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Is your magnetic separation, vibratory equipment or inspection system ready for an upgrade or replacement? Follow these guidelines from Eriez’ 5-Star Service Group.

Eliminating or reducing equipment downtime is the constant concern of many plant managers and operators, no matter the industry. Attention to proper working order is no different when it comes to inspection systems, magnetic separation and vibratory equipment, which is prevalent in industries spanning recycling, food, packaging, pharmaceutical, chemicals and more.
Beyond equipment maintenance, industrial manufacturers today are wrestling with major costs associated with core expenditures like raw materials, personnel and shipping. Energy costs and the movement toward more sustainable processing methods are also factors in allocating dollars for daily plant operations.

Manufacturers are faced with other production issues that challenge their budgets, including increasing product purity, improving cycle times, maintaining material consistency, consolidating operations, standardizing materials and processes, speeding up mold changes and training personnel.

While it is becoming even more of a challenge in these tough economic times to fit equipment maintenance and upgrades in the budget, it is essential. When your equipment is operating at peak performance, you achieve maximum efficiency and increased profits. When you consider the potential increase in profits, it’s easy to justify spending for equipment maintenance and upgrades.

Upgrades, Maintenance Important for Capital Investments
Plant operations rely on numerous pieces of equipment working together in a seamless operation to bring the finished product to market. Many manufacturers today use a variety of vibratory screeners, feeders, magnetic separation units, metal detectors and x-ray systems to complement the entire production process as all play an integral role in the processing function. Manufacturers use this equipment independently or in a comprehensive flow system to help increase product purity, preserve downstream equipment and improve productivity.
Since metal separation equipment, vibratory equipment and inspection systems represent a significant capital investment, plant operators should perform routine inspections to detect any malfunctioning or underperforming equipment. This procedure help spots trouble areas, minimizes downtime and prevents potential harm to plant personnel and downstream equipment.

Optimum operating efficiency and product longevity depend greatly on the individual piece of equipment and operating environment. Routine tests can determine when it’s time to upgrade/replace some components to the equipment or whether to consider purchasing a newer model.
Annual maintenance checks can be performed by qualified plant personnel or an outside party, such as the Eriez 5-Star Service Group, which is headquartered in Erie, Pa. 5-Star Service technicians travel to customers’ plants to perform on-site equipment inspections. By planning ahead and purchasing preventive maintenance and inspection service plans offered by Eriez, customers can pinpoint equipment issues before they become major problems that cause downtime. When equipment problems or potential problems are discovered, technicians recommend an upgrade, repair or total replacement.

“Our goal is to limit costly downtime and make sure equipment is operating as efficiently as possible,” said Dave Hansen, Eriez Customer Service manager. “Once an inspection is completed, we're better able to determine the next course of action, whether this means replacing one component or remanufacturing the equipment to original specifications. In some cases, we may recommend a total replacement, but only after we consider several scenarios to get that equipment back on line.”

Extending the Life of Metal Separation, Detection Equipment
Costly equipment repairs and downtime that may occur after years of continuous operation must be calculated against the cost of a total replacement. That’s where the 5-Star Service Group comes up with workable recommendations and repair versus replacement scenarios, according to Hansen.

Eriez maintains decades worth of equipment records to help its own customers determine the best course of action, although Hansen points out that the 5-Star Service Group handles other manufacturers’ brands. The 5-Star team also offers instruction and operation manuals (IOMs), parts list and step-by-step troubleshooting procedures.

The majority of repairs and upgrades fall into several product categories: eddy current separators, suspended electromagnets, lifting magnets, wet drums, scrap drums, vibratory feeders and metal detectors.

Naturally, each piece of equipment contains different components that, over time, may develop problems that cause a loss of effectiveness or gradual decrease in operating efficiency, according to Hansen. After a thorough analysis, either on site or at the Eriez facility, the 5-Star technicians recommend the next steps with a repair/replacement budget analysis.

What components are easily replaced or upgraded to extend equipment life? Here is a partial list of the most common components for each product category that begin to fail over time, but ones that can extend equipment life once they are refurbished or replaced by the 5-Star Service Group.

Eddy Current Separators
Eddy current separators are widely used to separate nonferrous metals from auto shredder residue, solid waste incinerator ash, crushed glass, electronics waste and foundry sand as well as aluminum beverage cans from comingled curbside waste.

This nonferrous metallic separator consists of an external drum, internal permanent magnetic rotor, a drive and belt conveyor. The eddy current rotor is the heart of the separator and the one component that has the biggest impact on operating efficiency.

Since the most important and expensive part is the magnetic rotor, good protection of magnets and the rotor guarantees long durability and optimal performance. Simple change-out of worn components saves time and cuts the costs of the eddy current separator's downtime.
5-Star technicians look for any changes in the operating characteristic of the system, such as noise levels and increased vibration. Typically, technicians repair any shaft end damage, replace hubs, bearings, shell and wrap and balance the rotor to operate at the peak RPM. Belt conveyors are typically replaced due to punctures, tears and wear.

Suspended Electromagnets
Suspended electromagnets (SEs) remove damaging tramp metal from flows of coal, limestone, sand, gravel, municipal waste, wood products, recycled materials, other ores and almost any conveyed nonferrous material.

SE magnets consist of various components to provide the magnetic force necessary to collect large pieces of tramp metal. The coil, core, backbar and steel enclosure provide an efficient and effective magnetic circuit for collecting tramp metal. Aluminum or copper coil use NOMEX insulation and fiberglass spacers to prevent shorts.

Eriez has incorporated an external oil expansion tank on its SE models, which helps prevent coil burnout on oil-cooled electromagnets, and the company offers a five year warranty of the internal coil assembly.

SE magnets can operate virtually maintenance free with routine inspections, but magnets can lose their effectiveness over time. Eriez 5-Star Service technicians typically look for gradual loss of conductivity and magnet strength and any short in the system.

Over time, excessive heat from the processing line can damage insulation around the electrical wiring leading to the coil. Eventually, the wire short circuits and the electromagnet loses its magnetic properties.

Bringing the SE magnet up to optimum strength requires a disassembly of the unit, upgrading the coil, replacing any damaged wiring and re-assembly. Eriez offers 'as new' warranties on the coil once the SE magnet is reconditioned to original specifications, according to Hansen.

Lifting Magnets
Lifting magnets enable users to lift and move steel without direct attachment by slings, hooks or cables. Eriez offers a complete line in both permanent and electro designs with various models, sizes and strengths to handle many different lifting jobs. Lift magnets can be used singularly or in gangs to make quick work of difficult, time-consuming steel handling.

Routine maintenance is generally all that is needed to maintain magnetic strength of lift magnets. Anything that prevents the face of the magnet from making full contact with the part being lifted is considered an air gap. Rust, dirt, ice, snow, machine grooves and holes are just a few examples of an air gap.

If a lift magnet begins to lose its holding force, 5-Star technicians look for worn contact surfaces and loose or broken components. After years of use, worn bottom surfaces may not allow the magnet’s original rated lift capacity.

Eriez’ procedure includes inspection of lift magnet surface and resurfacing of poles (if needed): inspection of all other parts, replacement of any missing parts, repair/replacement of all damaged parts, replacement of warning labels and capacity markings and load testing and certification.

Every magnet repaired by Eriez is returned with a “Certificate of Compliance” guaranteeing the repairs and the load test of the serviced magnet comply with ASME B30.20 standards. Eriez Certified repairs come with a one year “As New” Warranty.

Eriez 5-Star Service also includes a Magnet Exchange program, which is a suitable solution for customers who need to get a magnet back in place quickly when their lifting magnet needs repair. Customers may be able to get a pre-certified, refurbished SafeHold Lift Magnet from Eriez’ stock shipped to them within 24 hours of Eriez receiving their magnet for repair.

To meet the criteria for the Exchange program, the customer’s magnet must pass Eriez’ two point inspection. If the load test is within specifications and the rotor is intact and operational, it may qualify. Exchange magnets, which are the same make and model of the returned magnet, ship with a “Certificate of Compliance” and include a one year “As New” Warranty.

If a customer’s SafeHold Lift Magnet is not eligible for the Exchange Program, Eriez will refurbish it to “As New” condition and ship it back to the customer within three to five days. The refurbished magnet ships with a “Certificate of Compliance” and includes a one year “As New” Warranty.

In cases in which inspection of a magnet at Eriez indicates internal magnet damage, customers are contacted with a quote and lead time on internal magnet repairs or a new magnet. Most new magnets are available from stock.

Magnetic Drum Separators
These hard-working units have been used for many years to reclaim ferrous materials from shredded automobiles, scrap metals, municipal solid waste, wood waste, slag, incinerator bottom ash, foundry sand and numerous other minerals, feed or aggregate processing applications.
Modern drums offer state-of-the-art electro or permanent magnetic circuits to provide maximum performance. They are ruggedly built to provide long service life with minimum maintenance. However, routine inspection of drums is recommended to ensure optimum performance and service life.

Electro-style magnetic drums can experience problems similar to the SE magnet, excessive heat from the processing line can damage insulation around the electrical wiring leading to the coil. Eventually, the wire short circuits and the electromagnet loses its magnetic properties.

Bringing the drum up to optimum performance requires the 5-Star Service Group to dissemble the unit, upgrade the coil, replace any damaged wiring and re-assemble. Replacement of the drum shell bearings and drive chain (if applicable) might also be necessary if these components are discovered to be worn or ready to malfunction.

Vibratory Feeders
All vibratory equipment share common components: a drive system to generate the vibration, a tray or trough to carry the product and springs to give the vibration amplitude creating motion. Every system uses an AC or DC power source and must be must be mounted either from above or below in order to produce a consistent force.

When no vibration is present, the usual suspects are a coil that is shorted out or one or more springs that are cracked or broken. Metal shavings could enter the variable transformer and cause a disruption in power. 5-Star Service technicians look for these issues before proceeding with repairs or upgrades.

Many feeders can be refurbished to a like-new condition. The 5-Star Service Group offers many styles of linings and finishes to replace the old worn out linings and finishes in the feeder trays.

Metal Detectors
Electronic metal detectors for dry bulk solids applications are highly-sensitive frequency instruments that require regular inspection. Metal detectors locate and reject products that are contaminated with metal, which elevates their status as critical elements of many processing lines, especially in FDA-controlled operations.

A poorly functioning metal detector can lead to problems along the manufacturing line as well as an increase in product contamination. Over time, this highly-sensitive piece of equipment may require maintenance. In many industries, such as food and pharmaceutical operations, regular certification of metal detector performance is a requirement of quarterly assurance such as Hazard Analysis and Critical Control Points (HACCP) programs.

The technical skills required for maintaining and calibrating a metal detector may go beyond the scope of plant personnel. The services offered by the Eriez 5-Star Service Group include inspecting, calibrating, cleaning and certifying a metal detector.

Sometimes, the metal detector can falsely reject product, an indication that the detector's electromagnetic balance is out of sync. The electromagnetic balance is set at the factory before shipment. An Eriez 5-Star technician can rebalance the unit at a customer’s facility for greater efficiency.

Time for a Plan
With profits at stake, it is vital to find a trusted partner to perform routine equipment inspections and maintenance. A proactive approach reduces the chance of costly downtime that can slow or shut down production. For more information about Eriez’ 5-Star Service, visit http://service.eriez.com

Dan Zimmerman is the Manager-Sales/Service Support, as well as the Market Manager-Metalworking at Eriez. Dan also oversees customer support development and “lean” office at Eriez World Headquarters. Zimmerman is a graduate of Gannon University with a Bachelor’s Degree in Finance. He holds a Master’s Degree in Business Administration from the University of Pittsburgh. Dan can be reached at dzimmerman@eriez.com.

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