Magnetic Separators – Is 100% Metal Separation Achievable?

In a perfect scenario, a magnetic separation system would remove 100% of all metal contaminants while causing zero product loss.However, real industrial environments are far from perfect. This leads to an important question frequently asked by customers:“Is 100% metal separation actually possible?”

When magnetic separator manufacturers receive a project specification, customers often request a guaranteed metal separation percentage. Some even stat

e their expected separation rate upfront. But such numbers cannot be assigned without proper analysis and supporting data. To answer this question responsibly, several key considerations must be addressed first.

1) What is the primary objective of metal separation?

• In industries such as food, pharmaceuticals, or plastics, the goal is to prevent metal contamination from damaging equipment or compromising product quality.

• In recycling operations, the priority is to maximize recovery of valuable metal from mixed materials.

These different objectives require different performance targets.

2) How much product loss is acceptable?

In some processes—such as plastics manufacturing—non-metallic material is extremely valuable, and any product loss must be minimized.In other applications, the plastic or bulk material may be waste, and the metal is the valuable fraction.

Typically, higher metal separation rates result in higher product loss.

Additionally, cleaning frequency matters:

• More frequent cleaning → higher separation rate but slower production

• Less frequent cleaning → improved throughput but potentially lower separation performance
  

3) What is the required purity level of the final product?

• In food and plastics manufacturing, the final product must meet strict purity standards.

• In metal recovery operations, some level of contamination may be acceptable until it begins to affect the value or usability of the recovered metal.

Understanding purity expectations is essential for selecting the correct separator design.

4) How will the metal separation percentage be measured and verified?

Material properties vary widely. For example:

• Dry, free-flowing materials may achieve high separation percentages.

• Damp, sticky, or inconsistent materials may produce lower separation rates.

A realistic performance guarantee must be paired with a practical measurement and validation process.

Application Assessment and Engineering Recommendations

By reviewing these four points with the customer, AKSA Process can conduct a reliable initial assessment and propose:

• the correct magnetic separator design,

• the optimal installation position,

• and the appropriate operating conditions.

A crucial reminder: Higher gauss levels do not automatically mean better separation performance.

Effectiveness comes from the right balance of magnetic strength, equipment design, and installation strategy.

“100% Metal Separation” Realistic?

In practice, no. There are too many variables—most importantly, the size of the contamination. For instance:

• Removing a large metal fragment is easy.

• Removing a metal particle the size of 20 mesh is significantly more difficult.

Therefore, claims such as “100% metal separation guaranteed” are generally unrealistic.

At AKSA Process, we deliver high metal separation rates — often up to 97% and we support these claims with real performance data and testing.

Commitment to Transparency and Engineering Excellence

By working closely with customers and fully understanding their process conditions, AKSA Process designs magnetic separation systems optimized for each application. This ensures:

• consistent performance,

• reliable contamination control,

• reduced downtime,

• and high-quality end products.

For more information about custom-engineered magnetic separation solutions, feel free to contact AKSA Process.