Metal inthe plastic? The solution is simple
detectors of
metals
separators of
metals
detection systems and
metals separation
inspection systems and
X-ray separation
Mesutronic, technology and safety
A metal detector is an electronic device that uses the waves generated by an electromagnetic field and offers multiple applications for product inspection.
In the processing of plastics, it often happens that the product is contaminated with metal shavings such as ferrous, aluminium, copper, bronze and steel (AISI304).
The best solution is to have a metal detector on the plant MESUTRONIC to easily detect and separate all metal contaminants and to ensure that the plastic, whether virgin or recycled, is always clean and safe.
separating metal during processing
In the modern era where technology allows for the increasing use of recycled plastics, metal pollution is a frequent occurrence that can be easily remedied.
The presence of metal contaminations is the first cause of problems during plastics processing, such as clogging of filters or injector nozzles, breakage of extruder screws, damage to mill blades, machine downtime, customer complaints, etc.
The use of a metal detector ensures that the plastic is thoroughly cleaned of all metal contaminations, safeguarding production and productivity.
Metal detectors made in Germany
the solution for every problem
Metal detectors and separators are MESUTRONIC detectors and separators are designed so that they can be installed on a production line without compromising the regular work programme and product flow. They offer multiple application solutions and are used in theplastics, wood, textile, mining and food industries. Metal detectors consist of a part called a detector or coil and an electronic control unit that signals the presence of a metal contamination.
Metal detectors
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PLATE
The metal detector plate for plastics detects the presence of metals (ferrous, bronze, brass, aluminium and AISI 304) close to its surface. The metal contamination is detected even if it is included inside the plastic product. This equipment can be used in different ways:
- for the control of plastic products transported on a conveyor belt, in this case the metal detector plate can be placed under the belt or hung over the plastic passing on the belt;
- For the inspection of plastic granules or flakes, the plate detector can be used as a chute, the plastic to be inspected is then slid over the surface;
- In the textile or plastic field, where it is necessary to check a product before it is reeled in, the metal plate detector can be positioned at a point of passage in contact with the fabric or film.
The plate metal detector is identified, among the various sizes available, by its scanning width, usually coinciding with the width of the belt. The scanning sensitivity of plate detectors is fixed, even in different sizes. The use of a metal detector, as in these cases, is intended to check for the presence of metals. In applications where plastic or wood products have to be ground or cut with blades, the metal detector in this case has the function of preventing metal contaminants from damaging the mill blades or other machine parts. In case of metal in the plastic, the control unit indicates its presence and from this it is possible to activate different alarms or lights or stop the belt or the system.
A TUNNEL
The tunnel metal detector for plastics is an evolution of the plate detector because it basically consists of two plates, one lower and one upper. Inside the tunnel detector window, an intense electromagnetic field is used, which allows different sized products to be analysed with greater sensitivity.
Metal contaminations are detected even if they are included within the plastic product. The use of tunnel metal detectors is especially dedicated to products transported on belts where contaminations such as ferrous, bronze, brass, aluminium and AISI304 may be present. The tunnel metal detector is identified, among the various sizes available, by its scanning width, usually coinciding with the width of the belt.
The standard version of the tunnel metal detector consists of 2 plates, as mentioned above, and is therefore defined as openable or decomposable into 2 parts. There is also a version of the tunnel detector where, in addition to the plates, the sides of the window are also active parts of the detector. With the closed tunnel metal detector, high sensitivity levels can be achieved even with large window sizes. This type is generally used in the food industry because of its high performance.
A very important aspect of tunnel detectors is that the level of sensitivity is proportional to the size of the window, i.e. a large detector will not have a high capacity to detect small metallic impurities which are simply detectable with a detector with a small window.
As with plate detectors, the use of a tunnel metal detector is intended to check for the presence of metals, thus preventing claims from end users. In applications where plastic or wood products have to be milled or cut with blades, the metal detector in this case has the function of preventing metal contaminants from damaging the mill blades or other machine parts.
In case of metal in the plastic, the control unit indicates its presence and from this different alarms or lights or stops of the belt or system can be activated.
TUBE
The plastic tube metal detector, conceptually the same as the closed tunnel detector, also consists of internal circular antennas that emit and receive the electromagnetic field signal.
The use is intended to verify the presence of metals (ferrous, bronze, brass, aluminium and AISI 304) in a plastic product which is slid inside the detector or inside a tube passing through the hole of the metal detector. The metal contamination is detected even if it is included within the plastic product.
In some cases it is also possible to use this type of scanning for fluid products. A very important aspect of tube-type metal detectors is that the level of sensitivity is proportional to the size of the through-hole, i.e. a large detector will not have a high capacity for detecting small metal impurities that are simply detectable with a small metal detector.
The tube metal detector is identified, among the various sizes available, by the diameter of its hole, which is chosen according to the hourly flow rate of the product to be controlled. In case of metal in the plastic, the control unit indicates its presence and from this it is possible to activate different alarms or lights or stop the system.
Metal separators
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GRAVITY IN FREE FALL
Metal separators for plastics are equipment that combine the characteristics of tube metal detectors with those of a separation machine. The aim is to have an automatic machine that detects the presence of polluted metals (ferrous, bronze, brass, aluminium and AISI 304) and then rejects only the polluted product without interrupting the regular work programme and material flow.
This is a machine consisting of a frame and a vertical tube into which the plastic product to be checked falls by gravity, without it stopping in a column inside. The metal detector is located at the top of the tube, while the separation mechanism is located at the end of the tube. The separation mechanism consists of a paddle that opens and closes rapidly, separating the metal contaminations. The metal contamination is detected even if it is included in the plastic product.
A very important aspect of gravity metal separators is that the level of sensitivity is proportional to the size of the passage hole, i.e. a large separator will not have a high capacity to detect small metal impurities that are simply detectable with a small metal separator. In this case, too, there is an electronic control unit that monitors the electromagnetic field of the coil and subsequently drives the rejection mechanism.
The use of gravity metal separators, with free falling product, has many applications, especially in end-of-line controls. It should be noted that the intention is to verify the presence and discard metal contaminations, thus preventing complaints from end customers. The gravity metal separator is identified, among the various sizes available, by the diameter of its hole, which is chosen according to the hourly flow rate of product to be controlled.
In some cases, the use of a gravity metal separator with a magnetic tube filter is suggested. The combination of the two systems offers different benefits, especially in the presence of a heavily polluted plastic product. It is recommended to install the magnetic filter first and then the gravity metal separator.
The product is first cleaned of all magnetic metal contaminations, including ferrous dust and filings, as it passes through the magnetic filter. Then the metal separator controls and rejects all other non-magnetic metals that have not been retained by the magnetic filter. In this way two separate controls are obtained and the gravity metal separator will reject less polluted plastic product.
Typical uses are: bagging and loading plants, plastic product output from an coclea (screw conveyor), loading of storage silos, plastic product discharge from a granulator, twin-screw extruder feeding, etc.
FOR PNEUMATIC TRANSPORT
The metal separators for plastic products in pneumatic transport are devices that combine the characteristics of circular tube metal detectors with those of a separation machine. The aim is to have an automatic machine that detects the presence of metals contaminations (ferrous, bronze, brass, aluminium and AISI 304) and then rejects only the contaminats product without interrupting the regular work programme and material flow. It is a dynamic multifunctional machine that can be mounted either horizontally or vertically, with plastic flow both downhill and uphill.
This is equipment designed to control plastic products that are transported inside pipes, through the flow of air, under suction or pressure. The system consists of a frame and a tube that replaces a section of pipe in the plant. At the beginning of the pipe is the metal detector and at the end is the separation mechanism, which basically consists of a paddle that opens and closes rapidly, separating the metal contaminations. The system is managed by an electronic control unit that monitors the electromagnetic field of the coil and then operates the rejection mechanics.
The special feature of these machines is that they can be adapted to both pressurised and suction conveyor systems. For both, there are special constructive devices that allow the separation from the plastic flow of only the contaminated product without causing pressure losses or blockages on the line. The machine is also equipped with a collection box for the rejected material, which is periodically discharged, also automatically. The metal separator in question is identified, among the various sizes available, by the diameter of its passage hole, which is chosen according to the diameter of the plant pipeline.
Metal contaminations are detected even if they are included within the plastic product. A very important aspect of metal separators is that the level of sensitivity is proportional to the size of the hole through which they pass, i.e. a large metal separator will not have a high capacity to detect small metallic impurities that are simply detectable with a small metal separator. The use of metal separators of this type has unique applications only on pneumatic conveying systems.
The intention is to check for and discard metal contaminations, thus preventing complaints from end customers. Typical uses are: loading of storage silos, transfer from silos to mixers, transfer from silos to truck tanks, etc. The main advantage of metal separators for products with pneumatic conveying is that a separation of metal contaminations from the plastic is carried out during loading-unloading and transport of the plastic, without having to engage other parts of the plant for the installation of metal separators.
GRAVITY IN SLOW-MOVING MATERIAL COLUMN
Metal separators for plastics are equipment that combine the characteristics of tube metal detectors with those of a separation machine. The aim is to have an automatic machine that detects the presence of polluted metals (ferrous, bronze, brass, aluminium and AISI 304) and then rejects only the polluted product without interrupting the regular work programme and material flow.
This is a machine consisting of a frame and a vertical tube into which the plastic product to be checked falls by gravity, with a slow column descent. The metal detector is positioned at the top of the tube, while the separation mechanism, consisting of a valve that opens and closes rapidly, separating and rejecting the metal contaminants, is located at the end. An electronic control unit monitors the electromagnetic field of the coil and then activates the rejection mechanism. The metal contamination is detected even if it is included in the plastic product.
A very important aspect of gravity metal separators is that the level of sensitivity is proportional to the size of the passage hole, i.e. a large separator will not have a high capacity to detect small metal impurities that are simply detectable with a small metal separator. The use of gravity metal separators is indicated for the control of plastic product in full column descent. In some cases the use of a gravity metal separator with a magnetic tube filter is suggested.
The combination of the two systems offers different benefits, especially in the presence of a plastic product heavily polluted with metals. It is recommended to first install the magnetic filter and then the gravity metal separator. The product is first cleaned of all magnetic metal contaminations, including dust and ferrous filings, when it passes through the magnetic filter. The metal separator then controls and rejects all other non-magnetic metals that have not been retained by the magnetic filter. In this way 2 separate controls are obtained and the gravity metal separator will reject less polluted plastic product.
The use of a gravity metal separator is intended to check and discard metal contaminations, thus preventing complaints from end customers. In the situation where plastic products subsequently have to be extruded or processed by a machine, the metal separator has the function of preventing metal contaminations from damaging the extrusion screws or other machine parts.
Typical uses are bagging plants and feeding the single-screw extruder. In case of metal in the plastic the control unit signals the presence of metal and from this different alarms or lights or system stops can be activated.
Detection and inspection systems
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METAL DETECTION AND SEPARATION
Metal detection and separation systems (ferrous, bronze, brass, aluminium and AISI 304) are equipment intended for the control of packaged, moulded or other products with particular dimensions. The assembly consists of a frame on which a conveyor belt is mounted together with a tunnel metal detector.
The product is then placed on the belt that transports it through the metal detector. The metal contamination is detected even if it is included in the plastic product. If metal is present, the control unit signals the contamination and different alarms or lights or belt or system stops can be activated.
In a complete and automatic version of the system described above, it is possible to install, after the tunnel metal detector, an air or piston nozzle ejection system together with a collection box for rejected products. In this configuration the equipment becomes fully automatic and can be integrated into a production and transport line.
The use of metal detection and separation systems are suitable for end-of-line checks, remembering that here too the intention is to check for the presence of metals, thus preventing complaints from end customers. Typical uses are packaging plants or final product control before shipment.
X-RAY INSPECTION AND SEPARATION
X-ray inspection and separation systems are high quality equipment for the inspection of packaged, printed or other products with special dimensions. The assembly consists of a frame on which a conveyor belt is mounted together with an X-ray scanner.
The X-ray scanner generates a true image of the product and has the ability not only to detect the presence of metals such as ferrous, bronze, brass, aluminium and AISI 304, but also to identify contaminations such as glass, stone and all materials of a different density from the product to be checked. The product is then placed on the belt which transports it through the X-ray scanner.
In the event of the presence of impurities of different densities, the control unit, which in this case is a real computer, signals the contamination and from this it is possible to activate different alarms or lights or stop the belt or the system. In a complete and automatic version of the system described above, it is possible to install an air or piston nozzle ejection system after the scanner, together with a box for collecting the rejected products. In this configuration the equipment becomes fully automatic and can be integrated into a production and transport line.
The use of X-ray inspection and separation systems is suitable for end-of-line checks, remembering that here too the intention is to check for the presence of contaminations, thus preventing complaints from end customers. Typical uses are packaging plants or final product inspection before shipment.
