How Does Advanced Magnetic Filtration Work?
During the process of magnetic filtration, fluid flows around a magnetic rod or core which attracts ferrous particles, removing them from the fluid. This ensures that clean fluids are returned to the contact area either on a machine tool or wash system. When the magnetic core becomes saturated with ferrous contamination it is then cleaned either manually or automatically.
High strength neodymium magnets attract virtually 100% of the ferrous particles including sub-micron size particles. The advanced magnetic core design creates a magnetic field pattern which ensures that the filters do not block even in high contamination applications.
Further design and development after thorough research into fluid flow characteristics means that magnetic filters are designed to optimise the fluid flow. This maximises contamination exposure to the magnet and ensures almost 100% collection rates, without interrupting or reducing the fluid rates.
Why is Advanced Magnetic Filtration more Effective than Traditional Filtration Techniques?
Magnetic filters are very advanced when compared traditional magnetic applications to remove ferrous particles. In the past, magnetic systems were very basic, often consisting of randomly placed low strength magnetic bars or rods in a settlement tank, or a low strength magnetic roll. Unfortunately, the results are largely ineffective.
Whilst the basic principles of magnetic filtration are similar, there are huge differences in the product design and levels of performance between advanced magnetic filters and the magnetic systems of the past.
Why Use Magnetic Filtration over Traditional Filter Methods?
Magnetic filters are more effective at removing ferrous particles than virtually all other types of filtration. Traditional barrier filters are constrained by the pore size in the barrier; if the pore is too big, the contamination continues to circulate; but if it is too small, it will block.
Advanced magnetic filtration has been specifically developed to overcome some of the typical problems experienced when using traditional filters. Fully automated magnetic filtration systems an effective solution for continuous manufacturing lines, offering 24/7 uninterrupted filtration and resulting in minimal downtime.
In Which Applications can Magnetic Filtration be used?
Magnetic filtration can be used in a variety of applications to maintain clean coolants and lubricating oil, which is vital in ensuring efficiency and quality output on processes such as grinding, lapping, wash systems, honing, drilling and other “super-finishing” operations.
Eclipse Magnetics’ magnetic filtration systems are widely used in the automotive industry within OEMs and tier 1 and 2 suppliers for the efficient manufacture of powertrain and engine components. They are also used by some of the world’s largest bearing manufacturers to ensure sub-micron accuracy in the production of bearing components.
Magnetic filtration systems are used to enhance performance on a variety of machine tools, offering a competitive edge to machine tool users and OEMs particularly on high precision machining applications. They can also be used to improve efficiency in steel production, both hot and cold operations, as well as achieve a high precision “mirror” finish on high speed steel and tungsten carbide tool cutting applications.
Magnetic filters also ensure that industrial wash systems remain free from problem ferrous particles, keeping them clean and ensuring that the finished product is clean and complies with quality inspection.
How Does Magnetic Filtration Increase Product Quality?
Advanced magnetic filtration increases product quality because up to 100% of ferrous particles are removed from the fluid, ensuring a cleaner cut or grind. A magnetic filter protects the part surface from the abrasive effects of ferrous particles and ensures a premium “mirror” finish to meet demanding tolerances. In turn, this reduces reject rates, improves quality consistency, and in applications such as cutting tools, means that the product can command a higher sale price.
How Does Magnetic Filtration Increase the Lifespan and Quality of Metalworking Fluids?
Longer lasting, cleaner fluids are also an advantage of magnetic filtration. Magnetic filtration offers sub-micron filtration capability, ensuring that fluids such as oil and coolants are not only cleaner, but run for longer periods. In many cases this results in huge fluid, coolant or oil purchase and disposal savings, as all the cleaned fluid is returned back into the cycle.
Traditional barrier filters typically leave particles smaller than 5-10 microns circulating in the fluid. These particles significantly affect the performance of fluids and also act as a focus for bacterial build up. Magnetic filters remove particles smaller than one micron in size, keeping the fluid cleaner and reducing the risk of bacteria building up.
Conventional filtration media, at 5 microns and below, can also strip oils of anti-foaming, anti-bacteria and other additives. Magnetic filtration enables sub-micron filtration without affecting the oil’s properties, and can actually aid the effective control of bacteria.
Is Magnetic Filtration an Environmentally Friendly Option?
Yes. A major consideration for any business is its responsibility to the environment. Magnetic filtration provides a positive contribution to companies’ environmental policies and ISO14001 accreditation, and reduces the environmental impact of a business.
Advanced magnetic filtration does not require consumables, therefore reduces waste. Unlike some traditional filters which use replaceable media such as powder or paper, magnetic filters require no consumable items thereby presenting significant cost savings, and reducing the amount of waste sent to landfill. Any ferrous contamination can be collected and recycled.
Using a magnetic filter also reduces the need to replace metalworking fluids, oils and coolants as frequently, therefore reducing the amount of waste spent fluid, and saving on disposal costs.
Will Magnetic Filtration Save my Business Money?
Yes. Magnetic filtration is perfect for cost reduction and continuous improvement programmes. It can significantly lower operating costs and provide a rapid return on investment through increasing productivity.
Unlike some types of traditional filters which use replaceable media such as powder or paper, magnetic filters require no consumable items. This results in a massive cost saving. In addition, ferrous contamination can be collected and recycled, therefore generating a small revenue stream.
Longer lasting fluids also means a reduction in purchase and disposal costs. Money can also be saved due to the increased quality of components, therefore reducing product rejects.
How does Magnetic Filtration Increase Productivity?
Magnetic filtration increases productivity in variety of ways. High flow rates can be maintained without affecting filtration efficiency. Fluid does not flow through filter media, so flow is uninterrupted. Flow rates are, therefore, determined by your process requirements, not by your filter.
There’s also no back pressure when a magnetic filter is used. Even when the filter is ‘full’ there is no blinding or risk of burst filters, reducing downtime.
Can a Magnetic Filter be Fitted to an Existing System?
Yes, magnetic filtration systems can be easily fitted to significantly enhance existing filtration systems. They are also ideal for new build projects as a standalone solution.
Can Magnetic Filtration Help me Comply with the New Safe Handling of Metalworking Fluid Guidelines?
Yes, including a magnetic filter in your metalworking fluid system is a great way of ensuring that your business is compliant with the new Guidelines for the Safe Handling and Disposal of Metalworking Fluids introduced by The United Kingdom Lubricants Association (UKLA).
Metal contamination has been identified by the UKLA, the Metalworking Fluid Product Stewardship Group (MWFPSG), and the Health and Safety Executive (HSE), as a major factor affecting the quality of metalworking fluids. In order to ensure compliance with the safe handling and disposal of metalworking fluid guidelines, fluid needs to be correctly maintained with regard to the concentration of metal contaminants in the fluid. Magnetic filtration is a very effective way of reducing the concentration of metal contaminants, therefore ensuring compliance with the metalworking fluid handling guidelines.
Why Choose Eclipse Magnetics for your Magnetic Filtration Requirements?
Eclipse Magnetics is a world leader in magnetic technology with over 100 years’ experience in the design and manufacture of high performance magnetic systems. We supply critical equipment to some of the leading names in the most demanding industries, with our magnetic technology widely used at leading worldwide companies and in major development projects, all requiring a guarantee of equipment performance.
We have a track record of producing high quality products backed by a commitment to total customer service. Our technical application teams have a wealth of experience, thus ensuring many of our products are market leading innovations. All manufacturing is carried out under an ISO 9001 certified quality management system
Is there a Magnetic Filter suitable for High Pressure Applications
Yes, the MicromagHP50 and HP80 filters are to suit high pressure applications , up to 50 or 80 bar respectively. They are predominantly used in applications which have start-up pressure surges or through spindle coolant applications, where the smallest of particles can damage seals, spindles and even the efficiency of the cutting tool.
For Machine Materials which have low Magnetic Properties will Magnetic Filtration still work.
Magnetic filters are available for extracting materials with lower magnetic permeabilities. For example our Filtramag+ (11,000 Gauss Version) is used in many Tungsten Carbide or Cast Iron machining applications. To check if your materials are compatible please contact us.
Typically Where Can I Install a Magnetic Filter
Generally magnetic filters can be installed anywhere in the fluid circuit either pre or post pump. Some typical installation configurations are shown below. If you need advice our engineers would be pleased to visit your site and assess the most suitable location. (there are 4 drawings required)
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