remove ferrous metal contamination.

Our final blog of the month focused on how contamination is hindering the recycling of plastic.  Plastic recycling companies face huge challenges due to unnecessary and avoidable contamination.

March

Our first blog in March asked whether recycling in the UK was reaching crisis point.  What were the politicians going to do with recycling targets unlikely to be achieved and the ongoing pressure to deal with plastic waste?

Mark Harris Bunting Magnetics EuropeWe announced the expansion of our sales team with the appointment of Mark Harris, a field sales engineer for the Southern part of the UK.

In February 2018, Youngs Seafood had recalled fish cakes due to the possible presence of metal and plastic.  We investigated how this could occur and what measures were needed to prevent re-occurrence.

In March, Bunting and Master Magnets were announced as the joint headline sponsors of the WASTE’18 exhibition.  We also announced that Bunting and Master Magnets were exhibiting high intensity magnetic separators at the Ceramitec trade show in Munich, Germany.  Master Magnets has a global reputation in the ceramics and mineral processing industries and Ceramitec is one the premier world exhibitions.

In a move to pacify environmentalists, the UK Government announced a new UK drinks container recycling strategy in March 2018.  However, the announcement raised more questions than answers and we assessed whether the proposed changes would make a difference.

April

In 2017, the UK Food Standards Agency reported six cases of food being recalled due to metal contamination.  We reviewed all six cases and assessed why the problems occurred and how they could have been prevented.

Ceramitec 2018

Ceramitec was held between 10th and 13th April 2018 and proved to be a great success.  An order for two Master Magnets Electromagnetic Filters was placed at the show by a Turkish ceramics producer.

In Telford, UK the Polymer Training and Innovation Centre added a Bunting Magnetics Drawer Filter Magnet to the range of equipment at their plastics manufacturing training facility.  This extended the range of equipment used to train the next generation of plastics engineers.  Later that month, the Polymer Training and Innovation Centre held the Technivation conference, attracting delegates from across the UK plastics sector.

In April, we had conducted 3 separate Magnetic Separation Audits at UK food companies.  Each audit using the Pull Test assessment method of determining magnetic strength by measuring the force needed to remove specific metal items from the surface.  The audits found that several of the Magnetic Separators were no longer fit for purpose due to damage, age or location.

May

We announced our support and sponsorship for the Tŷ Hafan #5in55 Mountain Challenge.  Between the 5th and 7th July 2018, a group of Dads, whose families have been supported by Tŷ Hafan, were aiming to climb and travel between five UK mountains in a maximum of 55 hours.  We had been thrilled to sponsor the Ben Nevis leg of the challenge.

Bunting Master Magnets IFAT 2018

Our next exhibition was 2018 was the IFAT tradeshow in Germany.  IFAT was the largest waste and recycling focused event in Europe and an ideal location to demonstrate the Stainless Steel Magnetic Separator and Eddy Current Separator.  The show proved to be exceptionally successful.

June

In early June, the UK Food Standards Agency announced the recall of 59 pastry products due to the potential presence of metal.  This affected products being sold by major UK food retailers Tesco, Aldi and Nisa.

Bunting Magnetics Drawer Magnets at Ecovyn

The busy exhibition schedule continued with a review of the Hillhead 2018 event.  Master Magnets had exhibited at the show for decades and this was the first joint stand.  The show was another success with orders were secured on the stand.

Plastic waste returned to our news with a review of FF Drawer Filter Magnets installed at EcoVyn in Wrexham, UK.  Since the installation of the magnetic separators, EcoVyn had reduced their waste by 94%.

July

We started with a review of the WASTE’18 show where we were offering companies a ‘Metal Separation MOT’.  The exhibitions train kept rolling and our next blog reviewed the CARS 18 exhibition at NAEC in Stoneleigh, UK.

Plastic waste and recycling hit the headlines again in July.  Brussels-based Plastic Recyclers Europe (PRE) and the Association of Plastic Recyclers in Washington, USA concluded that there are four conditions that define a plastic product as being “recyclable”.  This appeared to be a logical and helpful proposal that is yet to be accepted by the EU and the UK.

August

With the RWM show being less than 1 month away, we reviewed our attendance at the show.  With such a prominent stand, we wanted it to be very interactive and turned it into a metal separation test centre.

metal_in_sugar-1853-e1533716896631.jpg

The UK Food Standards Agency announced the latest metal-in-food safety alert, reporting that Tereos UK had recalled Granulated Sugar due to the presence of small metal pieces.  We reviewed the challenges of removing metal from sugar.

In August, Skip Hire Magazine featured an article we had written entitled ‘Metal Detectors Detecting More Than Treasure‘.  The article was re-published as a blog and looks at how Metal Detectors are used widely in the waste and recycling industry.

In anticipation of the RWM waste and recycling show in September, we reviewed 3 facts about plastic packaging waste.  These included how much plastic waste is produced, the present recycling rate, and the existing plastic recycling plant infrastructure.

September

RWM 2018 Exhibition

The rejuvenated RWM18 proved to be a huge success for the organisers and Bunting.  There was a constant flow of traffic on the stand with a great deal of interest in the working Stainless Steel Magnetic Separator and Eddy Current Separator.

Later in the month, we celebrated the 2018 Recycle Week (24-30 September) by reviewing three successful plastics recycling projects.

October

In October 2018, the Master Magnets brand celebrated its 40th anniversary.  Over 40 years, Master Magnets has developed into one of the world’s leading suppliers of magnetic separators and metal detectors to the mineral processing, ceramics and recycling industries.

Our technical article ‘Practically Measuring Magnetic Separator Strength‘ reviewed practical and accurate methods of testing magnetic separators.  This method is used by many food processing companies as part of an annual audit of their processing equipment.

Bunting Europe Health and Safety Committee

We had reason to celebrate in October, with the announcement that we had been awarded the ISO45001 international standard for occupational health and safety (OH&S).  This relates to all activities on their European manufacturing headquarters in Berkhamsted, United Kingdom.  Congratulations to our Health and Safety Committee!

One extensive Magnetic Separation Audit undertaken in 2018 was for Jordans Dorset Ryvita at their factory in Poole, UK.  The 3-day audit reviewed 52 different Magnetic Separators.

There was more export success with the sale of 24 Drawer Filter Magnets to a plastics producer in France.  The sale had been secured by Bunting’s local representative BMS.

November

Despite the growing unrest about BREXIT, there was still positive news about business overseas.  15 Magnetic Liquid Traps were sold to fruit juice producers in Spain.  Additional orders are expected in 2019.

Tekemas Team at Scanpack 18

Dave Hills and Tom Higginbottom provided support to local representative Tekemas at two trade shows in Scandinavia.  The Scanpack show in Goteburg, Sweden and FoodTech in Herning, Denmark provided an opportunity to gather information on the local market and provide training.

Plastic waste returned to the news with a blog that was first featured as a headline article in the British Plastics & Rubber magazine (Nov/Dec 18).  The article was titled ‘The Changing Face of Plastics Recycling‘ and assessed changes made in 2018.

December

Eder_Design_Training_Visit_4489Laura Joubert from our South Africa representative Eder Design traveled to the UK for product training.  Over a week, Laura had the opportunity to meet both the Master Magnets and Bunting teams, whilst receiving training on Magnetic Separators and Metal Detectors.

As 2018 draws to a close, we reviewed our first overseas exhibition of 2019:  ArabPlast.  We attended ArabPlast, Dubai, UAE in 2017 and it proved to be a big success with orders secured on the stand.  We will again be exhibiting in 2019 (5-8 January 2019).

We hope you have enjoyed reading our news and blogs in 2018.  If there are any topics that you would like reviewed, then please get in touch and send an email to Paul our press officer (press@buntingeurope.com).

For further information on Magnetic Separators or Metal Detectors please contact the Bunting team on:

The Changing Face of Plastics Recycling

The Big Story Headline Article in British Plastics & Rubber (Nov/Dec 18 Issue)

The BBC’s Blue Planet II appeared on our television screen in September 2017.  The amazing documentary series highlighted the challenges faced by marine life and generated a global anti-plastic tidal wave that shows no sign of diminishing.  However, has anything actually changed?

Since September 2017, there has been a swathe of political rhetoric culminating in the UK’s Autumn 2018 budget announcements.  Chancellor Philip Hammond outlined several new measures to tackle plastic waste.  This included introducing a new tax from 1 April 2022 on produced or imported plastic packaging that does not include at least a 30 per cent recycled content.

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Baled cleaned plastic waste

The European parliament is also taking action against plastic waste.  Under the parliament-backed directive, items such as plastic straws, cotton swabs, disposable plastic plates and cutlery would be banned by 2021.  Additionally, 90% of all plastic bottles would be recycled by 2025.

However, the fundamental difficulties in collecting, separating and re-using plastic remain.  In the UK, each council adopts their own recycling strategy.  Households in different regions are told to separate and collect different materials.  Swindon council has taken one step further and is considering burning plastic along with other rubbish rather than sending the material abroad for recycling.  Other councils, such as Basingstoke, has instructed residents to only recycle certain types of plastic.  Despite the Chancellor committing £20 million to tackle plastics and boost recycling, there is no unified country-wide strategy.

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Baled plastic waste

The successful recycling of any material requires good planning and execution.  Ironically, this must start at the end of the process.  Firstly waste plastic must be clearly categorised into material than is recyclable and unrecyclable, possibly using the global definition proposed by Plastics Recycling Europe and The Association of Plastic Recyclers.  This ensures that recovered plastic waste can be re-used.  Recovering, transporting and then discarding materials than are unrecyclable is costly in terms of effort, money and energy.

Ongoing research and changes in product design, will identify new techniques to broaden the scope of recyclable plastic waste.  The criteria for plastic waste collection will change accordingly.

Secondly. strategically located plastic waste recycling plants are needed to keep transportation to a minimum.  Each plant will receive the same mix of plastic waste, enabling continued development and improvement of the recycling process.  This stops each plant having to develop unique processes to suit the plastic waste collected in one region.

Hanbury Plastics Bunting Overband Magnet-2
Plastic Waste Recycling Plant

By having a clear country-wide recycling collection specification, contamination levels of the plastic waste will reduce.  Separation technology, such as magnetic separators and metal detectors, will still be required, but the purity levels of the end-product will increase.

Bunting Magnetics Drawer Magnets at Ecovyn
Metal contamination removed from granulated plastic waste

Politicians have only introduced these new policies due to the unprecedented reaction from the general public.  However, setting a target without any definitive plan of how to achieve that result may be considered foolish.  Equally, introducing new taxes, that may ultimately be paid by the consumer, is not addressing the key issues that prevent plastic waste from being recycled.  It is time for the politicians to sit down with the industry and agree a proper plan.

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

Photographs taken by Paul Fears Photography

Other Plastics Industry Articles

Scandinavian Exhibitions with Tekemas

Bunting Provide Technical Support at Two Overseas Shows

Local representative Tekemas has exhibited at two Autumn international trade shows in 2018.  The equipment displayed on their stands included a selection of Magnetic Separators.  Both exhibitions proved to be successful, with leads for both magnetic separation and metal detection equipment.

Tekemas is based in Rodovre, Denmark and specialises in providing solutions in the handling and processing of powders and granules.  They represent a number of international equipment and technology suppliers including Wysetech Materials Handling and Matcon.

Scanpack (Gothenburg, Sweden, 23-26 October 2018)

Tekemas Team at Scanpack 18
Tom Higginbottom (far right) with the Tekemas team

Scanpack is an international event for the packaging industry.  Exhibitors showcase solutions for the entire packaging process.  Visitors included managers, marketers, brand managers and others involved in packaging, from conception and design, through to production and logistics.  Representatives from companies based in over 40 countries attend the show.

Bunting’s Sales Engineer, Tom Higginbottom, attended the show.

“Overseas exhibitions provide an ideal opportunity to learn about the local markets,” Tom explained.  “The time I spent with the Tekemas team has been precious.  I was able to provide support with technical information and, potentially more importantly, develop my relationship with the Tekemas engineers.”

FoodTech (Herning, Denmark, 13-15 November 2018)

Tekemas_Stand_FoodTech18_4413
Dave Hills (left) with Fleming Petersen, owner of Tekemas

FoodTech is a food technology event, held every two years in MCH Messecenter Herning.  The exhibition is focused on showcasing the latest technology for the food manufacturing and processing sectors.

Tekemas were supported by Bunting’s Head of Sales, Dave Hills.

“Before I had even left the United Kingdom, Tekemas had arranged meetings on the stand with prospective customers,” said Dave.  “Supporting our local representatives at shows like this is so important.  The time can be used for product and application training as well as developing all-important relationships.  It has been a very successful show.”

Bunting and Master Magnets are continually searching for new overseas representatives in a wide range of industrial sectors.  For further information, contact Dave Hills on dhills@buntingeurope.com.

For further information on Magnetic Separators or Metal Detectors used in removing and detecting metal contamination in food, please visit our website or contact us on:

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

15 Magnetic Liquids Traps Keep Orange Juice Metal Free

Export Success to Fruit Juice Industry in Spain

In the past 18 months, Bunting has manufactured and supplied 15 Magnetic Liquid Traps to citrus juice producers in Spain.  The magnetic separators are used to capture and remove fine iron from the juice.

Need for Magnetic Separator Protection

Magnetic-Liquid-Trap-Cartridge-md-gasketsFine iron is commonly found in most food processes.  The origin of the metal contamination is often difficult to pinpoint.  Typical sources include:

  • When the fruit is harvested.  Dirt can often have a magnetic constituent and is carried on the surface of the fruit;
  • During transportation.  Even if the fruit is collected in plastic containers, metal contamination can be introduced from the transport (eg rust, metal dust, dirt).
  • When the fruit is processed.  The process of extracting the juice from the orange or grapefruit involves several stages where the fruit is sliced and compressed.  Wear to the process equipment will produce fine metal contamination.

Extracting the Metal Contamination

Due to the fine nature of the metal contamination, high strength magnets are required.  The Bunting Magnetic Liquid Traps are fitted with Neodymium Rare Earth Tube Magnets, the strongest permanent magnets presently available.

20180424_170346
Fine iron contamination removed from fruit juice

The Magnetic Liquid Filters are designed to ensure maximum contact is made between the juice and the magnetic fields by forcing liquids through a tightly spaced grid of magnets.  Ferrous contamination is magnetically extracted from the liquid flow by the extremely powerful Rare Earth magnet design and held firmly on the surface of the Tube Magnets.

Cleaning of the Tube Magnets is simple.  On a designated frequency, determined by the level of contamination, the lid of the Magnetic Liquid Trap is removed.  The Tube Magnets are attached to the lid and are then manually wiped clean.

Dealing With Acidity

Fruit juices are naturally acidic, ranging between 2.00 and 4.80.  This level of acid has the ability to corrode standard welds.  In the Magnetic Liquid Trap, the Tube Magnets are welded onto the lid.  The welds are all to food grade standards.

20180424_161133
Welds eaten away by the acidic juice causing swelling and failure of the magnets

However, if standard welding materials are used, these will pit and corrode over time.  Eventually, the weld will be eaten away, allowing the ingress of liquid into the Tube Magnet casing.  This catastrophically damages the magnets, causing them to swell and lose their magnetic properties.  As the magnet swells, it can also split the outer casing.

Exporting Success

“We are now regularly supplying Liquid Magnetic Traps into Spain,” explained Dave Hills, Bunting’s Head of Sales.  “Our local representative has done a great job in helping the local citrus juice producers.  He understands the industry and fully understands the challenges.”

For further information on Magnetic Separators used in removing metal contamination from fruit juices or for any food processing application, please visit our website or contact us on:

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

 

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

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

3 Successful Plastics Recycling Projects for Recycle Week

Celebrating Recycling Success

The theme of the 2018 Recycle Week (24-30 September)  is ‘Recycling. We do. Because it matters.’  Recycle Week is a celebration of recycling, organised by WRAP under the ‘Recycle Now‘ brand.

Recycling has never been more prominent in the news, with managing plastic waste high on the agenda.  We work with many plastic recycling companies and have provided many magnetic separators and metal detectors to remove metal contamination.  To celebrate Recycle Week we wanted to talk about plastics recycling success and also highlight the changes faced by companies recycling plastic.

EcoVyn Reduce Waste by 94% with Bunting Drawer Magnets

Bunting Magnetics Drawer Magnets 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.  By installing Drawer Magnet Filters, EcoVyn reduced their waste by 94%.

HFS Drawer Magnets Removes Metal from Recycled Plastics

HFS_Grate_Magnet_Plastics-1866

A French plastic recycling company installed the Drawer Magnets to remove fine iron contamination present in the recovered and granulated plastic.  If the metal is left in the reclaimed plastic, it causes serious defects in the new plastic product and can also damage processing equipment.

Metal Separation Module Cleans Recycled Plastics for Recapture Plastics

Bunting Metal Separation System Recapture Plastics LinkedIn

A new plastics recycling plant was built in Kent, UK.  The plant was designed to handle up to 25 tonnes per hour of reclaimed plastic.  Once shredded, the plastic is passed over a strong Drum Magnet (to remove small ferrous metals) followed by an Eddy Current Separator (to remove non-ferrous metals).  The end product is also passed through a Quicktron Metal Detector prior to the clean plastic being bagged ready for shipment.

Contamination Hinders Plastic Recycling

We work with many plastic recycling companies located across the world.  Every company is faced with the problem of contamination.  Contaminated plastic waste is worthless and processing is required to remove contaminants, such as metal and stone, to make this waste product reusable.

We are fortunate to be working with some amazing companies in the waste and recycling sector.  Their innovation and knowledge continually increases the amount of materials we can recycle and reuse.

For further information metal separation equipment designed for removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

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

Photographs taken by Paul Fears Photography

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A Rejuvenated RWM Exhibition

Busy Stand for Bunting Magnetics at RWM

At this year’s rejuvenated RWM Exhibition (NEC, Birmingham, 12th – 13th September), the Bunting Magnetics and Master Magnets stand proved to be a great success.  Being positioned in a prime stand in front of the entrance, and with working metal separators on the stand, visitors were drawn to see the latest developments in magnetic separation technology.

RWM 2018 Exhibition
Stainless Steel Magnetic Separator in action

In January 2018, Prysm Group announced that they had taken on the flagging RWM exhibition.  Attendance of the RWM exhibition in 2017 had been poor and many exhibitors had lost faith with the event.

At an event in the Google headquarters in London, RWM exhibition manager Nick Woore announced their intention to inject new life into the show.  The plans sounded positive, although there was still a great deal of doubt from many exhibitors.  In fact, in 2018 the number of exhibitors were lower than in 2017, but visitors numbers were higher.

“It was great to see people queuing outside the entrance on the first morning of the exhibition,” said Dave Hills, Bunting’s Head of Sales.  “As soon as the doors opened, our stand was full of visitors.”

Bunting had two operating production-sized metal separators on the stand:

Dave Hills also gave two presentations on ‘Stainless Steel Separation in Modern Day Recycling’.

RWM 2018 Exhibition

“Being able to show visitors the separation capabilities of the equipment was vitally important,” explained Hills.  “This made it easier to relate to their metal separation requirements.  Following the exhibition we will be conducting tests at our Master Magnets Redditch laboratory, where we can confirm the separation capabilities.  It is going to be a busy few months.”

Hills also explained the importance of a successful RWM.  “Recycling and good waste management is no longer an option but a necessity and it is essential that there is a UK based trade event.  We are looking forward to hearing how the organisers plan to further develop RWM for 2019.”

More photographs from the RWM exhibition can be seen on our Flickr photograph album.

For further information metal separation equipment designed for removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

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

Photographs taken by Paul Fears Photography

Other Plastic Waste & Recycling Articles

RWM 2018 Exhibition

 

3 Facts About Plastic Packaging Waste

Latest 2016 Waste Recycling DEFRA Data

The UK’s largest recycling exhibition, RWM, takes place on the 12th and 13th September 2018 (NEC, Birmingham, UK).  Leading up to the show, we wanted to review three key facts relating to the latest DEFRA data (from 2016) on plastic packaging waste (published in February 2018).

Waste Drinks Containers-9048

The Amount of Plastic Packaging Waste

UK households generated 1,015,000 tonnes of plastic packaging waste in 2016.  This is actually 12% lower than in 2012, although the amount has been relatively stagnant since 2103.  In 2016, 20% of all packaging waste was plastic (by weight), although this percentage would be far higher if measured by volume due to the low bulk density of the material.

A Rising Recycling Rate

45% of plastic packaging was recycled or recovered in 2016 compared with 25% in 2012.  The 2016 figure is higher than the EU target of 22.5%.  Since the beginning of 2018, the UK Government has set a new recycling and recoverable target of 57% by 2020.  This means that new strategies are needed to raise the rate by 12% in just four years.

Plastic Packaging Recycling Rates

However, there remains a question about what to do with the plastic once it has been recovered.  The UK still exports a large proportion of its waste, but this is still classed as being ‘recovered’ and is included in the 45%.  Since China closed their doors to waste, plastic waste has being shipped to countries around the world, including Malaysia, Thailand and Vietnam.  This is not a sustainable solution, but it not reported in the statistics.  An increasing amount of plastic waste is expected to remain in the UK and it is unclear how it will be managed.

Plastics Recycling Plants

It is widely accepted that there are not enough plastic recycling plants in the UK.  In the past, it has been difficult to economically operate a plant with high costs associated with equipment investment and site difficulties due to the flammable nature of plastic waste.

Bunting Magnetics Drawer Magnets at Ecovyn
FF Drawer Filter Magnets (supplied by Bunting Magnetics Europe Ltd) removing metal from plastic waste to enable recycling

One successful plant is located near Wrexham in North Wales where EcoVyn process 1,000 tonnes per month of good quality plastic waste.  EcoVyn installed several Drawer Filter Magnets to remove ferrous metal contamination from the granulated plastic.

The Future

There has been a huge change in the public perception of plastic waste since the showing of the BBC series Blue Planet II in 2017.  This has forced politicians to start taking action and it will be interesting to see the level of political and governmental engagement at the RWM exhibition.

For further information on metal separation equipment designed for removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

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

Other Plastic Waste & Recycling Articles

Metal Detectors Detecting More Than Treasure

Technology Keeping Waste Metal-Free

The BBC television series Detectorists has significantly increased the public’s awareness of metal detectors, but many people remain unaware of their importance in the recycling of waste materials.

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Although the size and design of metal detector used in the recycling industry may be different to those used by the enthusiasts on the television show, the basic concept is the same.  When an electric current is passed through the coil of a metal detector, it creates a magnetic field.  If a piece of electrically conductive metal is close to the coil, eddy currents will be induced in the metal, and this produces a magnetic field of its own.  A separate control recognises that the new magnetic field has changed the metal detector’s magnetic field and identifies that there is metal present.

Metal Detectors are becoming increasingly important in the recycling industry.  Magnetic Separators and Eddy Current Separators are widely used to remove liberated ferrous, non-ferrous and even some stainless-steel metals, but are unable to separate metals that are imbedded in material or are unresponsive to these types of metal separators.

This is particularly important in recycling operations where the waste material is large in size and needs to be shredded or granulated.  A common location for the Metal Detector is on the conveyor prior to size reduction, where it identifies the presence of any metal that may damage the shredder or granulator.  The effect of metal damage can be costly in terms of repair and also downtime.  Typical waste materials include plastic, wood, and demolition waste.

There are primarily two different types of Metal Detector suitable for detecting metal in such conveyed material.  The Underbelt Conveyor Metal Detector is ideal when handling larger materials of variable shapes and sizes and the aim is to detect larger metal.  Two different coil designs mean that the Metal Detector is suitable for belt widths from 100mm to 1200mm.  This design of Metal Detector identifies and then stops the conveyor belt.  Operators then locate and manually remove the metal contamination.

The second type of Metal Detector surrounds the conveyor belt.  This increases the detection sensitivity and is also needed when there is a deeper burden depth on the conveyor.  There are various coil configurations, such as the QDC, QTA, and TN77, and the selection is based upon each application.

Once the waste has passed through the process of size reduction and separation, Metal Detectors are commonly used to check that metal is not present in the final product.  In some applications, the material will still be conveyed and so previously mentioned designs are used.  However, in applications where the particles are now significantly smaller different designs of Metal Detector are required.

Bunting Metal Separation System Recapture Plastics-0424In plastic recycling plants, Free Fall Metal Detectors such as the quickTRON 03R not only detect but also reject metal contamination.   Gravity free-fall style metal separators are specifically designed to isolate and separate any contaminated material moving in the product flow.  They automatically detect, pick up and reject both ferrous and non-ferrous from the product flow without any interruption to the line process.

As each application can be unique, selecting the optimum Metal Detector for an application is best achieved by conducting a site visit to understand the process and the objective.

Bunting Magnetics is one of the world’s leading suppliers of Magnetic Separators and Metal Detectors which includes the Master Magnets and Metal Detection branded range of equipment.

For further information on metal separation equipment designed for detecting and removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

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

Other Plastic Waste & Recycling Articles