Fines and metal contaminants can cost you a fortune. Plants with seemingly effective magnetic separators and particle capture systems in place often run smoothly for weeks on end. Then, without warning, they suddenly find themselves scrapping tens of thousands of dollars in parts.
In one case, we worked with an automotive powertrain manufacturer who was struggling with cost overruns and missed production goals because of metal particles in their honing oil. Although they had magnetic separators designed to catch the ferrous materials and fines they worked with, impurities in their honing oil still regularly spiked orders of magnitude above their 30 parts-per-million (PPM) upper control limit (UCL). These spikes didn’t just result in unexpected downtime and ballooning costs (from dumping their honing oil, cleaning the magnetic separators, recharging the fluids, etc.). They were also scrapping multiple engine blocks each week.
The problem was their magnetic separator. The company was relying on an older style of bar magnet separator. These tend to have weaker magnetic fields, to begin with (only capturing fines down to around 30 µm). This solution might have been sufficient in an ideal world. But no filter runs in an ideal world. In the real world, as any magnetic separator runs, ferrous particles accumulate on the magnet. This accumulation naturally diminishes the magnetic field and degrades the separator’s capacity to catch more ferrous material. In this particular plant, the separator had to be manually cleaned—which rarely happened. The issues with the metal fines and rejected parts kept everyone continually racing to keep up. As a result, their normal operating conditions were just barely below the UCL—making spikes in metal fines in the honing oil inevitable.
High-Intensity Magnetic Separators for Industrial Applications
We helped them pull their old magnets offline and temporarily replaced them with something more suitable: A modern in-line, auto-purging, self-cleaning high-intensity magnetic separator. This separator can capture particles as small as 1 µm. It has a footprint four times smaller than conventional, gravity-fed fluid purification designs. And because it’s both self-cleaning and media-free, it can run 24/7 with little or no operator interaction—freeing up time as well as floor space.
During a six month test period with this magnetic separator, metal particle contamination in the honing oil never exceeded the UCL. Two-thirds of the time, particulate level in the honing oil was below 50 percent of UCL—and frequently as low as 90 percent below UCL. This solution made it orders of magnitude easier to stay ahead of any oil purity issues before any parts were damaged. During the entire trial period, they didn’t scrap a single engine block (a savings of $27,000) and enjoyed a net increase of 3.3 jobs per hour at the end of the line. After three years with this solution, they found that the system had continued operating with remarkable consistency and reliability: Their maintenance costs had dropped to near zero, saving hundreds of work hours each year.
Process-Oriented Magnetic Separation Applications Design
We’re dedicated to a process-oriented approach. This approach has meant building teams with a broad range of experiences and specialties: non-disposable media filtration, centrifuges, magnetic separation, non-magnetic/non-ferrous metals processing and capture, the fundamental physics and chemistry of fluid separation, and the specific challenges faced in manufacturing and fabrication. That team will work with you to find the right intervention, use the right technology, and match it to the proper application.
Our operations team can maintain the entire solution on an ongoing basis so you can completely outsource your magnetic separator and other filtration technology to us. With the largest fleet of separation assets, including magnetic separators, in North America, we are ready to take care of your needs.
No one else offers this comprehensive magnetic separation service level because every one of our solutions begins with a conversation. Contact us today to begin that conversation. A member of our team will come to your facility—at no obligation or cost—to walk your entire process, sample fluids, and develop a deep understanding of what you do and what obstacles you face. We take your fluids back to our labs for analysis, then design and pilot a separation/purification system that will meet your spec. As needed, we will run a trial of those solutions on your site for as long as it takes to ensure that it will get the job done.
Comprehensive Magnetic Separation Equipment, Solutions & Services
Trucent provides comprehensive solutions for capturing magnetic particles and other contaminants in your fluid. We can help you maintain your existing magnetic separator—or supply you with a plug and play separation system. We can install one piece of equipment or an entire team to manage all your fluids and filtration technology on a daily basis. The goals remain the same: Cleaner fluid, longer tool life, higher quality parts, and lower costs.Contact a Magnetic Separator Expert
Since implementing the solution, the engine manufacturer reduced fluid-related costs on this honing operation by 70% and realized an investment payback in less than three months. The plant is more productive after eliminating the introduction of contaminants to their process.
“Quick responses, personal service, and knowledgeable technicians are able to achieve desired results with little fuss or disruption of our process.”
Schedule a Plant Walkthrough
Our team will come out for a free on-site consultation.
Ask an Expert
Every solution begins with a conversation.
Committed to Service
With the largest fleet of separation technology, advanced engineering, and chemistry capability across a wide array of industries and experienced operations personnel throughout North America, you can count on us when you need us most.
- 9 Service Locations Across North America
- The Largest Fleet of Separation Technology
- Over 150 of Fluid Experience