Magnetic conveyor belts
A magnetic conveyor belt, magnetic separator, or overbelt magnets are used to remove unwanted metal parts from a material flow in order to obtain an end product that is as pure as possible. The metal parts are filtered out of the material flow with an overbelt magnetic separator.
overbelt magnets for mobile installations
Overbelt Magnets are deployed in machine factories or end users. An overbelt magnet separates high volumes of iron or steel (various metals), or ferrous parts, from raw materials quickly and effectively and discharges these metals automatically and continuously. In the case of mobile installations, >90% of the magnetic belt hangs transversely on a flat, profiled or magnetic conveyor with carriers. This can be either flat or in a trough. The aim of this magnetic conveyor system is to remove undesirable metal particles for the cleanest possible end product or for further processing so that nothing is damaged on machines further down the line.
An overbelt magnetic separator has a drive and reversing drum including a frame. The frame then contains the magnetic core that attracts the material. Near the core, the material is attracted (this is where the forces are strongest). The moment the material reaches the drive or reverse roller using the Hotcleat® cleats, the force of the conveyor magnets decreases to such an extent that, in combination with the belt speed and flights, the material is released. This is then discarded sideways. In this way, the metals are separated from the remaining material by the magnetic belt conveyor.
Hotcleat® on a magnetic conveyor belt
The belt magnetic made of highly abrasion-resistant rubber is fitted with cleats. To ensure that the metal parts are captured properly, our Hotcleat® cleats are hot vulcanised on the Probelt® base belt. It is often the case that too small drum diameters make great demands on a base belt, so not all belts are suitable for a conveyor belt magnetic separator. The right and unique composition of the magnetic conveyor belts and technical know-how is important to deal with the often common small drum diameters. There is also a high belt speed which exerts an additional load on the joint, making correct joint techniques and monitoring of this crucial.
Our Hotcleat® magnetic belt
In addition, our Hotcleat® cleats are made of unique compounds that ensure, for example, tear-resistant and abrasion-resistant cleats. This is also because these are often sharp and abrasive pieces of metal that can quickly damage the magnetic belt and cleats when configured incorrectly. The de-icing efficiency of top over belt magnet systems ranges from 70% to 90%. This varies depending on the magnet design, product flow and placement. It is a reliable and effective method of separating large quantities of iron using conveyor belt magnets. This method of separation prevents also machines from being damaged by larger metal parts.
The technical complexity of magnetic conveyor belts for mobile plants is well known to our specialists. We combine our knowledge and experience of applications in various industries from Recycling, Agro and Food. We like to think along with our customers, even if the solution is completely new.
DOWNLOAD WHITEPAPER FOR FREE
When designing a conveyor belt for a plant, more is possible than is often assumed. It is precisely in the smallest details that lies the hidden technology that makes the difference in the final performance of the conveyor for production. For overbelt magnets, you have very specific considerations to take into account.
This white paper can be used as a checklist to help you make the right choice when designing a magnetic conveyor belt.
key benefits
Hotcleat® magnetic conveyor belts
HOTCLEAT® magnetic conveyor belts:
Our Hotcleat® technology optimizes the performance of your magnetic conveyor system. Through unique hot vulcanization, these magnetic conveyor belts offer crucial advantages for any magnetic separator:
-
No detached cleats: Cleat detachment on a magnetic belt conveyor is a thing of the past. The Hotcleat® becomes one with the belt magnetic, regardless of weather influences or temperature.
-
Ideal for small pulley diameters: This magnetic conveyor design reduces tension on the drums, resulting in less wear and lower power consumption.
-
Improved working life: The durable bond on the magnetic belt is resistant to sharp metal parts processed by the overbelt magnetic separator.
-
Eco-friendly & Cost-saving: Produced without industrial glues, making these magnetic conveyors more sustainable while reducing maintenance costs for your conveyor belt magnetic separator.
Solutions for mobile installations
Mobile installations require robust and flexible equipment to maintain high efficiency on-site. We offer specialized solutions for various processes where a magnetic conveyor system or a reliable magnetic separator is essential:
- Pulverising and/or shredding: Protecting downstream equipment by using conveyor belt magnets to catch metal early.
- Screening: Refining material flows where an overbelt magnetic separator ensures the removal of fine ferrous contaminants.
- Separation with a magnetic separator: Utilizing a high-performance magnetic belt conveyor to automatically discharge steel and iron parts.
- Transporting: Ensuring a steady flow of material with a heavy-duty magnetic conveyor.
There are several demanding applications for mobile installations where our magnetic conveyor belts make the difference:
- Composting & Wood: Removing nails and staples to create a clean, organic end-product.
- Household & Residual waste: Using an over belt magnet to recover valuable metals from mixed waste streams.
- Stone & building rubble: Protecting crushers by deploying an overbelt magnet to intercept reinforcement steel.
- Metal recycling: Efficiently sorting and transporting ferrous materials via a dedicated magnetic belt.
Benefits anti-magnetic mechanical fasteners
The method of making the magnetic belt conveyor for overbelt magnets endless is also an important aspect for the quality of the belt magnetic. What does it mean to choose anti-magnetic mechanical fasteners compared to an endless hot vulcanized joint?
The advantages of these fastener are:
-
Faster replaceable; this is because the tendon can be removed from the connector quickly and easily. This allows the magnetic conveyor belt to come off quickly. By just turning back the span of the drums, the new conveyor belt magnetic separator fits easily around the installation. When the new strap is on it, the tendon can go through the connector and the strap can be tensioned.
-
Less production loss, this is because the magnetic conveyor can be replaced quickly and the machine is stopped for a short time.
-
A major difference between a mechanical fastener and a hot vulcanized weld is that you do not have to disassemble the overbelt magnetic separator (completely or partially) to assemble an endless welded conveyor belt. Especially on location where the right tools are not available.
It is very important to choose a completely anti-magnetic mechanical fastener. This is because otherwise the mechanical fastener can be attracted to the conveyor magnets and cause damage to the installation. Additionally small parts can “stick” to the mechnical fastener which can result in a broken mechanical fastener over a period of time due to wear and tear.
request your hotcleat® magnetic conveyor belt
Would you like to request a Hotcleat® magnetic conveyor belt for your mobile installation? We like to think along!