In any industrial setting handling, locking, or separating ferrous materials are routine. For this reason, magnetism isn’t just an idea, it’s what lifts, holds, and and sorts. Choosing between an electromagnet and a permanent magnet directly affects productivity, energy costs, and operational reliability.

Professionals know this well: choosing the wrong magnet type can slow a production line, increase maintenance, or pose safety risks. On the other hand, the right solution, tailored to your plant, reduces waste, simplifies operations, and optimises every cycle.

Today, we’ll compare electromagnets and permanent magnets. We’ll look at their pros and cons, and highlight which technology fits best in metal‑working, logistics, scrap processing, or automated plants.

If you’re exploring new magnetic solutions or want to understand which option best suits your operational needs, you’ll find answers to questions that often go unasked, especially when choosing the right component for your system.

When electric current flows through the right metal configuration, you get an electromagnet: it turns electricity into magnetic force with remarkable precision. Its real strength lies in the control it offers.

Unlike permanent magnets, the electromagnet only works when powered. Switch it on, and it responds. Switch it off, and the magnetism disappears. No waste, no energy lost.

It uses a soft-iron core wrapped in copper wire. It’s simple, yet powerful: apply current, and the core becomes a temporary magnet. One moment it’s plain steel; the next, it’s lifting tonnes of ferrous material.

The key advantage? Flexibility.

• You can precisely adjust the magnetic field.
• It turns off instantly, ensuring safe release.
• It can be customised in shape and strength for linear, rotating, or space‑constrained setups.

The permanent magnet is one of those simple and linear solutions that seem perfect… until you look for something more. It doesn’t require power. It’s silent, compact, and provides a constant magnetic field thanks to ferromagnetic materials with stable internal structure.

This makes it ideal where a steady field is needed without electronics or continuous power. Common materials include:

• Neodymium: small but extremely strong.
• Ferrite: less powerful, yet durable and cost‑effective.
• Samarium‑cobalt: stable, heat‑resistant, and demagnetisation‑proof.

It works well, but its simplicity brings limits: its field can’t be turned off, adjusted, or modulated. It’s always on, no flexibility, no dynamic response.

This limits its use to specific tasks: magnetic couplings, encoders, passive locks, small brushless motors. Yet in processes requiring control, safety, or versatility, it may fall short.

In short:

• Pros: zero energy use, long-lasting, compact.
• Cons: fixed field, poor adaptability, no remote control.

The permanent magnet may seem convenient, but it is not always the best choice when the production process requires precision, variable cycles or automated handling. And in a world where every detail counts, the ability to adapt can be worth more than simplicity.

In some specific applications, such as those where the safety of the load in case of voltage failure is a fundamental requirement, there is a third technology: the electropermanent magnet. This system uses a combination of permanent magnets and an initial electrical pulse to activate or deactivate the magnetic field. The main advantage is that, even in case of power failure, the load remains engaged.

However, in sectors such as demolition, recycling or scrap handling, this type of magnet has some critical features: the cost is higher than traditional electromagnets, the magnetic field is less deep (not effective more than a few millimetres in the presence of dirt, rust or iron), and the force of attraction may be compromised in environments that are not perfectly clean.

In industrial environments with high temperatures, such as steel mills, the electromagnet remains much more suitable, thanks to its thermal resistance and ability to maintain high performance even under critical environmental conditions.

Zanetti Magneti is specialized in electromagnets, but if you think that an electropermanent can be useful, contact us: we will evaluate together your specific case and propose the most suitable solution.

The differences between electromagnets and permanent magnets lie not only in the principle of operation, but also in practical factors which influence the industrial choice:

Electromagnets excel in dynamic scenarios, while permanent magnets suit stable, continuous tasks.

Benefits

In the industrial field, the electromagnet is much more than a simple component: it is a strategic tool for those who seek control, safety and maximum efficiency in processes. This is why it is the first choice in many production sectors:

• Magnetic field on request

The electromagnet is activated only when needed. Just power it to generate magnetic force, and turn it off to release it. This allows you to automate production cycles and ensure maximum security in the release phase.

• Total control of force

The field power can be modulated in real time by adjusting the current. In this way the magnetic force can be adapted to the weight of the material, the type of application or the operating conditions.

• Active safety

In the event of an emergency or power failure, the electromagnet switches off automatically. This reduces the risks in plants where load release has to take place under controlled conditions. When it is necessary to guarantee the safety of the lifting, even in case of voltage interruption, it is good to know that it is possible to install battery packs that keep the electromagnet active until the power supply is restored.

• Adaptability to specific needs

There are rectangular, circular and custom-made solenoids for every type of installation. They are particularly effective in sectors where customization is essential: demolition, scrap handling, industrial separation.

• Integration with automated systems

Electromagnets easily interface with PLCs, sensors and industrial control logics, facilitating process automation and traceability of operations.

Limits

As any advanced technology, the electromagnet also has limits to take into consideration, especially in relation to the context of use and the design of the system.

• It depends on electricity 

Without power, the electromagnet does not work. This implies the need of stable electrical installations and, in some cases, the use of batteries or emergency generators.

• Continuous energy consumption

During operation, the electromagnet consumes energy constantly. This can have an impact on operating costs if used for very long cycles or in environments where energy efficiency is a priority.

• Generation of heat

Prolonged activation may cause overheating. In some cases, cooling or ventilation systems are required to prevent a drop in performance.

• Greater plant complexity

Compared with permanent magnets, an electromagnet requires wiring, control units and electronic management. A poorly connected plant can increase downtime or maintenance.

Benefits

In certain contexts, permanent magnets are a solid, practical and functional choice. Their magnetic force is always active and, in many applications, this continuity can be a real advantage. The main strengths are:

• No energy consumption

A permanent magnet does not need power to work. This makes it ideal for passive devices, environments without access to electricity or in applications where energy consumption must be minimized.

• Zero active maintenance

No wiring, no electrical components to control, no control unit. A permanent magnet, once mounted, can work for years without intervention if used under the right conditions. Obviously there is to consider, however, the wear of the part in contact with the material to be lifted which can compromise the effectiveness of lifting. 

• Compactness

At the same power, some materials such as neodymium offer an intense magnetic field in a small volume, making them suitable for limited spaces or micro-applications.

• Long durability

Quality materials, such as samarium-cobalt, retain magnetism even after years of use, if not subjected to extreme stress.

Limits

But if the benefits are clear, so too are the limits, especially when it comes to automation, control or complex industrial environments. This is why it is important to consider carefully:

• Fixed magnetic field

Once installed, the permanent magnet always does the same thing: it attracts. It cannot be adjusted, deactivated or varied. And in many applications this becomes a hindrance, not an advantage.

• No remote control

No possibility of switching on or off via electrical signals. This effectively excludes it from all applications where a minimum of automatic security control logic is needed.

• Environmental sensibility

Permanent magnets, especially neodymium, may lose some of their effectiveness if exposed to high temperatures or mechanical shocks. Some require protective coatings to prevent corrosion.

• Not suitable for dynamic lifting

In areas where it is necessary to hold, lift and then release metal materials quickly (such as magnetic lifting or industrial separators), the lack of active magnetic field management is a structural limit.

Lifting and handling electromagnets are not a generic technology: they are targeted tools, designed to meet specific needs in the most demanding industrial sectors. From demolition to recycling, from construction to steel, they are a solution that optimizes time, improves safety and reduces operating costs. Let’s see where they really make a difference.

Demolition sites

Among the most challenging environments for lifting equipment, demolition sites test every component. Here, excavator-mounted solenoids are used to quickly and safely separate steel from concrete during the dismantling of buildings or infrastructure.

Not only do they increase iron recovery efficiency, but they also protect the machines from wear and tear in subsequent steps. What’s the result? Less waste, more recovered value, and smoother operations.

Iron and steel industry

In steelworks and foundries, where work is done with hot materials and extreme weights, the electromagnet is an essential ally. Allows you to lift and transport blooms, billets, steel coils and sheets in a controlled, fast and safe way. In an environment where every second counts and every mistake can be costly, the maneuverability offered by an electromagnet makes the difference between efficiency and production slowdown.

Shipyards

Shipbuilding involves the placement of imposing metal sections: hulls, beams, load-bearing structures. With a suitable electromagnet, these masses can be lifted and placed in place with millimetre precision, reducing the margin of error and increasing safety for operators. A real benefit for those working on large projects.

Recycling plants

In scrap recovery platforms, speed is everything. Electromagnets for mobile loaders and cranes are used to quickly collect, sort and move metal pieces ofMetal parts of all types: scrapped cars, discarded household appliances, ferrous scrap. The magnetic efficiency allows a continuous and fluid cycle, reducing operating breaks and increasing site productivity.

Construction sector

In construction, the assembly of metal structures is a delicate phase. Electromagnets are used to transport and position beams, slabs, tube bundles and columns with extreme precision. This reduces the risk of errors, speeds up assembly times and lowers labour costs while maintaining high safety standards.

Heavy machinery and industrial plants

In the mining sector, large mechanical workshops and industrial sites, solenoids are an effective solution for lifting and handling bulky loads such as engines, metal blocks, plant sections. They are a viable alternative to traditional chains, hooks and systems, providing greater stability, speed and operational control.

Permanent magnets are everywhere: from the most sophisticated devices to the quietest everyday technologies. Their stable, continuous and power independent magnetic force makes them ideal for applications where long-term reliability, zero maintenance and compactness are required. Here are the main areas where they make a difference:

Electric Motors for Industry and Vehicles

In synchronous and brushless motors used in fans, industrial automation, and electric vehicles, permanent magnets—especially neodymium ones—are crucial for generating a steady magnetic field. They offer high energy efficiency and strong performance in compact spaces, reducing consumption and improving overall output.

Speakers and Audio Components

In every speaker, a permanent magnet works with a moving coil to convert electrical impulses into sound. A stable magnetic field ensures sound fidelity and dynamic response. Even in micro speakers, headphones, and professional audio devices, magnets play a key role.

Hard Disks and Storage Devices

Hard disk drives (HDDs) use precision permanent magnets to guide the read/write arm. Three separate magnets work in sync to ensure accurate, stable, and synchronized movement, enabling fast data access.

Magnetic Drive Pumps

In industrial and chemical settings, these pumps eliminate direct contact between motor and fluid by using permanent magnets to transfer torque. This reduces loss and enhances safety, especially with corrosive or volatile substances.

Medical Instruments and Imaging

MRI machines rely on powerful permanent magnets to generate the stable field needed for detailed tissue analysis. Many surgical tools and monitoring devices also use magnets for continuous, quiet operation.

Magnetic Separators in Industrial Processes

In recycling and mining, permanent magnets are used in separators to automatically remove ferrous particles from non-magnetic materials. This continuous process is essential for material purification or metal recovery.

Jewellery and Closure Systems

In magnetic jewellery, neodymium magnets provide secure but easy-to-open closures. They are also used in therapeutic necklaces or earrings, offering a firm hold without complex mechanical parts.

Security Systems and Magnetic Locks

In many door locks and access control systems, permanent magnets work with electromagnets to ensure secure locking. This reliable technology is used in offices, hotels, and sensitive industrial sites.

Wind Turbines and Renewable Generators

Wind turbine generators use permanent magnets to convert blade motion into electricity. This enables efficient operation even at low wind speeds, increasing energy output.

Vibration Motors in Mobile Devices

In phones, smartwatches, and wearables, miniaturised permanent magnets activate vibration motors that provide tactile feedback. Small but essential for daily interaction with modern tech.

The decision between an electromagnet and a permanent magnet should always be based on the application context. There is no universally “better” solution, only the right one for each industrial need. Here are the key factors to consider:

• Application type

If you need to lift, hold temporarily, or release materials in a controlled way, an electromagnet is ideal. If the goal is to generate a constant magnetic field for sensors, encoders, or compact motors, a permanent magnet is more suitable.

• Operating Environment

In harsh environments (high temperatures, moisture, dust), permanent magnets require resistant materials such as samarium-cobalt. Electromagnets, instead, can be designed with active cooling and specific protections.

• Energy Consumption

Permanent magnets use no energy during operation but cannot be controlled. Electromagnets, while needing constant power, allow dynamic field control and on-demand deactivation.

• Operational Flexibility

Electromagnets can be turned on, off, and adjusted. They integrate easily into automated systems with control logic, sensors, and PLCs. Permanent magnets are static, non-programmable, and non-adjustable.

• Duty Cycle

In intermittent or repetitive cycles, or where timely release is essential, electromagnets are indispensable. In continuous, predictable cycles with no variation, permanent magnets can be an effective and durable solution.

In short: permanent magnets suit simple, passive, and stable systems. Electromagnets offer flexibility, safety, and control, making them the right choice for complex and dynamic operations. A smart decision requires analysing your processes, energy constraints, and operational priorities. And you can trust a partner like Zanetti Magneti, who can guide you through the choice.

A rotating electromagnet is the best option in systems where continuous removal, holding, or separation of ferrous material is required. It’s commonly used in:

• Industrial shredders, where it is necessary to remove metal fragments in real time during grinding;
• Installations for the treatment of metal dust, to avoid accumulation on fixed surfaces;
• Rotating magnetic rollers, integrated in transport lines, to move and hold metal along the route.
• Precise handling and positioning of sheets or long beams: the rotation allows a more accurate and fast positioning.

In these cases, the combination of magnetic force and mechanical rotation allows:

• Maintain the continuous flow of materials;
• Reducing discharge or separation times;
• Increase productivity by avoiding clogging or line stoppages.

You choose a rotating electromagnet when the process cannot afford breaks, stationary loads or slow machining. Unlike a fixed magnet, the controlled movement avoids material accumulation and ensures a more uniform and constant separation or handling.

Zanetti Magneti designs and supplies hydraulic magnets, rotating electromagnets and customized lifting and separation solutions for every industrial need. Whether you work in metal engineering, logistics, demolition or automated production, here you will find competence, reliability and continuous support.

Contact us to request a customized quote or talk with our specialized technician.

What’s the main difference between an electromagnet and a permanent magnet?

The electromagnet generates a magnetic field only when electrically powered, so it can be switched on or off as desired. The permanent magnet has a constant magnetic field and requires no power. The choice depends on the need for control over the magnetic field, especially in the recycling sector and demolition where permanent or electro permanent magnets are not effective, also because of the shallow magnetic field which does not permit the lifting of scrap and rods between the rubble.

When should you avoid a permanent magnet?

The permanent magnet should not be used in applications where it is necessary to activate or deactivate the field on demand, or when it is necessary to modulate the magnetic force. In addition, it is not suitable for use in high temperature environments unless materials such as samarium-cobalt are used.

Do electromagnets use lots of energy?

It depends on power and usage duration. Short cycles have low consumption, but long, continuous use can increase costs. Still, their control and safety benefits often justify the energy use.

Can you customise an electromagnet?

Yes. Zanetti Magneti makes bespoke electromagnets for lifting or integration with conveyors, rotators, or automated systems. You can specify voltage, force, shape, mounting, and protections.

What is the average life of an industrial electromagnet?

With proper maintenance, an electromagnet can exceed 10 years of operational life. The duration depends on the working environment, the number of cycles and the quality of the components (coil, insulations, core, etc.).

Can a permanent magnet lose strength over time?

Yes, especially when exposed to shock, high temperatures, strong magnetic counter fields or can demagnetize due to high voltage electric shocks. However, when used correctly, a neodymium or samarium-cobalt magnet can retain its effectiveness for decades.

Which sectors use rotating electromagnets most frequently?

They are in high demand in recycling, shredding, material separation and magnetic roller conveyor systems. They prevent material build-up and improve productivity in continuous lines.

Does Zanetti Magneti offer after‑sales support?

Yes. From design to post‑installation, Zanetti Magneti supports customers from design to post-installation assistance, with technical support, spare parts and advice for integration into production processes.