Handling metal scrap, sheet metal, pipes, beams and other ferrous material means working every day with loads, operative conditions and machines very different from one another. For this reason, when it comes to industrial electromagnets, there is no single configuration suitable for every application.

Loads shape, quantity of material to handle, operative machine available, power supply, working environment and cycle frequency are all elements that have an impact on the configuration of a magnetic system.

At its core, however, the underlying principle remains the same: using a controllable magnetic field to attract, lift, move and after release the ferrous material.

It is precisely this ability to control magnetic force that makes electromagnets particularly suitable for industrial handling. The magnet can be activated when a load needs to be gripped and ceases its action the moment the material needs to be released.

In practice, however, behind this apparent simplicity lies a design that must take the actual application into account.

A scrap yard and a steel mill could have the same necessity to move ferrous material, but the conditions of use are very different.

In the first case it could be necessary to lift irregular and different size scraps. In the second case, a stable grip on metal sheets, pipes, billets or other elements with defined geometry may be required. On a mobile construction site, on the other hand, one of the main constraints could be the power supply.

Therefore, sizing an electromagnet does not depend solely on the theoretical weight to be lifted.

It is necessary to take in consideration also geometry, characteristics of the material, machine where the magnet is gonna be installed, available voltage, environmental conditions, duty cycle and handling method.

The goal is to integrate the electromagnet in the product process or in the operative machine, avoiding being considered an isolated component.

The line Zanetti Magneti includes different types of electromagnetic for the lift and handler of ferrous material, developed to meet different operational requirements.

The ESA series hydraulic electromagnetic, for example, are suitable for use on excavators, loaders, and other machinery. They are particularly well-suited for the demolition, recovery, and recycling sectors, where mobility and durability must go hand in hand… with a fast-paced working environment.

For scrap handling, ESM, ESP, and ESH circular electromagnets, are available, designed with different levels of robustness and magnetic capacity. The circular geometry is suitable for collecting ferrous materials distributed in irregular ways, as frequently occurs in scrap yards and metal recovery plants.

The line also has low-voltage circular electromagnets (12 or 24 V), suitable for use in applications where the available power supply and machine configuration make low-voltage operation preferable.

However, when long elements or items with more regular surfaces such as metal sheets, beams, bars, and bundles need to be handled, Zanetti Magneti offers rectangular lifting electromagnets and low-voltage rectangular electromagnets (12/24 V) solutions designed to distribute the magnetic field uniformly over large surfaces and adapt to different operating conditions.

These solutions are supported by the  battery-operated electromagnets with radio control, the  grapple magnets and the self-contained configurations powered by petrol or diesel engines, designed for jobsites or areas where there isn’t a traditional electric system.

Therefore, the type of electromagnet should always be determined based on the work it is to perform and the characteristics of the machine on which it will be installed.

To learn more about the differences, power supplies and parameters to evaluate, we recommend reading the article dedicated to How to identify the lifting electromagnet best suited to your application.

Whatever the external configuration, the principle allowing an electromagnet to attract ferrous materials stems from the interaction between electric current, winding, and magnetic field.

When current flows through the electromagnet’s internal coil, a magnetic field is generated. The device’s magnetic circuit concentrates this field in the area designated for gripping the material.

Once brought close to a compatible ferrous element, the electromagnet exerts the force necessary to attract and hold it during handling.

The process can be summarized in four stages:

1. power supply to the electromagnet;
2. generation of the magnetic field;
3. attraction and holding of the ferrous material;
4. interruption of the power supply and release of the load.

It is precisely the ability to control magnetization and demagnetization that makes this technology particularly useful for lifting applications.

Actual performance, however, does not depend solely on the presence of the magnetic field. Winding dimensions, design characteristics, power supply, contact surface area, and the properties of the material being handled all influence the behavior of the entire system.

If you would like to know more, we invite you to read the article to find out  the operating principle of an electromagnet.

Knowing the physical principle is important, but in the industrial application what matters above all is how it is translated into a reliable work cycle.

An electromagnet used in a recycling facility may perform numerous scrap pickup and release cycles. Conversely, a unit installed in a steelworks setting might be required to handle materials that are heavy, bulky, or subject to specific thermal conditions.

Changing also the machine: excavator, Industrial material handler, truck-mounted cranes, overhead cranes, and stationary systems impose different constraints regarding operating weight, power supply, installation, and lifting capacity.

For this reason, performance should not be evaluated based on a single parameter.

A properly designed system stems from the balance between the electromagnet, the material, the machine, and the operating conditions.

Two companies handling apparently similar material may have completely different needs.

Handled quantities, part dimensions, temperature, available space, cyclem frequency, and system characteristics can radically alter the required configuration.

To this end, Zanetti Magneti develops industrial electromagnets and customized solutions, evaluating the characteristics of the application and the machine on which the system will operate.

From scrap handling to steelmaking processes, and through to demolition and recovery activities, the best solution is one designed to operate effectively within the specific production process.

What materials can an electromagnet handle?

Electromagnets are primarily used for ferromagnetic materials, including iron and various types of steel. Materials such as copper and aluminum, on the other hand, are not attracted to a magnetic field in the same way.

Is a circular or rectangular electromagnet better?

It depends on the material to be handled. Circular models are particularly suitable for scrap and irregularly distributed materials, whereas rectangular models may be better suited for sheets, pipes, billets, and other elements with elongated or regular geometries.

Can an electromagnet be installed on an excavator?

Yes. There are configurations designed specifically for excavators and other heavy machinery. However, before installation, the machine’s weight, the available system, and the application requirements must be evaluated.

Are there electromagnets that do not require an electrical grid?

Yes. In addition to models connected to dedicated power supplies, there are battery-operated electromagnets and self-contained petrol- or diesel- powered configurations, which can also be used in areas without a traditional electrical connection.

How do you determine the right electromagnet for an application?

The evaluation must consider several parameters: material and quantity to be handled, load geometry, operating machine, available power supply, environment, and cycle frequency. For this reason, sizing should be calculated based on actual working conditions.