Metal Extractors for Vacuum Conveyor Systems
Worried about metal particles invading your plastic processing system and damaging your machinery causing expensive production breakdowns? In a typical plastic processing plant, plastic granulate is pulled through a network of pipes from a material suppy silo to the processing machinery using a vacuum. There are several points along the way where the granulate can be contaminated. Even the smallest of these metal contaminants have to removed before they can damage your equipment. Not only can they cause your molding machine to break down causing you expensive losses in production and low quality granulate, they can become a serious health hazard. Ease your mind and eliminate all of these problems with one of our new metal extraction devices.
Choosing the Right Metal Extractor
We offer three types of metal extraction devices that can be categorized in terms of performance or sensitivity levels: 1) an analog or standard metal extractor sensitive enough to detect metals parts starting at 0.5 mm, 2) a digital metal extractor for the removal of metal parts at a higher level of sensitivity starting at 0.4 mm, and 3) a digital metal extractor that can achieve levels of sensitivity starting at 0.3 mm due to a new powerful digital interference suppression capability that prevents environmental conditions from disturbing the metal detection process.
Finding the right metal removal system is a major concern for most processors. Not every process requires the highest levels of sensitivity. Depending on the size of the metal parts to be detected, the kind of material being conveyed, and where the metal extractor fits into the process, we can help you choose the right solution for your process.
1. Standard Metal Extractor
Our standard analog metal extractor is ideal for those plastic processing applications that require the removal of metal particles starting at the 0.5 mm range. This device, as well as the digital models, was designed to deal with the problem in most vacuum conveying systems. In most injection molding processes, for example, the speed of the granulate material in the suction vaccum lines is rarely consistent. Metal contamination is most likely to occur at those points where the speed of the granulate varies. Our metal extraction devices reduce the effects of this variable speed using a special cyclone inside the housing. With this cyclone, you can reliably extract the metal depending on the speed of material and how long the material rotates in the cyclone. This means that you don't have to adjust the distance between the ring and flap. All our extractors feature an ultra high sensitive control unit. If you require higher sensitivity, we recommend the M-Pulse electronic board. See Standard Specifications
How Our Metal Extractors Work
For the metal extractor to work properly, it must be installed directly in the suction line. Once the suction line is open, the inlet and outlet flanges are connected with the open ends of the line. The granulate material is drawn through the ring detector, then the cyclone and flap. Once the ring detector detects metal impurities, the separation process begins and a pneumatic cylinder moves from the good material position to the metal detection position. Once the outlet of the extractor is closed, the material inside the ring and cyclone falls out of the extractor over the third outlet flange. Normally there is a box under the extractor to collect the contaminated material. At the same time, a stream of air blows out all the material inside the unit to be sure that all the metal parts are removed from the cyclone and ring. After a short time the cylinder will move back to its original position and the line will reopen.
Main Advantages of Our Metal Extractors
All our metal extractors are easy to use, require very little maintenance and can be serviced and checked out in a matter of minutes. All of their parts are contained in a compact painted housing. Each device can be mounted on the wall and all the flanges can be connected using plastic tubes. The only thing needed will be a supply of air pressure and power. While the sensitivity level of the standard analog extractor is controlled using a potentiometer, the digital models use a multifunctional panel. Metal detection is activated by the simple pressing of a test button. All our metal extraction units allow you to control the main supply line of the granulate material providing protection for several machines at once. We offer different extraction units for pipe diameters ranging from 35 mm up to 70 mm. To handle a higher material throughput we recommend installing several units in a parallel arrangement. Please note that if your plastic granulate is fairly expensive, we recommend that you use a second smaller diameter separator unit. Once the metal is separated from the granulate material, you can add the MESEP® NS unit which will reduce the amount of material lost in the process.
2. Digital Metal Extractor
If you require higher levels of sensitivity, consider our digital metal extractor. Capable of sensitivity levels starting at 0.4 mm and a higher rate of reliability than its analog counterpart, the digital extractor uses a digital PC board and a different mode of operation. The new digital technology provides greater protection against metal contamination, is more reliable, and is more automated due to its multifunction panel. Instead of using a potentiometer like the standard analog extractor, this device has greater self monitoring capabilities and provides better protection against environmental conditions that can adversely affect the metal detection process. See Digital Specifications
3. M-Pulse Metal Extractor
At the top of the metal detection scale, is the M-Pulse generation of metal extractors. To reach higher levels of sensitivity and reliability than standard analog and digital models, the M-Pulse units use a very powerful digital PC board. The M-Pulse unit is normally recommended for use in the food industry where the demand for great sensitivity is much higher. In the plastic industry, the demand can even be higher. For these reasons, more and more processors expect more than a standard metal detection solution. Since even the smallest metal particles can damage a food or plastic processing machine, most processors are looking to the new M-Pulse generation as a possible solution. With the highest levels of sensitivity on the market, and capable of being updated to keep up with the latest in software development, the M-Pulse units of fast becoming the metal detectors of choice. See M-Pulse Specifications
No False Metal Detection
A major problem with highly sensitive metal detectors is their tendency to sense metal where there is none. As the sensitivity of metal extractors increases, so does the frequency of false metal reports. The accuracy of a metal detection system depends on how effectively environmental conditions can be eliminated from the metal detection process. Vibrations, impacts, malfunctions in the voltage supply, magnetic fields and other bothersome product characteristics can all lead to false metal reports. Designed with a powerful digital interference suppression capability, superior software and electronic components, our digital extractors rarely report metal contamination where there is none.
No Calibration Required
Unlike any other metal extractor on the market, and if used properly, our digital models are calibration free. They will maintain their levels of sensitivity for their entire service life without any readjustment whatsoever. Gradual aging of the electronic components will be automatically compensated without having to replace the components.
All of our metal detectors are equipped with self-diagnostic capabilities, which makes them less prone to breakdowns. Metal contaminated products are often shipped to a customer because a defective metal extractor has gone undetected. To minimize the risk of a malfunction, regular functional checks are highly recommended, but difficult to implement in practice. The only solution is a metal extractor with a self-diagnostic function. This self-diagnosis tests the ring detector, the function of the flaps and the evaluation electronics. If an error is noted, an acoustic or visual alarm transmitter can be generated to immediately draw the user’s attention to the error.
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