In the industrial sector, every component must contribute to the efficiency, safety and precision of the entire process. Among the most reliable and versatile technologies there are electromagnets: devices capable of transforming electrical energy into magnetic force with speed, full control and high performance.

They are essential tools in countless production contexts: from the handling of ferrous materials to safe clamping, from robotics to precision automation. The principle behind them is simple yet powerful: when an electric current passes through a conductor wound around a metal core, an instantaneous magnetic field is generated, able to perform essential functions with exceptional reliability.

In this article we will take a clear and in-depth look at what an electromagnet is, how it works and what are its main components, with particular attention to real-world applications. Whether you are assessing new automation solutions, optimising a plant, or designing customised machinery, knowing how electromagnets work can help you make more effective and strategic decisions for your company.

An electromagnet is more than just a magnet: it is a device capable of generating controlled magnetic force thanks to the flow of electric current. In practice, it is a “magnetism on demand” source, which can be switched on and off with extreme precision depending on operational requirements.

Its structure is based on a simple concept: a conductive wire, usually copper, is wound around a ferromagnetic core (such as soft iron). When current flows through the wire, physics comes into play: a temporary magnetic field is generated, capable of attracting metallic objects or activating magnetic mechanisms. When the current is interrupted, the field instantly disappears.

This ability to be “switched on” and “switched off” according to command makes it a fundamental tool for control and automation in industrial processes, especially where precision, safety and speed are critical factors.

Electromagnets are used in an extremely wide range of applications: from lifting and separating ferrous materials in logistics and steelmaking, to electronic and medical equipment such as relays, coils, loudspeakers and even MRI scanners.

An electromagnet is a deceptively simple system, built on three fundamental components which, when combined correctly, generate one of the most powerful and controllable forces used in modern industry.

1. The coil: where current takes shape

The electric conductor is the first element. In the vast majority of cases, enamelled copper wire is used, chosen for its high conductivity and its ability to withstand thermal and electrical stresses.

This wire is wound neatly around a support, forming what is technically called a coil or solenoid. The number of turns, the wire’s cross-section and the winding density are parameters that determine the strength of the resulting magnetic field.

The more turns there are, the stronger the field. And the more precise the control over what the electromagnet must do: lift, attract, hold or release.

2. The core: the silent engine of magnetic force

Inside the coil lies the real protagonist: the ferromagnetic core. Usually made of soft iron, this element plays a key role: concentrating and amplifying the magnetic field generated by the current flowing through the coil.

Why soft iron? Because it has an excellent magnetic response: it magnetises rapidly when exposed to the field, but does not retain residual magnetism once the current stops. The result: maximum efficiency, zero waste, rapid reaction times.

The shape and size of the core are never random: they can be cylindrical, U-shaped, flat or fully customised to fit complex systems and specific production needs. This is where the real difference lies between a generic electromagnet and a carefully designed solution.

3. The power supply: the energy that drives the system

No magnetic field is created on its own. A stable and reliable power supply is required to provide the energy to set everything in motion.

This may be a battery, a power supply unit, a transformer or an industrial generator, depending on the plant’s specifications.

The key factor? Current management. In many industrial applications, the supply is integrated into an automated system and can be regulated via controllers, PLCs or management software, offering complete control over the electromagnet’s activation cycle.

In other words, energy is delivered only when required, optimising both consumption and performance.

Each component of the electromagnet has a role. But it is their union that creates a strong and precise magnetic field, capable of responding exactly to what your plant requires.

Whether you are designing a magnetic lifting system, a ferrous material separation application, or a high-security mechanical clamping system, knowing the structure of an electromagnet allows you to identify where improvements can be made and how innovation can be introduced.

Want to know more? Discover Zanetti Magneti’s range of customised solutions.

The operation of an electromagnet is based on a single principle: transforming electrical energy into controlled magnetic force. But it is in the way this force is managed and applied that the real industrial challenge lies.

• When powered by a current source, the internal coil generates a temporary magnetic field. This field is concentrated in the metal core (usually soft iron), which becomes immediately magnetised.

 With the right wire gauge, correct number of turns and optimised core design, the electromagnet can generate powerful and precise attraction, even in confined spaces or on irregular surfaces.

• When the electrical signal is interrupted, the field disappears and the object is released without residual magnetism. This process is repeated in extremely rapid cycles, with total reliability even in complex or demanding work environments.

Electromagnets are active components of the industrial system, designed to operate in synergy with other elements.

At the heart of every electromagnet’s operation lies a fundamental law of physics: electric current generates a magnetic field. This principle, described by Ampère’s law and Faraday’s electromagnetic induction, is the beating heart of every electromagnetic application in industry.

In industrial contexts, this physical principle translates into operational efficiency. The magnetic field produced can be switched on and off in a modular way, synchronised with other production processes, allowing the electromagnet to function only when required.

The activation cycle of an electromagnet is rapid and effective. Here is how it works:

Coil power supply

The system receives current from a source (electrical, battery, hydraulic or thermal). The current is channelled into the conductor coil.

Generation of the magnetic field 

The current passing through the coil turns generates a magnetic field around the wire. The field strength depends on the current intensity and the number of turns.

Activation of the core

The magnetic field is concentrated in the core, which temporarily magnetises, becoming a powerful source of attraction for ferrous materials.

Attraction of the metallic object 

The electromagnet exerts magnetic force on the material to be handled: whether scrap, sheets, mechanical components or other metal items, the attraction is instantaneous and controllable.

Deactivation and release

When the current is interrupted, the core immediately loses its magnetisation. The field disappears, allowing safe and precise release of the material.

The structure of an electromagnet is never standard. On the contrary, each configuration is chosen based on the operating environment, the type of material to be handled, and the system in which the electromagnet will be integrated.

We offer a full range of electromagnets designed according to application logic, each with structural features aimed at maximising performance and durability.

Among the available solutions are:

• Circular scrap electromagnets, designed to operate in harsh environments and ensure powerful, evenly distributed magnetic force.
• Rectangular lifting electromagnets, ideal for moving sheets, plates or elongated metallic materials in a stable and safe way.

• Hydraulic and grab electromagnets, designed for mobile plants and work machines, where mechanical strength and compactness are essential.

• Petrol- or diesel-powered electromagnets, perfect for construction sites and situations without an electrical grid.

• Battery- or low-voltage-powered versions, ideal for vehicles, cranes or mobile plants requiring autonomy and flexibility.

Each type differs in shape, materials, type of core and protective features, but all share the same construction philosophy: reliability, precise magnetic control and maximum compatibility with industrial plants, including existing ones.

Whether it is a lifting plate or a scrap electromagnet, the structure is designed to:

• Withstand shocks, vibrations and extreme conditions
• Resist high temperatures and contaminants
• Ensure optimal thermal and electrical insulation

The birth of electromagnets dates back to one of the most intense phases in the history of science: the early 19th century, when physics and electricity began to converge in revolutionary ways.

It all started in 1820, when Danish physicist Hans Christian Ørsted demonstrated that a wire carrying electric current generates a magnetic field. A seemingly simple insight, but one that forever changed the relationship between energy and matter.

A few months later, French scientistAndré-Marie Ampère built on this discovery by formulating the first laws of electrodynamics, laying the theoretical foundations of electromagnetism. The key concept was now clear: electricity can generate movement, force, attraction.

But it was in 1824 that theory turned into concrete technology. English scientist William Sturgeonbuilt the first working electromagnet by winding a conductor wire around an iron horseshoe-shaped core. The result? A device capable of lifting heavy metallic objects with a surprisingly small amount of energy. The first example of what today, in its evolved form, we find in industrial plants, automated workshops and high-performance lifting systems.

Zanetti Magneti offers a complete range of industrial electromagnets designed to meet the specific needs of every client. The quality of the materials used, combined with a deep understanding of customers’ production processes, allows us to be a reliable partner for all types of industrial operations, from SMEs to large companies. Contact us for a personalised consultancy or to ask for information.

What is an electromagnet and what is it used for?

An electromagnet is a device that generates a temporary magnetic field through electric current. It is used to attract or repel ferromagnetic objects and is widely used in industry, medicine and technology.

What is the difference between an electromagnet and a permanent magnet?

An electromagnet is active only when powered by current, while a permanent magnet has a constant magnetic field. The former is more versatile for controlled uses. We have dedicated an article to the difference between electromagnets and permanent magnets. 

How can the strength of an electromagnet be increased?

By increasing the number of turns, the electric current, and by using a high-quality ferromagnetic core. The winding arrangement also affects the strength of the field.

Which materials are attracted by an electromagnet?

Ferromagnetic materials such as iron, nickel and cobalt. Other metals, such as aluminium and copper, do not respond significantly to the magnetic field.

Do electromagnets consume energy even when not attracting?

They consume energy only when the circuit is closed and current flows through the coil. When switched off, there is no consumption.