Why Do Crossbelt Magnets Need Armored Belts?

It's no surprise that the crossbelt magnet experiences significant wear and tear on the belt that moves separated metal away from the conveyor. To protect this rubber belt from damage, Bunting has developed a specialized, lightweight armored belt designed specifically for crossbelt magnets. As a global leader in magnetic separation technology, Bunting is known for its innovative designs and high-quality manufacturing of magnetic separators, eddy current separators, metal detectors, and electrostatic separators. Their facilities are located in Newton, Kansas, just outside Wichita, in the heart of the United States.

Armored Belts Protect Crossbelt Magnets from Excessive Wear and Extend Belt Lifespan

These crossbelt magnets are typically installed over conveyors that transport materials such as aggregate, waste, shredded wood, or mined ore. They operate by generating a magnetic field—either through permanent magnets or electromagnetic blocks—that attracts ferrous metals from the material being conveyed. The self-cleaning rubber belt then lifts the metal and transports it to a collection area.

The impact of ferrous metal hitting the belt can be quite strong, especially as the metal gets closer to the magnet’s surface. This causes the metal to accelerate toward the belt, momentarily sandwiching it between the lifted metal and the magnet until the belt's upstands catch and remove the item from the magnetic field.

Applications where self-cleaning belts experience heavy wear include:

  • High levels of ferrous metal in the material being conveyed.
  • Large and heavy ferrous objects.
  • Nails or thin, sharp metal pieces.
  • Models with stronger magnetic fields, like the ElectroMax and ElectroMax-Plus.

To reduce wear and extend the life of the belt, Bunting engineers created a lightweight yet durable armored solution. While alternatives like wear-resistant coatings exist, the armored belt offers superior protection and significantly increases the belt’s lifespan.

The armor consists of high-density polyethylene (HDPE) slats, each 100mm wide and 10mm thick, custom-fitted to specific crossbelt magnet models. These slats are secured using special 304 stainless steel elevator bucket bolts and nyloc nuts.

Adrian Coleman, Bunting’s Technical Director in the UK, said, “This armored belt design has been very well received. Previous attempts at belt armor didn’t work well, but the HDPE version has proven highly effective.”

Contact us today to discuss your application or request a quote.

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