Up-suction Magnetic Roller

Technical Parameters

Case 1: Recycling Industry

Background

A large - scale recycling plant was facing challenges in separating ferrous metals from a complex mixture of recyclable materials. The existing separation methods were inefficient, leading to a high percentage of ferrous contaminants in the non - ferrous recycled output, reducing its market value. Also, the presence of sharp ferrous objects was causing frequent damage to the conveyor belts and other downstream processing equipment.

Solution

The plant installed an Up - suction Magnetic Roller in the key sorting section of the conveyor line. The Up - suction Magnetic Roller was chosen for its strong magnetic field, which could penetrate through the thick layers of mixed recyclables. Its design allowed for efficient removal of ferrous materials, even when they were buried within non - ferrous materials.

Results

• Improved Separation Efficiency: The separation efficiency of ferrous metals increased from 60% to over 90%. This led to a significant improvement in the purity of non - ferrous recycled materials, enhancing their market value.
• Reduced Equipment Damage: The number of conveyor belt replacements due to damage from ferrous objects decreased by 70%. Downstream processing equipment, such as shredders and grinders, also experienced fewer breakdowns, resulting in reduced maintenance costs and increased overall plant uptime.

Case 2: Mining and Mineral Processing

Background

A mining company was processing ore that contained a significant amount of ferrous contaminants. These contaminants not only affected the quality of the final ore product but also caused severe wear and tear on the grinding and milling equipment. The traditional magnetic separation methods were unable to effectively remove the fine - sized ferrous particles.

Solution

An Up - suction Magnetic Roller with a high - intensity magnetic field was integrated into the ore processing line. The roller was positioned in a way that the ore passed over it at a controlled speed, allowing the magnetic field to attract and remove ferrous contaminants. The up - suction design ensured that even the smallest ferrous particles were captured, as the magnetic force pulled the particles upwards against the flow of the ore.

Results

• Enhanced Ore Quality: The percentage of ferrous contaminants in the final ore product was reduced from 8% to less than 2%. This improvement in quality increased the market price of the ore, resulting in higher revenues for the mining company.
• Extended Equipment Lifespan: The wear and tear on grinding and milling equipment decreased by 50%. The reduced presence of ferrous particles meant less abrasion on the equipment surfaces, leading to longer - lasting machinery and lower replacement costs.

Case 3: Food Processing

Background

A food processing company was concerned about metal contamination in its products. Any metal particles in the food could pose a serious health risk to consumers and also lead to costly product recalls. The existing metal detection and removal systems were not fully effective in capturing all types of metal contaminants.

Solution

An Up - suction Magnetic Roller was installed in the food processing line, just before the packaging stage. The magnetic roller was carefully calibrated to ensure that it attracted and removed any ferrous metal particles without affecting the food products. The up - suction design was beneficial as it could capture metal particles that might be present on the surface or within the food product as it passed over the roller.

Results

• Improved Food Safety: No metal contaminants were detected in the food products after the installation of the Up - suction Magnetic Roller. This not only ensured the safety of consumers but also enhanced the company's reputation for producing high - quality, safe food products.
• Avoided Product Recalls: The elimination of metal contamination risks saved the company from potential product recalls, which could have cost millions of dollars in terms of product replacement, legal fees, and damage to the brand image.

Case 4: Automotive Manufacturing

Background

In an automotive manufacturing plant, small ferrous metal particles were getting mixed with automotive components during the production process. These particles could cause malfunctions in the assembled vehicles, leading to costly rework and customer dissatisfaction. The plant needed a reliable solution to remove these particles.

Solution

Up - suction Magnetic Rollers were placed at various critical points in the manufacturing and assembly lines. These points included areas where components were being transferred, machined, or assembled. The magnetic rollers were able to capture ferrous particles that were generated during machining operations or were present in the environment and had adhered to the components.

Results

• Higher Product Quality: The number of vehicles with component malfunctions due to ferrous particle contamination decreased by 80%. This led to a significant improvement in the overall quality of the automobiles produced, resulting in higher customer satisfaction and fewer warranty claims.
• Reduced Rework Costs: The amount of rework required on assembled vehicles dropped by 60%. The early removal of ferrous particles meant that fewer components had to be replaced or repaired, saving both time and money in the production process.