In the aggregate, mining, and minerals industries, permanent crossbelt (overband) magnets play a vital role in safeguarding critical equipment such as crushers, screens, and conveyors from damage caused by tramp ferrous metal. These magnetic separators are not one-size-fits-all solutions; they come in various designs tailored to specific operational needs. A clear understanding of your application is essential to selecting the right magnet that meets your requirements effectively.

The Crossbelt Magnet: A Workhorse of Efficiency

Since the early 1980s, Bunting has been at the forefront of innovation in magnetic separation technology, pioneering the development of the first permanent crossbelt magnets. Over the decades, these devices have become an essential part of industrial processes worldwide. While the basic principle remains the same, continuous improvements in magnet materials and manufacturing techniques have significantly enhanced their performance and efficiency in separating ferrous metals from material streams.

Designed with durability in mind, crossbelt magnets consist of a powerful magnet block mounted on a strong frame, paired with pulleys and a self-cleaning rubber belt. As material passes beneath the magnet, it attracts and removes unwanted ferrous contaminants, ensuring smoother operations and reducing wear on downstream equipment.

The choice between a permanent or electro-magnetic system depends on several factors, including conveyor width, material depth, and the type of tramp metal present. Each option offers unique advantages, making it important to evaluate which solution best suits your operation’s specific needs.

Crossbelt Models and Applications

Bunting’s OCW Heavy Duty Oil Cooled Electro Crossbelt Magnetic Separator is engineered for high-performance ferrous removal, especially in demanding environments like recycling facilities. Its robust design allows for greater clearance and handling of heavier loads, making it ideal for deep troughed conveyors. Available in multiple sizes, the OCW can be installed inline over head pulleys or across conveyor belts ranging from 36” to 84” in width.

For applications where maintenance is a concern, the ACW Heavy Duty Air Cooled Crossbelt Magnetic Separator provides reliable performance with minimal upkeep. This model uses an air-cooling system to maintain efficiency without the need for oil, making it a practical choice for many industrial settings. The strong electromagnetic field ensures effective capture of ferrous particles, improving product purity and reducing downtime.

Bunting also offers Heavy-Duty Electro Crossbelt Magnetic Separators, which represent the pinnacle of our magnetic separation range. These units deliver exceptional power and flexibility, capable of extracting ferrous material from deep troughed conveyors efficiently. With standard models available for belt widths from 24” to 78½”, they are suitable for a wide range of applications, whether placed inline or across conveyor systems.

Choosing the Right Crossbelt Magnet

Selecting the appropriate crossbelt magnet—whether permanent or electro—depends on the specific requirements of your operation. Bunting’s team of experienced engineers evaluates key factors such as the purpose of metal removal (e.g., protecting plant equipment), the nature of tramp metal (e.g., size, shape), and the characteristics of the conveyed material (e.g., particle size, load depth). This thorough assessment ensures that the chosen magnet is perfectly suited to your process.

With over 40 years of experience and a commitment to customized solutions, Bunting continues to lead in the development of advanced magnetic separation technologies. Our products are designed to meet the evolving needs of the mining and aggregate industries, helping you achieve higher efficiency and safer operations.

Whether you're looking to enhance your current system or explore new solutions, we’re here to help. Contact us today to discuss your application or request a personalized quote.