The Masters ‘Sort Out’ BMW

Master Magnets Ltd custom built and designed a swarf separator for one of the world’s largest car manufacturers. BMW had the problem of obtaining clean aluminium from left over swarf at their engine manufacturing plant at Castle Bromwich in the Midlands BMW.

BMW had the problem of obtaining clean aluminium from left over swarf at their engine manufacturing plant at Castle Bromwich in the Midlands. BMW were originally selling scrap swarf mixed with aluminium and iron for low value, and they were aware that clean aluminium separated from iron swarf would produce a more valuable material, which would enable BMW to make a greater financial return when selling waste swarf.

The enquiry for a swarf separator came to Master Magnets Ltd from Magna Force Ltd, who distribute and install a range of magnetic equipment to major car manufacturers across the UK. Master Magnets Ltd offered Magna Force Ltd assistance in the design and build of the swarf separation plant. To ensure that BMW were getting a high performance swarf separator, Master Magnets also offered Magna Force the use of their laboratory, where extensive sample tests were carried out free of charge.

After the sample testing stage was completed, the results were sent to BMW, Master Magnets Ltd advised the correct type of separation equipment, and produced a specialised drawing of the plant with the quotation. The Plant consisted of two custom-made totally enclosed drum separators and a specialized vibratory feeder.

The Vibratory feeder is driven by 2 out of balance vibratory motors, for the purpose of controlling the throughput rate of 1 ton/hr, feeding the material into the enclosed drum.

The totally enclosed drum separators consist of 2 permanent magnetic drums with a stainless steel cover fitted with wipers. The two drums are specially arranged in a specific way to ensure a greater separation of aluminium from iron, the swarf is fed into the top of the enclosed drum by the vibratory feeder. The material is then uniformly fed directly on to the magnetic face of the drum. The Permanent drums are constructed having a 180-degree stationery magnet system, around which a shell cover revolves. This then allows non-magnetic material (e.g. aluminium swarf) to fall following its normal trajectory separating itself from the magnetic material (e.g Iron swarf), with magnetic’s attracting to the drum cover as it revolves around the magnet. The purpose of having a double drum arrangement is to enrich the magnetic performance of the drum to gain cleaner aluminium.

The swarf separation plant was manufactured by Master Magnets Ltd, at their custom built site in midlands UK, using their knowledge and expertise in the field of magnet manufacture. Magna-force then provided the installation service for BMW as the plant was put into full operation. BMW are now able to produce a more valuable material currently worth around £1100 per tonne, with the separation plant turning out clean Aluminium that is ferrous free. BMW are expecting the swarf separation plant to pay for itself after 18 months.

Master Magnets Ltd can offer customers a wide range of products to help solve many problems within many industries benefiting amongst tohers the Food, Material handling, and Ceramic, Powder, Mining, Quarrying and Recycling industries.