A simple piece of iron can stop your entire production.

Screws, chains, tools, sheets and other metal contaminants can pass unnoticed along the conveyor belt until they reach crushers, mills, shredders and other critical equipment.

The result is unexpected downtime, corrective maintenance, lost productivity and increased operating costs.

The good news is that these problems can be avoided with the correct installation of a magnetic separator.

What are magnetic separators?

Magnetic separators are equipment used to remove impurities or ferrous parts present in non-magnetic materials.

Also known as magnetic extractors or metal extractors, this equipment can be installed close to conveyor belts, vibrating feeders and other systems used to transport materials.

During the passage of the product, the magnetic field attracts ferrous contaminants, preventing them from continuing to advance through the line.

Suspended separators act externally to the conveyor, capturing ferrous material that passes over or under the equipment. This feature can facilitate its integration into existing structures, without the need for major changes to the transport system.

Why should ferrous contamination be controlled?

Throughout the production process, metallic fragments can mix with the transported material. Screws, nuts, wires, tools and particles resulting from machine wear are among the most common contaminants.

How much does a stop caused by a piece of iron cost?

Then you say:

• crusher stopped;
• broken belt;
• change of hammers;
• bearings;
• stop hours;
• team stopped;
• trucks waiting.

When not removed, these materials can travel down the line and cause damage to equipment, production interruptions and increased maintenance costs.

In some processes, smaller particles can also compromise the quality of the final product and reduce its commercial value.

Magnetic separation helps avoid these problems by removing ferrous contaminants before they progress to more sensitive stages of the operation.

ITAL emphasizes that pieces of iron can cause serious damage to equipment, while smaller particles can significantly reduce the value of the processed product.

Where to install a magnetic separator?

·       before the crusher;

·       before the mill;

·       before the crusher;

·       before sieving;

·       before processing.

When to choose a magnetic separator?

When the presence of contaminants already poses a risk to production, reducing response time becomes essential.

A ready-to-deliver magnetic separator allows you to speed up line protection, preventing the operation from remaining exposed while waiting for equipment to be manufactured.

This solution can be indicated when:

• Metallic fragments have already been found in the processed material;
• The line suffered damage or stoppages caused by ferrous contaminants;
• A new operation needs to start with magnetic protection;
• The company wants to reinforce process safety;
• There is an urgency to replace or install a magnetic separator.

In these cases, prompt delivery helps to reduce risks, preserve equipment and maintain production continuity.

Top applications

Mining

Protection of crushers and screens.

Recycling

Removal of scrap metal.

Sugar

Mill protection.

Biomass

Removal of metals before grinding.

Ceramics

Crusher protection.

Cement

Removal of contaminants.

Fertilizers

Metal separation.

Ports

Belt protection.

What are the advantages of prompt delivery?

Faster to secure your operation

The main advantage is the reduction of the interval between identifying the need and installing the equipment.

When the available model is compatible with the application, the company can move more quickly to the acquisition, preparation and installation stages.

This agility is especially important when the line already shows signs of contamination or when the operation of important equipment is threatened.

Less exposure to damage

While the operation remains without an adequate separation system, contaminants continue to advance through the process.

Each new production cycle can allow screws, fragments and other metal parts to reach sensitive components.

By speeding up the installation of the separator, the company reduces the period in which machines and products remain exposed.

Reduced unexpected downtime

A metal part that reaches a crusher, mill or conveyor can cause damage and interrupt production.

In addition to repair, an unexpected stoppage can affect deadlines, productivity and other steps that depend on the functioning of that machine.

Magnetic separation acts preventively, removing the contaminant before it reaches these critical points.

Preserving product quality

In addition to protecting machines, magnetic separators help prevent ferrous fragments from remaining in the processed material.

This control helps to preserve the quality of the final product and reduce the risk of failure, rework, disposal or customer complaints.

More agility in implementing new lines

Ready-delivery equipment can also serve companies that are implementing or expanding a production line.

In this scenario, immediate availability helps prevent the start of the process from being delayed due to the absence of an adequate magnetic protection step.

Where can magnetic separators be applied?

Magnetic separators can be used in different segments that transport or process materials subject to ferrous contamination.

Among the applications are:

• Mining;
• Quarries;
• Steel industry;
• Recycling;
• Ceramics;
• Agroindustry;
• Food plants;
• Biomass production;
• Cement plants;
• Processing of bulk materials.

Installation must consider the type of product, the conveying system and the point in the line where contaminant removal will be most efficient.

ITAL presents applications of this equipment in quarries, mining, steel, ceramics and food plants, among other industrial sectors.

Contact ITAL

WhatsApp: (11) 96416-4821