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Bunting – New Stronger ElectroMax-Plus Overband Magnet

The design objective of creating a more compact and powerful electromagnetic Overband Magnet led the Bunting engineering team to develop the new ElectroMax-Plus.


Bunting - New Stronger ElectroMax-Plus Overband Magnet feat
Figure 1 – Bunting’s ElectroMax-Plus Overband Magnet

Bunting is one of the world’s leading designers and manufacturers of magnetic separators, eddy current separators and electrostatic separators for the recycling and waste industries. The Bunting European manufacturing and product testing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the United Kingdom.

Electromagnetic Overband Magnets use an oil-cooled or air-cooled wire coil to generate a deep and strong magnetic field. The electromagnetic force radiates from a coil wound around a steel core and mounted inside a steel box with a thick steel back-bar. This focuses the magnetic field in one direction: down towards the conveyed material. In operation, an Overband Magnet, suspended over conveyors, screens, and vibratory feeders, lifts and removes ferrous metals such as iron rebar and beverage steel cans.

Bunting - New Stronger ElectroMax-Plus Overband Magnet p
Figure 2 – Bunting’s ElectroMax-Plus Overband Magnet

Overband Magnets are a common feature on many mobile screens and crushers.  In such applications, minimising weight and size is crucial and, subsequently, operators use standard Ceramic Ferrite or, less frequently, Neodymium Rare Earth Permanent Overband Magnets rather than Electromagnets.

Neodymium Permanent Overband Magnets produce a strong but shallow magnetic force and often experience problems with belt and motor damage due to large ferrous metal clamping against the magnet block. The magnetic field of the light and compact ElectroMax-Plus is both deep and strong, enabling excellent separation performance at higher suspension heights. In addition, simply turning off the electromagnet releases any extremely large entrapped tramp ferrous metal. The shape and nature of this magnetic field mean there is less wear to the self-cleaning belt mechanism (e.g. belt, motor gearbox, and bearings).

The new ElectroMax-Plus operates at a 600mm suspension height (the distance between the conveyor belt and the face of the Overband Magnet), up from 450mm on a standard ElectroMax. At a suspension height of 500mm, the ElectroMax-Plus is over 105% stronger (in terms of Force Index) that the equivalent ElectroMax. This incredible additional magnetic force removes small tramp ferrous metal commonly missed by permanent Overband Magnets.

The latest ElectroMax-Plus provides companies in the recycling, quarrying, and mining sectors with a powerful and compact solution for separating tramp and secondary ferrous metal from conveyors.

“Companies supplying mobile recycling equipment are requesting stronger and lighter Overband Magnets,” explained Adrian Coleman, the General of Bunting’s Redditch operation. “The new ElectroMax-Plus provides a real alternative to Neodymium Rare Earth Overband Magnets. There is the requested additional magnetic strength, without the operating problems [as experienced with some Neodymium Rare Earth Overband Magnets].’

The new ElectroMax-Plus extends Bunting’s comprehensive range of Overband and Suspension Magnets. In addition to standard sizes, Bunting also designs and manufacturers bespoke models which are application-specific.

Additional information on metal recovery and separation using the ElectroMax-Plus Overband Magnet, ElectroStatic Separators, Magnetic Separators, and Eddy Current Separators is available on the Bunting website


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Owain Griffiths

Owain Griffiths

Head of Circular Economy at Volvo Cars

Owain joined Volvo Cars in June 2021 to lead Circular Economy in the Global Sustainability Team. The company has committed to being a circular business by 2040 and has financial, recycled content and CO2 based targets for 2025, all of which Owain is working across the company to make happen. Owain previously worked for circular economy consultancy Oakdene Hollins where he advised businesses on evidence led circular economy implementation. 

Turning into a circular business and the importance of vehicle reuse and recycling.

The presentation will cover the work Volvo Cars is doing to achieve 2025 but mainly focus on the transformational work towards 2040 and the business and value chain changes being considered. Attention will be paid to the way vehicles are being dealt with at the end of life and the complexities of closing material and component loops. Opportunities and challenges which Volvo Cars is facing will be presented including engagement with 3rd parties and increasing pressure from stakeholders.

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e2e Total Loss Vehicle Management [e2e] is the UK’s only salvage and automotive recycling network with nationwide, environmentally compliant sites delivering performance resilience and service reliability to the insurance and fleet markets.  The network’s online salvage auction drives strong salvage resale values and faster sales.  e2e’s salvage clients have access to the network’s stocks of over 5 million quality graded, warranty assured reclaimed parts. 

The power of the network model means e2e has the ability to influence industry standards and is committed to continually raising the bar whilst redefining the role and perceived value of the salvage operator.  Network members adhere to robust service level agreements, against which they are audited, in order to ensure performance consistency and a market leading customer experience.  

The salvage and recycling operating environment is evolving rapidly, and e2e is anticipating, listening and responding to changing market needs.  Regulatory compliance, ESG, reclaimed parts, customer experience, EVs, new vehicle technologies, data and reputation risk are just some of many considerations linked to the procurement of salvage services.  e2e will drive further added value to clients and members through the adoption and application of emerging technologies, continuing to differentiate its proposition and position salvage services as a professional partnership. 

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