The existence of ferrous metals in free-flowing materials often gives rise to a vast number of safety hazards and functional difficulties in several industries such as pharmaceuticals, mining, and food processing, and recycling.
Luckily, there is one such robust tool that can significantly help in taking out ferrous contaminants from certain constituents – a magnetic grill.
Keep reading this guide as we delve into the topic of what is a magnetic grill, along with its many types, features, working applications, and benefits.
Understanding Magnetic Grills
Known as a magnetic grate or a magnetic separator, magnetic grills are simply tools that are primarily used for the purpose of separating iron particles that are mixed with granular, free-flowing, or dry materials.
They are composed of stainless steel frames and are typically found in different sizes and shapes, including rectangles, squares, and rounds. Moreover, these grills have magnetic rods within the frame.
The high intensity and high gradient magnetic field offered by a magnetic grill serves as an excellent means to eradicate ferrous metals from free-flowing supplies. It includes an array of magnetic bars or tubes that are organized into a grid-type design.
The magnets create a powerful magnetic field. As the constituents pass through the magnetic grill, it draws in and retains the ferrous particles. The magnets’ strength, size, and composition all differ according to the type of application and performance you prefer.
Basically, the function of a magnetic grill is focused on the laws of magnetic attraction. The powerful magnetic field created by the magnet draws in and retains the particles when an element with ferrous metals passes through this magnetic grill.
Finally, the magnetic grill has a relatively simple design, so you can easily clean and remove the contaminants that have been seized.
You can typically find grate magnets in various shapes such as rectangles, squares, round, oval, rhombus – whichever shape best matches your requirements. A magnetic grill is primarily used in floor openings, underneath hoppers, catch bins, sealed chutes, and various other locations.
Fully enclosed in stainless steel, the primary purpose of these grids is to safeguard your processing equipment and make sure the product stays pure. However, if you wish to ensure a more significant protection level, it is advised to use double and triple banked grids. All metal grids are available with robust and unique earth magnets or ferrite.
Type of Magnetic Grills
A magnetic grill can be further classified according to different intensity levels. Here are the four main types of magnetic grill to help you better identify which one suits you best.
Low-Intensity
A low-intensity magnetic grill has an estimated Gauss value of 2,500 Gauss. These types of magnetic grills are best suited for trapping contamination such as broken washers, bolts, nuts, screws, and the like.
A low-intensity magnetic grill is ideally designed to draw in more significant pieces of iron from a relatively large distance.
Medium-Intensity
A medium-intensity magnetic grill has an estimated Gauss value of 6,500 Gauss. These types of magnetic grills are primarily used where the impurity is in the form of particles. Still, there might or might not be a constant flow of material that needs to be divided.
The size of the contamination can range as low as 150 micros, but nowhere below this level. Finally, the material must be non-sticky and have the ability to flow freely.
High-Intensity
A high-intensity magnetic grill has an estimated Gauss value of 11,000. These magnetic grills are typically used in places where you need the division of contamination particles to be as small as 1 micron.
A high-intensity metal grill is designed to draw in ultra-fine particles from the transporter material.
Super High-Intensity
Finally, a super-high magnetic grill has an estimated Gauss value of 12,000.
The most important thing to note about all four types of magnetic grills is that you must clean them frequently. It’s ideally recommended to clean the magnetic grill entirely as scheduled according to the experience and requirements of the user, or before every pass.
If the iron particles keep building up within the grill for a prolonged duration, the effectiveness of the magnetic grill is bound to decrease. As a result, if you want to ensure the maximum attraction for your magnetic grill, you must clean it thoroughly and at regular intervals.
Magnetic Grill Uses
A magnetic grill is used for a vast array of industries:
● Food Processing: In the food processing industry, a magnetic grill can be of great help as it ensures the purity of a product by getting rid of metal pollutants from raw materials like spices, grains, powders, etc.
● Recycling: In the recycling industry, you can utilize magnetic grills to get rid of metal contaminants from a vast range of recycled components such as glass, paper, plastic, etc.
● Aggregate and Mining: A magnetic grill can be used to extract metal impurities from different mined materials such as crushed rock, ores, etc.
● Plastics and Chemicals: This is yet another industry in which magnetic grills serve a vast range of purposes, such as avoiding product pollution and damage to the equipment caused by metal contaminants in pellets, granules, and powders.
● Biomass and Wood: Magnetic grills help to safeguard the processing machinery from damage to the metal by getting hold of the ferrous impurities in biomass materials, sawdust, and wood chips.
● Pharmaceuticals: In the pharmaceutical industry, you can keep the constituents safe by getting off metal particles through a magnetic grill.
In addition, magnetic grills are also used for many other things, such as
● Ceramic Industries or Powder
● Mineral Industries
● Pigments and Dies
● Alpha and Beta Blue
● Guar Gum
● Wheat Flour
● Intermediate
● Quartz Powder
● Emulsifier
● Limestone Powder
● Glass Plant
● Tile Plant
● Chemical Plants
● Plastic Granules
● Plastic Grinder
● Packaging Machine
Features of Magnetic Grills
Now that the different types and uses of magnetic grills have been highlighted, it’s time to look at different features of magnetic grills.
● The magnet ranges’ gauss power ranges between 10,000 to 10,500.
● A magnetic grill is composed of premium quality stainless steel with the most brilliant surface polish. Typically, magnetic grills are produced and supplied in two grades, namely SS304 and SS316.
● A magnetic grill can be found in different power ranges, two different sizes, and diameters. This includes square or rectangle and round.
● This magnetic grill can be positioned with any filtering and sieving machines, no matter which company has manufactured it. You can install the magnetic grill at an inlet, an outlet, or underneath the hoppers, based on the material’s nature that requires sieving.
● A round magnetic grill is mainly fixed in nature and installed at inlets and outlets. On the other hand, a square magnetic grill is usually a drawer kind of a magnet that is installed just underneath the hopper and is fairly easy to remove for cleaning purposes.
● A magnetic grill can be cleaned manually.
● A magnetic grill is ideally suited for slurries, dry powder, and fluids.
● The magnetic grill is relatively easy to install and remove, and requires no maintenance and operating costs.
● You can get the magnetic grill customized according to your own preferences and requirements.
Benefits of Magnetic Grills
Of course, there are many different ways in which you can benefit from using magnetic grills as a component of a material processing equipment. These include:
Improved Quality of Products
By getting rid of ferrous impurities as the ones mentioned above, you can enhance the overall purity of the processed raw materials while also ensuring to meet the regulatory needs and quality standards with a magnetic grill.
Protect your Equipment
A magnetic grill is an excellent and powerful tool that can aid you in avoiding damage to downstream machinery like mixers, mills, and crushers caused by ferrous metal remains.
Easy Maintenance and Quick Installation
Usually, a magnetic grill is relatively easy to install, portable, and calls for very little maintenance. Hence, you can significantly benefit from more significant operational efficiency and a drastic cut in downtime.
Better Safety
Getting rid of metal impurities through a magnetic grill mitigates the chances of fire, explosions, sparks, and other chemical hazards in surroundings where there is a presence of combustible materials.
Factors to Take Into Consideration While Selecting a Magnetic Grill
There are multiple factors worth considering when choosing a magnetic grill. For instance, it is important to take things such as the strength of the magnet, material compatibility, flow rate, and cleaning mechanism into account. Let’s look at these factors one by one:
Cleaning Methods
Based on your desired ease and frequency of maintenance, you must take into consideration whether you prefer to have an automated cleaning system, such as a shelf-cleaning magnetic grill, or a manual cleaning system.
Strength
The magnet’s strength must be apt for the kind and size of ferrous impurities expected in the material.
Compatibility of the Material
The materials from which the magnetic grill is composed should be well-suited for the specific application. Moreover, you must take factors like sanitation needs and resistance to corrosion into consideration.
Flow Rate
You must also consider the magnetic grill’s capability to manage the preferred flow rate. This way, you can guarantee efficient processing.
Best Supplier/Manufacturer for Magnetic Separators and Magnetic Grills
Suffice to say, a magnetic grill is the most ideal, effective, efficient, and dependable solution for getting rid of ferrous metal impurities from a vast range of free-flowing constituents, and it is well-suited for diverse sectors.
Given its ability to safeguard your valuable equipment, boost the overall quality of products, and enhance safety, a magnetic grill has earned quite the reputation for being a valuable and essential tool in material processing systems.
By taking the particular application needs into consideration and choosing the right grill magnet, you can boost your overall productivity in your business, mitigate chances of errors and risks with ferrous metal impurities, and guarantee the reliability of the products.
If you’re in search of the best magnetic grill supplier/manufacturer, we’ve got you covered. GME is one of the leading universal manufacturers/suppliers of premium quality magnets and magnetic solutions for a vast range of research, engineering, and industrial applications.
Renowned for its progressive growth of magnet technology as a reliable OEM wholesale supplier of a massive range of magnetic products and solutions, GME is your go to company if you’re looking to buy magnetic grills.
The company takes great pride in the manufacture, sale, and service of permanent magnets, and the product range consists of SmCo, Neodymium, FeCrCo, Alnico, magnetic assemblies, and mini magnets used extensively in electronic instruments, sensors, motors, meters, automobile, aerospace, medical devices, aviation, etc.
Magnetic Separators and Magnetic Grills at GME
GME offers an impressive range of magnetic separators, and here is just a glimpse of some our grill magnet range:
Customized Magnetic Grate Grid
A custom-made magnetic grade grid is the best tool to separate the iron particles from the granular, dry, or free flowing constituents. This magnetic grill is produced using stainless steel frames in square/rectangular or round shapes, along with magnetic rods within the frame.
Powerful Hopper Magnets
A magnetic grate separator, a.k.a grate or hopper magnets is used for separating the stray iron metal in round shells, drawers, chutes, hoppers, and dustbins. GME’s magnetic grills are an excellent way to get rid of tiny impurities from the entire line of production.
Thanks to its robust Neodymium rods, these grids have a magnetic field so powerful it can penetrate deep into the free flowing products and take out the ferrous impurities. This enhances the purity of the product and mitigates the chance of impurities from reaching the product.
Easy-Clean Magnetic Grid Hopper Magnet
If you want a tool with very little maintenance and that is fairly easy to clean, then you should opt for thee easy-clean magnetic grid hopper magnet. It comes with easy to clean design and allows for easy and effective cleaning.
All you need to do is remove the magnetic core, and the iron contaminants will fall out from the cover.
Wrapping Up
All-inclusive, the custom magnetic grate separators at GME have a striking appearance and come with a simple design that allows for quick disassembly and cleaning.
These magnetic grid separators also go by the names of grates in housing, magnetic grate separators, magnetic grid, and hopper magnets.
Moreover, here at GME, you can customize your magnetic grate separators based on various sizes, shapes, and setups, allowing you to find the magnetic grill that suits you best.
