Not all metal contamination is easily noticed.

While larger fragments can be visually identified, small ferrous particles can continue through the production process, reach equipment, remain in the final product and compromise the operation's quality standards.

Magnetic bars are used to attract and retain these contaminants before they advance to more sensitive stages of production.

Installed at strategic points, they help to preserve equipment, reduce contamination risks and maintain greater control over the processed material.

What are bar magnets?

Magnetic bars are cylindrical components that generate a magnetic field capable of attracting ferrous particles present in solid, granulated, powdered or liquid materials.

They can be installed individually or used as part of other equipment, such as:

• Magnetic grids;
• Magnetic filters;
• Systems installed in ducts;
• Gutters;
• Silos;
• Funnels;
• Pipes;
• Unloading points.

During the passage of the material, ferrous particles are attracted to the surface of the bar and are retained until cleaning.

This process helps prevent contaminants from continuing to circulate through the line.

Where do ferrous particles come from?

Even in organized operations, metallic materials can enter the process in different ways.

Among the most common sources are:

• Natural wear of machines and tools;
• Fragments of screens and sieves;
• Filings from previous processes;
• Screws, nuts or washers;
• Waste present in the raw material;
• Small metal parts detached during maintenance;
• Contaminants introduced during transportation or storage.

Because they are small, some of these particles may go unnoticed during visual inspections.

The absence of large fragments does not necessarily mean that the material is free from ferrous contamination.

What problems can these contaminants cause?

When not removed, metallic particles can generate impacts at different points in the operation.

Equipment damage

Contaminants can reach mills, pumps, valves, mixers and other components present in the following stages.

Over time, this can cause wear, failures and increased corrective maintenance.

Loss of quality

When particles remain in the processed product, they can compromise its purity and reduce its commercial value.

Magnetic separation is used precisely to purify materials and reduce losses related to loss of quality and corrective maintenance.

Rework and disposal

Identification of contamination after processing may require a new separation step or, in more critical situations, disposal of the material.

In addition to additional costs, this can affect deadlines and productivity.

Risk to the company's image

Contaminated products can generate complaints, batch rejections and loss of trust on the part of customers.

Therefore, controlling ferrous particles is also part of protecting the quality delivered to the market.

What materials can magnetic bars be used on?

The bars can work on different types of products, as long as the application is correctly sized.

Examples include:

• Flours;
• Grains;
• Sugar;
• Granulated plastics;
• Mineral powders;
• Chemicals;
• Ceramics;
• Liquids;
• Pasta;
• Materials used in the food industry;
• Pharmaceutical raw materials.

The choice of the installation point must consider the behavior of the material, its speed, its density and the way it passes through the magnetized region.

The greater the contact with the surface of the bars, the greater the possibility of capturing contaminants.

Are magnetic bars and magnetic grids the same thing?

Not exactly.

The magnetic bar is the component responsible for generating the field and retaining the ferrous particles.

The magnetic grid is formed by a set of bars positioned in a structure. This configuration enlarges the contact area and forces the material to pass close to the magnetized surfaces.

Depending on the amount of impurities and the characteristics of the application, the grids can be constructed with more than one row of bars. ITAL also uses neodymium magnets in its magnetic grids, which can offer greater intensity than equivalent models made with ferrite.

Therefore, the solutions are related but not identical.

Where to install the magnetic bars?

Installation must take place at a point where the material passes as close as possible to the magnetic surface.

Some common locations include:

• Silo exits;
• Feed hoppers;
• Ducts;
• Pipes;
• Gutters;
• Unloading points;
• Before mills or mixers;
• Before packaging;
• Between different stages of production.

The ideal position depends on the application objective.

In some processes, separation occurs at the beginning of the line to prevent contaminants from entering production. In others, it happens near the end, as an additional quality control step. Different separators can be sized according to the type of material, flow and volume of the operation.

What to analyze before choosing?

Efficiency does not just depend on the presence of a bar magnet in the line.

It is necessary to evaluate the actual process conditions, including:

• Product type;
• Physical state of the material;
• Granulometry;
• Density;
• Temperature;
• Flow speed;
• Volume processed;
• Type and size of contaminants;
• Available space;
• Cleaning frequency;
• Industry requirements.

A material that flows freely behaves differently than a product that is wet, viscous or subject to block formation.

Therefore, the design must consider how the material comes into contact with the bars and how long it remains exposed to the magnetic field.

Does cleaning influence performance?

Yes.

As the particles accumulate on the surface, they form a layer that can reduce direct contact between the magnetic field and new contaminants.

If cleaning is not carried out at the appropriate frequency, the retention capacity may decrease.

The routine must be defined according to the quantity of particles found and the volume processed.

During cleaning, it is also important to prevent the removed contaminants from returning to the product or falling back into the line.

Why use magnetic bars in the process?

Magnetic bars offer a simple and efficient way to reinforce control of ferrous contamination.

When correctly applied, they help to:

• Preserve machines and components;
• Reduce corrective maintenance;
• Improve product purity;
• Avoid rework;
• Reduce the risk of disposal;
• Strengthen quality control;
• Protect sensitive production stages.

Magnetic separation removes unwanted ferrous particles and helps the material remain cleaner for use or commercialization.

Protect the quality of your process

Small particles can cause great damage when they are not identified and removed at the appropriate time.

Magnetic bars help control this risk by trapping contaminants before they reach equipment or remain in the final product.

To obtain the expected performance, it is essential to analyze the material, flow, installation point and necessary cleaning frequency.

ITAL develops magnetic solutions according to the characteristics of each industrial process.

Contact the technical team and find the appropriate configuration to protect your operation.

Talk to ITAL

WhatsApp: (11) 96416-4821