Challenge
For producers of soils and composts, product quality is visible and uncompromising.
At a UK processing facility producing high-grade soils and composts, small ferrous metal contamination was an ongoing concern. Nails, screws, and fine wire entering the product stream could compromise finished quality and undermine customer confidence.
Suspended permanent magnets were already installed on two process lines. While effective at removing larger tramp metal, they struggled to capture smaller ferrous pieces, especially at higher belt speeds and throughput.
The challenge was clear.
-
Small ferrous contamination was still passing through
-
Product volumes were high, up to 300 tonnes per hour
-
Manual cleaning of permanent magnets was time-consuming and disruptive
The operation needed stronger separation performance without slowing production, along with a safer, more efficient way to clean captured metal.
Solution
Bunting Magnetics supplied two Suspended Electromagnets to replace the existing Suspended Permanent Magnets on both process lines.
The suspended electromagnets were installed above inclined conveyors, positioned approximately 300 mm above the belt surface. Each unit generates a powerful, controllable magnetic field capable of extracting small ferrous metals from deep within the conveyed material.
The electromagnetic design provides a key operational advantage. When cleaning is required, the conveyor is cleared and the magnet is switched off. With the magnetic field removed, captured ferrous metal drops safely onto the conveyor for easy removal before the system is restarted.
-
Stronger magnetic field for improved separation
-
Effective capture of small ferrous metals under 10 mm
Faster, safer cleaning without manual scraping
The magnets integrate directly into the existing process while delivering a clear upgrade in performance.
Result
With the suspended electromagnets in operation, the facility achieved:
Significantly improved removal of small ferrous contaminants, including nails and wire
Consistent separation performance at throughputs up to 300 tonnes per hour
Higher quality finished soil and compost products
Simpler, safer cleaning compared to permanent magnet designs
For high-volume bulk material processing, separation strength matters.
Control matters.
And sometimes, switching from permanent to electro is the difference between acceptable and exceptional performance.
 |
| Ferrous metal held on the face of one of the suspended electromagnets. |
