We are the first to introduce indigenous High Intensity, High Gradient Magnetic Roll Separator for use of dry material in Indian Market. It is capable of separating a wide variety of materials in an efficient and economical manner.

It use high energy Rare Earth Neodymium Permanent Magnets assembled in a proprietary configuration to generate forces of magnetic attraction, which can be used for processing any material from ferromagnetic to weakly paramagnetic.

The open design of this equipment allows both coarse and very weakly magnetic materials to be treated successfully. Proven dry process application include material from 75 microns up to 100 mm (4 inch) particle size, at through puts from 200 kgs to 60 TPH depending on size.

Technical Features

• Standard: 2.5,2,1.5,1,0.75,0.5 and 0.25 meter wide magnetic roll. Also available in a laboratory scale model with readily interchangeable rolls of 100 mm length.
• Supplied with a vibrating feeder to suit the roll width.
• Simple conveyor belt tensioning and tracking system accessible at the sides of the machine.
• Fixed or-variable speed roll drive options.
• Fractional HP motor having voltage and frequency to suit user.

We are one of the few names to offer over-band magnetic separator that is extensively used for removing magnetic parts from non-magnetic materials in order to project crushers, mills, processing plants etc., against too much wear and damage.

They serve for cleaning non-magnetic bulk goods with iron contamination, for instance cleaning of foundry sand, coal and the like. They are also used for recovering magnetic material from ore, steel mill slag etc.

It is also suited for removing tramp iron in quantities where continually discharging magnetic separators are necessary. Iron is extracted against gravity from the flow of material and held firmly to the magnet face until the magnet is de-energised.

The efficiency of the over-band magnetic separator or suspension magnet depends on the pole size, pole distance, field intensity in the conveyor burden, lines of the material to be separated.

Designed for high separation performance in over-the-belt conveyor applications, it is a heavy duty permanent magnet and is particularly effective in removing tramp metal in high volume applications.

Engineered for use in high volume and deep burden applications, its primary advantages are its "deep reach" and the ability to be turned on and off.

Features

• Permanent magnet field.
• No electrical hook ups.
• Compact design.
• Heavy duty impact plate.
• Stainless steel angled cleats.

We offer heavy-duty magnetic pulleys that helps in removing tramp metal. It is mostly used as head pulleys in belt continuous and automatic removal of tramp metal from metarial flow. As the tramp metal contaminated material comes within the pulley’s magnetic field, the ferrous tramp will be attracted and held to belt until it reaches the underside.

This comprehensive powerful permanent magnet separation pulleys meet the size and installation requirements of most conveyor systems applications. Installed as head pulleys in conveyor systems this magnet pulleys provide effective, full time automatic tramp metal removal.

It is also provided in four different hub styles-extended hubs, flush hubs, recessed hubs and with no hubs. Available with or without lagging and with crowned or flat faces, this pulley can provide many years of durability and extended service life.

We at Star Trace, also offer premium quality magnetic grills like magnetic tubes and grates in various shapes and sizes. Our wide collection of magnetic grills consists of:

• Round and Square Magnetic Tubes: Available in either round or square styles, these magnetic tubes fabricate any system for special applications requiring non-standard spacing or tube arrangement. Ruggedly constructed from 304 stainless steel, the one inch diameter round tubes have 1/4"-20 mounting holes and the one half inch ceramic square tubes have 3/8"-16 mounting holes. Standard tube sizes range from 4" to 48" long.
• Grates: Material consistency and compatibility which influence flow characteristics are important factors in grate magnet applications. It can be further categorized as:
  
  • Round Tube Type: This magnetic grate deliver ferrous tramp metal separation in bins, chutes, drawers, hoppers and circular enclosures. Constructed with one inch diameter magnetic tubes placed on two inch (2) centers in heavy duty 1/8" thick 2" wide 304 stainless steel framing, this round magnetic grates are also available in 30 standard diameters from 4 inches through 36 inches.
  • Square Tube Type: This square tube magnet separation grates are ideal for heavy duty applications where high product volume is involved. Having strong magnetic fields, the square tubes are installed with the leading edge toward the material flow.

Designed for handling Solid Slabs, Steel Ingots, Bloom Billets, we also manufacture circular lifting magnet. It is made from high permeability Steel Casting as per IS: 449 (BSS- 1617), properly machined, to provide the most efficient Magnetic Circuit. The periphery of the magnet is heavily ribbed to give added mechanical strength and an increased radiation surface to aid cooling.

Its center & outer poles are machined from high permeability Magnet Steel with Cored recesses arrangement to protect heads of through tensile bolts. The faces of poles from spigot joints in Magnet shell, the outer poles of larger Magnets are skirted for added protection. It consists of various parts like:

• TERMINAL BOX that ensure protection whilst in operation and are of double entry type enabling the leads from the coils to be sealed in a separate cavity.
• MAGNETIZING COILS for magnet size up to 900 mm dia is pure annealed wire wound and above these are strip wound. The glass insulation of class H standard with Fibre glass NOMEX tape forming an interlayer makes coil withstand high temperature.
• BUMPING PLATES are of high grade Manganese Steel Casting as per IS - 276 with heavy ribs for added strength. These are clamped in position by the center and outer poles offering complete protection to the coil.

It is most useful non-electric separator for separating tramp iron from non magnetic material processed in bulk quantity for the purity of end products, recovery of metal having commercial value and protection of processing plant and machinery.

It is widely used in all the processing industry for separation of iron contamination from mineral, chemicals, food, flour plastics, grains, sand, cement, fertilizers, rock, refractor and any other Products. It is available in standard drum diameters of 300mm, 400 mm. Drum width range from 300mm to 1200mm, while other sizes can be made as special to your requirement.

Features

• Its drum consists of high energy Rare Earth Neodymium Permanent Magnets.
• It has a strong & rugged construction along with automatic separator of iron impurities.
• It also has completely enclosed design to avoid dusting and pollution.

We offer a variety of rare earth plate magnets which are widely used in the industry to remove ferrous impurities from various mixtures. Our variety of plate magnets includes:

Flush Face: Flush face star trace plate magnets deliver optimum tramp metal separation performance when used in above-the-flow chute or belt application.

Exposed pole: Our exposed pole plate magnets are engineered to deliver high performance tramp metal separation in low volume applications.

Spout Magnets: Our diverter spout magnets provide maximum ferrous tramp metal separation in high volume chute applications where washing-off is difficult.

Self - Cleaning Spout Magnet: Our cleaning spout magnets provide ferrous tramp metal removal, in chute applications, with remote cleaning.

Rare Earth (Neodymium) Spout Magnet: Fine particle size separation is now available in a plate magnet. This magnet is substantially stronger than conventional plate magnets.

Flat Conveyor Plate Magnet: Our flat conveyor plate magnets are fitting for wide conveyors. They can be manufactured to match any conveyor width. Available in various thicknesses and strengths to effectively remove tramp metal that has fallen on the conveyor.

We manufacture Neodymium Iron Boron magnets (Nd-Fe-B). Our rare earth magnets are extremely strong for their small size, metallic in appearance and found in such simple shapes as rings, blocks and discs.

Neodymium
• Attributes of Neodymium
• Very high resistance to demagnetization
• High energy for size
• Good in ambient temperature
• High priced
• Material is corrosive and should be coated for long term maximum energy output
• Low working temperature for heat applications

Application of Neodymium
Magnetic separator, linear actuators, microphone assemblies, servo motors, DC motors (automotive starters), Computer rigid disc drives, hammer bank printers, and speakers.

Rare earth Tolerances
For as pressed material, tolerance on the thickness (direction of magnetization) is +/- .127mm. Other Dimensions are +/- 2.5% or +/-.254mm, whichever is greater.

Rare Earth Magnetizing and Handling
Rare earth magnets are very brittle and very strong magnetically. It is pivotal to handle these magnets with extreme care to avoid personal injury and damage to the magnets. Fingers can be severely pinched between attracting magnets. We recommend that when fabricating rare earth magnetic assemblies, they be magnetized after assembly.

Rare Earth Machining
The rare earth magnets are prone to chipping and cracking, it does not lend itself to conventional machining methods. Our rare earth magnets can be abrasively ground but only with the use of liberal amounts of coolant. The coolant minimizes heat fracturing and the risk of fires caused by oxidized grinding dust.

We manufacture two types of liquid line separators which are T-Trap magnetic separators and plate style T traps. Our T- Trap magnetic separators are designed for heavy duty, large volume liquid and semi-liquid line flow systems. The T-Trap run on the principle of a slip-in cage of stainless steel permanent magnetic tubes, which capture ferrous tramp metal particles and improve the purity of the product.

When tramp metal protection is required for liquid lines carrying viscous to fibrous products, the plate style T-Trap is ideal. This magnet allows the product to flow through the housing without causing product bridging. Vertical position eliminates the sump area, and in horizontal lines, cleaning is made easier when the magnet element is installed on top. Our magnets are available in standard line sizes of 2” and 3” diameters.

We make hump magnets which deal with ferrous tramp metal separation in gravity systems and are adaptable to either round pipe or rectangular chute transfer lines. The magnets employ two heavy duty diverters equipped spout magnets which are positioned so that product flowing through the hump is forced into the magnetic fields.

Star Trace humps take advantage of the offset flow of the material and insure maximum tramp metal removal from the product flow. Robustly constructed from stainless steel and with welded flange mounting systems to fit chute or pipe applications, our hump magnet separators are available in different sizes. We also offer custom sizes are available for special applications. We offer two varieties of hump magnets:

Extractors
We make continuous operation, high performance extractors, which are characterized by powerful parallel permanent magnets to capture ferrous tramp metal from dry material in high volume flows.
Star Trace extractor deliver effective tramp metal removal in a direct material flow. Extractors are ideal for protecting material processing and packaging machinery.

Ferrous tramp thus captured is held on the to magnets. Stripper drawer is quickly removed for fast cleaning. Our automated or remote cleaning of Extractor, use our Air-actuated self-cleaning style.

We manufacture permanent magnets lifter on/off which are widely used by the industry for separating ferrous tramp and scrap from products and mixtures. The salient features of our permanent magnets lifter on/off are:
• Permanent Magnetic Lifter
• Compact and lightweight
• Suitable for Flat and round material
• Very High Lift to its weight ratio
• Quick & Easy Operation with ON/OFF System
• Neodymium Magnetic Powered System
• Improves Plant Safety No direct contact with men
• Large and Heavy work piece can be moved/handled safely easily
by only one operator.

Our permanent magnets lifter on/off have a lot advantages over conventional magnets. Few of the advantages are:
• Easy handling heavy weight objects
• Apart from machine tool they are used in variety of industries
• Transforms the conventional, unsafe handling to safe and secure and faster operation of lifting and handling of heavy products
• High-end technology carefully used with appropriate material and testing