Choosing the right lifting electromagnet is not just a technical decision: it is a strategic choice that has a direct impact on productivity, safety and business continuity. In the industrial environment, where every minute counts and every operation has a specific weight, using an unsuitable magnet can slow down work cycles, increase the risk of downtime and generate unexpected costs.

This is why relying on solutions tailored to your operating environment is essential. But how to find your way around dozens of models, different voltages, shapes and alternative power supplies?

In this guide, we take you step-by-step through the choice of the ideal model, analysing the types of lifting electromagnets available, the differences between 24V and 220V systems, the most frequent industrial applications, and the technical and operational factors to consider before making a purchase.

Because when it comes to lifting electromagnets, Zanetti Magneti is more than just a brand: it is an Italian guarantee of power, reliability and innovation with over 40 years of experience.

When it comes to industrial handling, precision and power cannot be left to chance. That’s why Zanetti Magneti has developed, over time, a comprehensive range of lifting electromagnets designed to meet real-world needs across a variety of applications.

Let’s take a look at the main types of lifting electromagnets available, all proudly engineered by Zanetti Magneti.

When handling operations demand perfect synergy between magnetic force, mechanical strength and hydraulic control, this is the most advanced solution. Hydraulic electromagnets interface directly with the hydraulic circuit of the operating machine, providing immediate, precise and direct control. No additional wiring, no external control unit: everything is already integrated.

They are ideal for excavators, loaders, mechanical shovels and other machinery working in harsh environments, such as demolition, construction sites and waste treatment plants.

Compact, reliable and built to move with your machinery. These electromagnets are designed to be installed on cranes, excavators and industrial trucks using battery power. Powered at 12V or 24V, they offer the right balance between safety and magnetic force, even in dynamic environments with limited space. Ideal for those who often work on the road or on construction sites where agility is everything.

This is the realm of raw power. Perfect for stationary plants, scrap yards and metal processing centres, these 220V-powered electromagnets are capable of lifting large quantities of ferrous material very quickly. If the objective is to optimise work cycles without compromise, this is your ally.

Do you work in the waste recovery or heavy-duty recycling sector? Then you’re likely familiar with polyp grabs. Zanetti’s polyp grab electromagnets are designed to integrate perfectly with the hydraulic movement of the polyp grab, synchronising the opening, gripping and release of the material with millimetric precision. More efficiency, less waste and reduced downtime. Perfect in situations where iron separation is required before handling material with the polyp grab.

Zero cables, zero limits. These models are completely self-sufficient, thanks to integrated petrol or diesel generators and a remote control system that makes them easy to operate even from a distance. The perfect solution for working in remote locations, quarries, mobile worksites or on machinery without a power supply. Where the grid can’t reach, Zanetti can.

Not everything is round, and not all loads have the same shape. Rectangular electromagnets are designed to work with sheets, beams, bars and flat surfaces, distributing the magnetic field evenly and minimising the risk of load loss. They are available with 360 degree rotation. A technical choice, but with very practical impact on daily productivity.

This is technology at its finest. No cables, no limits, fully remote-controlled. These electromagnets offer maximum operational flexibility, thanks to their energy autonomy and remote operation capability. A top-of-the-range solution for those seeking maximum independence and safety, ideal for fast, safe and precise operations even in dangerous or hard-to-reach areas with zero emissions. Suitable for use both outside and inside structures, they are the preferred choice for those who demand top performance.

Choosing the right lifting electromagnet is not a process to be taken lightly. Every facility, site and sector has specific needs that make relying on guesswork or simply choosing the cheapest option impossible.

If you want to make an investment that truly delivers, here are the parameters to consider when selecting the perfect electromagnet for your operating context.

Type of material to be lifted

Not all ferrous materials behave the same under the influence of a magnetic field. For example, thin or irregular scrap requires magnets with a more intense and evenly distributed field. For compact or flat materials, such as sheet metal, rectangular magnets are the ideal choice.

Load weight and capacity

It is essential to know the maximum mass that the electromagnet will need to lift. Every model has an attractive force rated in kilograms. Exceeding this limit poses real risks: load loss, damage to the magnet or worse, accidents. 

Always allow for a 20-30 per cent safety margin above the maximum expected load. Better a ‘stronger’ magnet than one that operates at its limit.

Environmental conditions

The IP protection rating is often overlooked; however, the operating environments (rain, dust, oils, seawater…) can significantly affect the magnet’s life and performance.

Our electromagnets have various certified protections: 

• The ESA, ESB BATMAG, ESG and ESD series come with IP65 protection, perfect for standard industrial environments.
• All other models are supplied with IP66 protection, ideal for areas exposed to water and dust.
• IP67 and IP68 versions are also available on request, perfect for prolonged submersion or use in salt water, such as in ports, shipyards or off-shore installations.

Available power supply

A stationary system can work with 220V magnets, while industrial vehicles require 12V or 24V magnets. In the absence of an electrical power supply, battery- or diesel-engined models are the preferred option.

Operating cycles and durability

Heavy duty use requires electromagnets designed for continuous operation. Always check the duty cycle expressed as a percentage, which indicates the maximum continuous operation time in relation to rest time. We classify our products into two macro-categories:

• 100% duty cycle: The ESB and ESRB Series can operate continuously without pause, ideal for automated systems or intensive work-shifts.
• 75% duty cycle: All other standard models provide reliable and continuous performance even during intensive work cycles. In practice, the theoretical limit of the duty cycle is rarely reached. This is because, during typical use, the magnet benefits already from short breaks due to the demagnetisation cycle and the movements of the operating machine to reposition itself between lifts. This is a normal and expected process in the work, which keeps the magnet always efficient and ready for use.

Anyone who daily works with ferrous materials knows the importance of having a reliable, safe and system-independent tool. And among the many choices to make,one question often comes up: is it better to use a 24V or a 220V lifting electromagnet?

Thanks to decades of industry experience, Zanetti Magneti offers both solutions, but each with its own specific design and application characteristics. Let ‘s take a look at the real differences without unnecessary technicalities, to help you make an informed and effective choice.

The low voltage electromagnets (12V and 24V) we offer are a practical solution for those seeking high performance on mobile systems or in environments where high voltage is not feasible or desirable. 

Thanks to their compact and robust design, they are perfect for installation on industrial machinery, such as wheel loaders or truck mounted cranes with chain attachment or saddle mount option.

Advantages:

• Greater safety in humid or outdoor environments
• No need for high-voltage electrical systems
• Compatibility with vehicle electrical systems

Disadvantages:

• Less power available than 220V models
• Not suitable for extremely heavy loads or continuous use in fixed installations

When the objective is to lift heavy scrap in large volumes and without interruption, the choice falls on 220V models, especially those from the circular scrap electromagnet line ESM-ESP-ESH.

Designed for fixed installations, scrap cranes, crushing plants and metal collection centres, these electromagnets are the ultimate solution for those seeking high performance, durability and operational continuity.

Advantages:

• Superior power for high performance industrial applications.
• Continuous operation without performance loss.
• Robust structure designed for long-term durability, even under intensive use

Disadvantages:

• Requires a 220V power supply

In the industrial world, there is no one-size-fits-all solution. Each sector has its own challenges, pace and loads to be lifted. And when it comes to moving ferrous materials, choosing the right electromagnet can mean the difference between an optimised workflow and a production bottleneck. 

Here are some concrete examples to help you understand which type of electromagnet works best depending on your sector.

Recycling industry: 220V circular scrap magnets are the real protagonists in the handling of metals of all shapes and sizes. But that’s not all, polyp grabs, used for selective loading and unloading, specialised electromagnets are integrated seamlessly with the hydraulic system. The result? Maximum operational efficiency, with precise gripping and synchronised releasing.

Steel industry: In steel works and large metallurgical plants, the materials to be lifted are highly specific: metal profiles, sheet metal bundles, pipes and bars often at temperatures exceeding 600 degrees Celsius. In these cases, our 220V HT (High Temperature) series electromagnets, built with special materials and dedicated solutions, ensure safe lifting of even red-hot steel. Long, flat, compact elements that require uniform and stable gripping: here rectangular electromagnets are the natural choice, often used in multiple configurations to distribute the load over a larger surface. Depending on the set-up, either 220V or low voltage 24V versions are selected.

Quarries and mobile construction sites: when working in extreme conditions, often far from electrical infrastructure, you need a solution that does not rely on the grid. Here, mobility becomes everything.

The protagonists are battery-powered electromagnets with remote control, perfect for autonomous operations on mobile machinery, or petrol/diesel-powered units, ideal for quarries, demolition work and temporary interventions in isolated areas. However, hydraulic electromagnets often offer the best performance in these contexts, provided they are connected to an adequate hydraulic system.

The strength of these magnets lies precisely in their energy autonomy.

Some jobs don’t follow the rules of the catalogue. Operational needs can be so specific that no ‘off-the-shelf’ model is truly up to the task. That’s when custom electromagnets come into play: tailor-made solutions designed to tackle unique challenges and go beyond standard industrial limits.

When installation space is restricted, when loads have unusual geometries, or when advanced features and customised control systems are required, there’s no alternative: you need a magnet built around your work.

We offer a tailor-made design service, working closely with the client to evaluate every single technical detail in order to build a ‘tailor-made’ electromagnet.

A lifting electromagnet is much more than a technical component. It’s a real operational ally, and like any ally, it needs to be treated with care. A well-maintained magnet works better, longer and more safely.

Too often, it’s assumed that an electromagnet ‘either works or doesn’t work’, but the truth is that small measures can make a huge difference in performance, durability and reliability. Here are a series of simple but essential smart best practices to keep your electromagnet operating at its best.

Regular inspections

Regularly check the integrity of the wiring, electrical connections and the absence of oxidation on the magnet poles. The flatness of the magnet’s contact surface should also be verified at Zanetti Magneti we can restore it if necessary. 

Cleaning contact surfaces

Rust or non-ferrous debris on the contact surfaces can reduce the effectiveness of the magnetic field. It is good practice to clean the contact area regularly.

Temperature control

Overheating is one of the main enemies of electromagnets. Install thermal sensors or use built-in temperature protectors (many models are already equipped with them).

Proper use of the duty cycle

Each electromagnet has an optimal duty cycle, representing its capacity to work continuously without overheating. However, high ambient temperatures (above 45–50 degrees Celsius) can negatively impact the duty cycle, as heat dissipation becomes less effective

Software and remote control updates

Industrial electromagnets do not require scheduled software updates. However, we carry out tailored technical updates: mechanical, electronic, or electrotechnical only when truly necessary.

When?

• In the event of technical anomalies detected during maintenance
• When a magnet returns to the workshop after many years of use
• When original spare parts are no longer available and device modernisation becomes necessary
• Always in agreement with the client, carefully evaluating how to intervene efficiently and cost-effectively

If you have any doubts or would like to assess specific upgrades, the Zanetti Magneti team is at your disposal. We will guide you step-by-step towards the most efficient, safe, and long-lasting solution for your operational needs.

What is the difference between a circular and a rectangular electromagnet?

The former is better suited for lifting irregular or scrap materials, while the latter is ideal for flat and long objects such as sheets or pipes.

How much power does a lifting electromagnet consume?

Power consumption depends on the voltage and nominal power. A 220V model can consume anywhere from 1 to 30 kW depending on its size.

Can I use an electromagnet outdoors in the rain?

Yes, but it is essential that the device has an appropriate IP protection rating (e.g. IP65 or higher).

Do electromagnets require maintenance?

Yes, but it is minimal: mainly visual inspections, cleaning, and checking electrical connections.

Can I purchase an electromagnet directly online?

No, you need to contact the Zanetti Magneti technical team to determine the model best suited to your application.