Review of the Bulk Solids and Powders Industry in Poland

Tom Higginbottom Reports Following Attending the SyMas Exhibition

Last week, our Sales Engineer Tom Higginbottom spent 2-days at the SyMas Bulk Solids and Powders exhibition in Krakow, Poland with Bunting’s local representative, TEKPRO.  Whilst at the show, he gained an insight into the present state of the market and potential opportunities for UK exporters.Bunting_at_SyMas17-17

Tom gives us his insight in the show, local feelings about BREXIT, and the market in general

“SyMas was a really good show with a busy footfall.  There was a lot of equipment on show, from manufacturers based all over the world.

From the type of enquiries and from talking to clients and our distributor, it is clear that the bulk solids and powders sector is growing.  Despite being a member of the EU, Poland remains an emerging nation and wages are still lower than in more developed European countries like the UK, Germany and France, but that gap is closing.  Their skill base is very high and consistently improving.

There is a lot of Western European investment and many of the manufacturing facilities are state-of-the-art.  This matched with the lower wage cost and workforce skills make the Poles very competitive in both European and global markets.

It was interesting speaking with the Poles about the UK leaving the European Union.  Generally, people thought that being a part of the EU makes it possible to compete with larger economies such as China and the USA.  Brexit has introduced an unknown factor and there was a feeling that, without the UK, the EU would have less negotiating power on the world stage.SyMas Tube Magnets 2

I think that the growth of our local representative TEKPRO highlights the expanding market and potential opportunities in Poland.  Since they were founded 10 years ago, they have expanded their workforce from 4 to 84 people.  It is an exciting time and we are working closely with them to maximise our sales potential in Poland.

At the show we received enquiries for both Magnetic Separator and Metal Detectors, including 3 specific projects where clients require Pneumatic Self Clean Drawer Filter Magnets and Drum Magnets.

Attending the SyMas show was really worthwhile and allowed me to gain an insight into the market which simply is not possible without being at the exhibition.

krakow

And Krakow was a beautiful city.  I have never been before and found the people wonderfully friendly and the historical buildings beautiful.”

For further information on removing metal contamination from bulk goods, powders and granules with Magnetic Separators and Metal Detectors please contact us on:

Other relevant Bulk Goods, Powders and Granules Articles

 

Developing Business in Poland at SyMas 2017

Bunting Support TEKPRO at International Trade Fair for Powder & Bulk Solids Technologies in Krakow, Poland

As part of their export business development strategy, Tom Higginbottom from Bunting will be supporting their Polish distributor TEKPRO at SyMas, the powder and bulk solids trade fair in Krakow, Poland (18-19 October 2017).

SyMas is an international exhibition focused on the processing, transport and storage of bulk goods, powders and granules.  TEKPRO are on stand A68.Bunting_at_SyMas17-2

Company TEKPRO Sp. z.o.o. was founded in March 2007 by Danish company TEKEMAS A/S  and the Swiss Dietrich Engineering Consultants sa .  They specialise in providing individual equipment and complete plants to handle and process bulk materials to the Polish market.

“Attending the exhibition and supporting the TEKPRO team is very important,” explained Bunting’s Sales Engineer Tom Higginbottom.  “Being at SyMas allows us to gain an understanding of the market, meeting existing and potential customers, and discussing the industry in general.”

Bunting_at_SyMas17-1TEKPRO will be displaying Bunting FF Drawer Filters and Grate Magnets on the stand.  Tom and the TEKPRO sales team will be giving advice to visitors about eradicating the problem of metal contamination using both Magnetic Separators and Metal Detectors.

“Over the next 2-days it will be great to have an opportunity to get to know the TEKPRO team.  We will also take the opportunity to provide some additional training.  We are really looking forward to the show, and spending time in a very beautiful city,” said Tom.

For further information on removing metal contamination from bulk goods, powders and granules with Magnetic Separators and Metal Detectors please visit the TEKPRO stand at SyMas or contact us on:

Other relevant Bulk Goods, Powders and Granules Articles

The Challenges of Removing Fine Iron from Powders

Magnetic Separators Designed for Processing Powders

Removing metal contamination when the tramp metal and material is granular is far more straightforward than when in a powder form.  To determine the best solution to remove fine iron contamination from powders, it is necessary to have a good understanding of the way the fine materials behave.

Powders are produced and used in a wide variety of industries including food, pharmaceuticals, refractories, and chemicals.  It is estimated that 80% of materials used in industry are in a powdered form.

flour-791840_960_720A ‘powder’ is defined as fine dry particles produced by the grinding, crushing, or disintegration of a solid substance.  The nature of a powder means that the handling and processing tends to be problematic as powders exhibit similar properties to both solids and liquids.

Metal contamination, commonly in an iron form, can be introduced into a material at any stage within a process.  Tramp metal that is undetected and remains in the product before the powder production stage, becomes significantly reduced in size and, subsequently, increasingly difficult to extract.

Magnetically susceptible metal contamination (i.e. iron) is commonly removed using Magnetic Separation Equipment, which traps metal using Ceramic Ferrite or Rare Earth Neodymium Iron Boron (Neodymium) Magnets.  Although there are Magnetic Separators where the magnetic field is produced via an electrical current, the vast majority utilize permanent magnets such as Ceramic Ferrite and Rare Earth Neodymium Iron Boron (Neodymium).  Ceramic Ferrite Magnets produce low strength but deep magnetic fields, while Neodymium Magnets create the strongest permanent magnetic presently commercially available.

Where Does The Metal Originate?

Metal contamination commonly originates in a powder from two sources:

  1. Primary large tramp metal, such as a nail, screw or bolt;Tube Cartridge Magnets Bunting Magnetics-5
  2. Primary or Secondary fine tramp iron. Primary fine iron or magnetic particles are often present in the raw material.  This originates from primary processing, transportation, or even naturally occurs in the original material.  Secondary fine iron originates from a larger tramp metal source that has been reduced in size during the process.  Typically, this could be from a nail, screw or bolt that has been through a size reduction process, or from damaged or worn processing equipment.  Another common source of secondary fine iron contamination is rust, falling into the process from weathered and worn processing equipment such as chains, hoists, and building cladding.

The separation and detection of tramp metal is easier when the metal contamination is in a larger form and can be successfully removed using a wide range of suitable Magnetic Separators and Metal Detectors.  Magnetic Separators using standard strength Ceramic magnets, with deep magnetic fields, are ideal.  A good example is the Plate Magnet, often installed in a chute, in a housing, or as part of an In-Line Magnetic Separator.

Quicktron05A_Sodium Bicarbonate 2

Larger metal contamination is also easier to detect on a Metal Detector.  Metal is detected as it passes through the coil of the Metal Detector and an automatic reject system removes it from the flow.  For detection, the magnetic field generated by the Metal Detector has to see a state change.  Finer sized metal produces a lesser state change and thus increases the difficulty in detection.

In a project in Pakistan, a processor of fine Sodium Bicarbonate is using a Quicktron Metal Detector to remove the larger tramp metal.

Removing larger tramp metal with a Magnetic Separator and Metal Detector prior to the processing stage not only prevents the metal from being reduced in size (e.g. converted into a secondary source of fine iron contamination), but also protects delicate processing equipment such as granulators, shredders, and mills from being damaged by the metal.

Once in a powder form, there are processing parameters to consider when assessing the optimum method to remove fine iron contamination.

How Does a Powder Flow?

When a powder is sprinkled, it remains light and free.  However, when the same powder is vibrated or compressed, it may become very dense and even lose the ability to flow.

Individual grains in a powder cling to each other in clumps, in accordance with the Van der Waals force.  This coagulation often results in the fine iron being trapped in among clean product.  The ability of any Magnetic Separator to attract, hold and separate the fine iron is dependent on the iron being as close to the magnetic field as is physically possible.  If the fine iron contacts the surface of a Magnetic Separator with a high strength magnetic field, it will be held.  However, when the fine iron is held inside a coagulation of powder, then it could be held out of the reach of the maximum magnetic force.  Thus, it will not be separated.

The way a powder flows impacts on the design of the Magnetic Separator.  Powders flowing in a hopper may experience classic flow problems such as ratholing, bridging or flooding, all of which could be exacerbated by the design of Magnetic Separator.

Different Designs of Magnetic Separator

Plate Magnets Bunting Magnetics-9797High strength magnetic fields, as produced by Neodymium, are needed to capture fine iron metal contamination.  There are four main magnet configurations suitable for handling powders.

  1. Tube Magnets (also known as Rod Magnets and Cartridge Magnets), often in a multi-rod Grate configuration;
  2. Flat-faced Magnetic Plates;
  3. Cone-shaped Magnets;
  4. Magnetic Drums with a curved magnetic arc;

Although occasionally a Tube Magnet may be used on its own, it is more commonly part of a larger multi-cartridge Grate system.  The Magnetic Grate is designed to fit inside a hopper, or can be supplied complete with a housing (i.e. as a Drawer Filter Magnet).ff-neo-4

In operation, powder falls freely onto the surface of the Tube Magnet where fine iron strikes the surface and is held by the strong magnetic field.  To ensure that the powder makes contact with the Cartridge surface, deflectors are often deployed above the gaps between the Cartridges.

Powder build-up on the surface of a Magnetic Cartridge will reduce the separation efficiency.  Also, in severe cases, a slight build up on the surface of the Cartridge may quickly cause a blockage of the whole housing.

Such blockages can be prevented by ensuring that there is optimum space between the Magnetic Cartridges.  Also, in some cases, the mounting of an external vibrating motor on the side of the hopper or housing will provide enough disturbance to prevent any material coagulation.  The frequency of the vibration needs careful consideration as it could affect the flow ability of the powder.  Additionally, when vibrators are used, the Magnetic Cartridges need to be manufactured to withstand prolonged periods of vibration.

Bunting Teardrop Tube Magnet

‘Teardrop’ shaped Tube Magnets are specifically designed to stop the build-up of fine powder on the surface.  The sharp edge of the teardrop faces up into the product flow and allows material to flow around the edge and into the magnetic field.  Magnetic particles are captured and held underneath the Tube Magnet.

Flat-faced Magnetic Plates are ideal when it is possible for the material to flow over the surface.  For fine iron removal, the Magnetic Plates would use high strength Neodymium Magnets.  This magnetic field is further enhanced when a Tapered Step is added to the face of the magnet.  Captured iron migrates behind the step and away from the material flow, reducing the risk of re-entering the cleansed product.

As well as being fitted into chutes, Magnetic Plates are incorporated into housings.  The Plate Housing Magnets resist bridging and choking to remove tramp iron and ferrous fines from flow-resistant bulk materials.  The stainless steel housings mount easily to enclosed spouting or directly on processing equipment.

There are optional square, rectangular, and round adapters for easy connection to existing chute work.  A baffle at the top of the housing helps break up clumps and directs product flow over the unit’s two powerful Plate Magnets.

Bunting Magnetics In Line Magnet

Plate Magnets are also used in In-Line Magnets and there are two designs:

  1. Gravity In-Line Magnets (GIM) – The Plate Magnets are positioned in round, sloping spouting where material is under gravity flow.  For effective tramp metal capture, the spouting should be angled no more than 60° from horizontal;
  2. Pneumatic In-Line Magnets (PIM) – These designs are for use in dilute phase pneumatic conveying systems (up to 15psi). They can be installed easily with optional factory-supplied compression couplings and work best in horizontal runs with the plate magnet down to take advantage of material stratification;

Another design of In-Line Magnet is the Center-Flow, although the magnetic field is generated in a Cone configuration instead of a Plate.  The Magnetic Cone is positioned in the center of the housing, allowing the powder to flow in the space left between the housing.  Center-Flow In-Line Magnetic Separators are commonly used in dilute-phase pneumatic conveying lines up to 15psi.

To achieve optimum contact with the product flow, a conical magnet is suspended in the center-line of the housing.  This tapered, exposed-pole cartridge has a stainless steel “nose cone” to direct the flow of materials around the magnet.  The tapered poles of the cone magnet allow ferrous fines to collect out of the direct air stream.  Additionally, the trailing end of the magnet is an active magnetic pole and holds any tramp metal that is swept down the cone.

Both types of In-Line Magnet are designed with clamps and doors to enable easy access for cleaning.

drumIn specific applications, a high strength Neodymium Drum Magnet will enable the best level of separation.  The Drum Magnet is gravity-fed, usually via a Vibratory Feeder.  The Drum Magnet has a stationary high-strength magnetic arc positioned inside a rotating outer shell.  When material flows onto the drum magnet, the magnetic field projected by the stationary magnetic assembly inside the shell captures fine iron and holds it securely to the drum’s stainless steel surface.  With contaminants removed, the good product falls freely to a discharge point.  As the drum rotates, the captured fine iron travels along the drum surface and out of the magnetic field, where it is discharged.

There are various magnetic field configurations possible, but the most suitable for removing iron from powder is one that produces a Radial Magnetic Field.  This ensures that once captured, the fine iron does not leave the Drum surface until it moves out of the magnetic field.

Processing powder on a Drum Magnet presents more difficulties that other designs of Magnetic Separators.  Firstly, it is recommended that the Vibratory Feeder has an air bed to produce a consistent feed of powder.  Standard Vibratory Feeders may deliver powder in clumps, significantly affecting the separation performance.

Secondly, the shell of the Drum Magnet should be rotated at high speeds.  This will result in some of the powder pluming, and this can be minimized by keeping the distance between the end of the Vibratory Feeder Tray and the rotating surface of the Drum Magnet to a minimum.

The high rotation speed of the Drum Magnet significantly reduces the amount of product lost to the magnetics.  This is because there is less material on the surface of the Drum at any one time, reducing the chance of entrapment.

The use of Drum Magnets operating at high rotational speeds has been very successful in removing fine iron from abrasives, refractories, and other applications where the material has a high specific gravity.

Ensuring Powder is Metal-Free

As the demand for finer and purer powders increases, so does the need to remove even the finest iron.  Understanding the properties and behavior of the powder is vitally important when considering the optimum method of fine iron separation.  Often the ultimate solution is a series of Magnetic Separators and Metal Detectors located at strategic points within the process.

For further information on removing fine metal contamination from powders with Magnetic Separators and Metal Detectors please contact us on:

Getting Metal Out of Plastic on the Bunting Stand at Interplas 2017

Bunting Magnetics Magnetic Separators and Metal Detectors at UK Plastics Show

The latest Magnetic Separation and Metal Detection technology will be on display on the Bunting Magnetics Europe stand (Hall 4, Stand H11) at Interplas 2017 (NEC, Birmingham, UK, 26th – 28th September 2017).

Bunting FFS Magnet-0064A
Bunting FF Drawer Grate Magnet

Bunting Magnetics is one of the world’s leading suppliers of Magnetic Separators and Metal Detectors.  The European manufacturing headquarters are based in Berkhamsted in Hertfordshire, UK and they have an extensive overseas network of distributors and marketing agents.  In January 2017, the company acquired Master Magnets, significantly expanding their range of Magnetic Separators and Metal Detectors.

“Interplas is the number one exhibition for the plastics sector in the UK,” said Dave Hills, Bunting’s Head of Sales, “and the show gives us a great opportunity to meet many existing and potentially new customers.”

Bunting Magnetics has a strong global relationship with the plastics sector.  Many of their Magnetic Separators have been designed specifically for use in the manufacture and recycling of plastics and plastic products.

The Magnetic Separators and Metal Detectors on the Bunting stand at Interplas are designed to capture, identify and remove metal contamination.  The presence of rogue metal damages processing equipment and affects the end-product quality and reject rates.

Bunting BPI-6151

The FF Drawer Grate Magnet is specifically designed for removing magnetically-susceptible particles from plastic.  The standard model has 2 banks of Neodymium Rare Earth Tube Magnets mounted inside a sealed housing.  Other variations are available including a low profile design for positioning underneath large hoppers and silos. Magnetic Separators with Neodymium Rare Earth Magnets remove even the smallest magnetically-susceptible particles.  On the stand will be examples of extremely strong Magnetic Grates, Plate Magnets, Tube Magnets, and the industry-standard FF Drawer Grate Magnet.  Visitors will be invited to test the magnetic strength for themselves.

Bunting Magnetics Europe at RWM16“This combination [FF Drawer Grate Magnet and the quickTRON Metal Detector] offers the best method of removing metal from free-falling materials,” explained Dave Hills.  “The Magnetic Separator captures and holds any magnetically attracted metals such as steel screws, bolts, steel slithers from worn equipment, and even work-hardened stainless steel.  This always proves to be the bulk of the metal contamination.For a complete metal separation solution, the FF Drawer Grate Magnet is fitted above a quickTRON Metal Detector.  The Metal Detector then identifies and rejects any non-ferrous metals.

“Any remaining metal will be identified as it passes through the Metal Detector and then ejected.  The cleansed plastic can then proceed safety into the next stage of the process, whether than is to the extruder or granulator.”

A working, production-sized model of the combined FF Drawer Grate Magnet and quickTRON Metal Detector will be on the Bunting stand at Interplas.  Regular demonstrations will enable visitors to witness the capabilities of the complete metal separation system.

p-TRON-GM-V2
pTRON Metal Detector

A range of pTRON Metal Detectors designed for use in Pneumatic transportation lines will also be on display on the Bunting stand.

With the acquisition of Master Magnets, Bunting also has an extensive range of Magnetic Separators and Eddy Current Separators for the recycling sector.

“The combined experience of Bunting and Master Magnets means that we have a solution for most metal separation problems.  The Master Magnets Eddy Current Separator is an industry standard and is used to remove non-ferrous metals from plastics in recycling operations across the world,” said Dave Hills.

For further information on the Magnetic Separators and Metal Detectors that will be on show at the Interplas 2017 exhibition, please contact us on:

Export Success at FIP Solution Plastique Exhibition

Bunting Magnetics Support BMS France at Plastics Show in France

Dave Hills, Bunting Europe’s Head of Sales, was on the stand of local distributor, BMS France for the duration of the major annual international plastics exhibition, FIP Solution Plastique, held in Lyon, France between 13th and 16th June 2017.  Dave gave us this report:

“Last week [13th to 16th June] it was hot and humid in Lyon.  And it was debatable whether the air conditioning in the exhibition centre was actually working.  However, the turnout for the show was fantastic.

FIP Solution Plastique is the number 1 show for the plastics sector in France.  There was a technically and globally diverse group of exhibitors present, all specialising in working in the plastics industry.

We were present to support our local distributor BMS France.  Being on the stand gave me the opportunity to develop relationships with the BMS team, deliver some product training, and also learn about the plastics market in France.  I also had the opportunity to meet the BMS Spain team, based in Barcelona.

It was also good to meet and talk with other equipment suppliers, many of who had equipment on display at the show.  It was interesting to hear their feedback on present market conditions.  We find exports visits such as this invaluable.

Bunting_FIP_Solution_Plastique_France-1987

Along with our Metal Detectors and Magnetic Separators, BMS had a wide range of equipment on the stand.  There were 3 operating Boy Injection Moulding Machines on one stand and a Woojin Injection Moulding Machine on a 2nd stand.

There were also 5 Wanner Granulators, and Pixargus had a live demonstration of their unique surface inspection and dimension measurement system.

The extensive range of products and the interactive nature of the BMS France stand made it one of the busiest at the show.

Bunting_FIP_Solutions_Plastique_17-1985

It was interesting to think that all of the aforementioned equipment relies on the plastic pellets and raw materials being metal-free.  And getting metal out of plastic is our speciality.

BMS France was able to talk to visitors about a complete solution, with demonstrations of the quickTRON 03R Metal Detector and FF Drawer Filter Magnet removing both ferrous and non-ferrous metals.

Being in France also gave me an opportunity to hear people’s thoughts about BREXIT.  Unlike some other European countries that I have visited since the referendum, people in France have a very negative opinion about the UK leaving the EU.  In fact, many people asked whether the decision could be overturned.  This just highlights the importance of a negotiated exit that involves free trade.

However, the atmosphere at the exhibition was very positive.  Indeed, BMS France sold 2 Injection Moulding Machines at the show, which was fantastic.  And both will be protected by Bunting Metal Detectors and Magnetic Separators.

An excellent show and we will be back in 2018.”

For further details on the Bunting range of Magnetic Separators and Metal Detectors used to remove metal from virgin and recycled plastic, please contact our technical sales team on:

Bunting_FIP_Solution_Plastique_France--2

Metal Detectors and Magnetic Separators at FIP Solution Plastique

Bunting Support BMS France at Major Plastics Show in France

Bunting Magnetics Europe distributor, BMS France, is exhibiting Metal Detectors and Magnetic Separators on stand D16/E13 at the FIP Solution Plastique show in Lyon, France (13th to 16th June 2017).  FIP Plastique Plastique has been the number 1 show for the plastics sector in France for over 30 years.

BMS France represent Bunting in France, providing local technical support to companies producing and recycling plastics.  BMS are based in Pringy and manufacture and distribute a wide range of products and equipment for the plastics industry.

Bunting_FIP_Solutions_Plastique_17-1982

“FIP provides the ideal platform to showcase a wide range of metal separation equipment,” said Dave Hills, Bunting’s Head of Sales.  Dave will be manning the stand with the BMS France team in Lyon.

On the stand, BMS will be showcasing Bunting equipment including:

Quicktron Metal Detector

Gravity free-fall style metal separators are designed specifically to isolate and separate any contaminated material moving in the product flow.  Ferrous and non-ferrous metals are automatically detected and removed from the product flow, without any interruption in the production process.

FF Drawer Filter Magnets

FF Series Draw Magnets are perfectly suited for collecting and separating contaminant ferrous metal from gravity fed, dry, free flowing materials.  Housed inside are the extremely strong Neodymium Rare Earth Magnets which capture and hold small pieces of ferrous metal contaminant.  Made specifically for the plastics industry, this is the only available drawer magnet design that features temperature-compensated rare earth magnets.Bunting_FIP_Solutions_Plastique_17-1985

Grate Magnets

Grate Magnets or Magnetic Grates are manufactured with a 25mm Tube Magnet from high quality 304 Stainless Steel, with 316 Stainless Steel as an option for high corrosive applications.  They are available for Square or Round Openings and with optional baffles.  Standard sizes range from 100mm to 1000mm.  These Grate Magnets can be placed in hoppers or feed pipes to collect ferrous metals and are ideally suited when they can be easily removed for cleaning.

“As a leading supplier to the plastics industry, it is important that we are here at FIP.  It gives us the opportunity to meet and talk to plastic producers about metal contamination issues,” said Dave.

For further details on the Bunting range of Magnetic Separators and Metal Detectors used to remove metal from virgin and recycled plastic, please contact our technical sales team on:

Other Articles Related to Plastics Recycling

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Metal Found In Rice

Magnetic Separator Ensuring Food Safety

There are a lot of negative Food Safety reports about metal being found in food (e.g. Morrisons’ Green Beans, Sainsbury’s Bread), but there is also a great deal of good practice.

Whilst undertaking an annual Magnetic Separation Survey at a rice processing factory, we were able to see the importance of installing metal separation equipment.

Fine Iron on Bunting Grate MagnetThe Food Processor had installed Bunting FF Drawer Grate Magnets at the base of hoppers holding Basmati rice prior to packing.  For maximum fine iron removal, the Grate Magnets were constructed with high strength Rare Earth Magnets with magnetic fields of approximately 11,200 Gauss on the surface.

A schedule had been established for the Grate Magnets to be cleaned on a weekly basis.  During the Survey, the amount of fine iron captured and held onto the surface of each of the Tube Magnets was found to be  substantial.  Subsequently, one of the recommendations was to increase the cleaning frequency.  This would then ensure that the Magnetic Separators were working optimally as performance can drop if the Magnets are laden with captured metal.

Where Does the Metal Come From?

Fine Iron on Bunting Grate MagnetThe majority of rice processed in the UK is imported from South-East Asia.  The process of collection, storage and transportation results in fine iron being introduced.  Additionally, very small amounts of fine iron may be introduced during the handling of the rice at the UK plant.  This could be from the wear of processing equipment.

Does the Amount of Metal Vary?

The UK food processor has very little control on the amount of metal present in the delivered rice and even working closely with the rice grower to improve Food Safety standards does not ensure a metal-free product.  As with all food imports, there are many stages of handling and storage where metal contamination occurs.  The amount of metal can vary significantly and, subsequently, the frequency of cleaning the Magnetic Separators will alter.

Good Food Safety Practice

As demonstrated at this rice processing plant, Magnetic Separators will separate magnetically susceptible metal (including work-hardened stainless steel) prior to any product reaching the consumer.  Annual reviews with the suppliers of the equipment will provide assurance of metal-separation performance.

For more information on good Food Safety practices and removing metal contamination, or to request a Magnetic Separation Audit, please contact the Bunting team on:

Phone:  +44 (0) 1442 875081

Email:  sales@buntingeurope.com

Via the website

Fine Iron on Bunting Grate Magnet
Fine iron captured by a Bunting Magnetics Europe Rare Earth FF Drawer Grate Magnet