Iron Filing Removal Machine

IFR Introduction

Iron is one of the most abundant materials in nature and is extensively used across various industries due to its superior mechanical properties and availability compared to other materials. Most products are manufactured on machinery and equipment that incorporate iron, which leads to iron contamination in the products.

Iron contamination can occur in different forms—loose, compound, or alloy—depending on the process. While it is an inherent part of production, iron contamination is undesirable in most products, with permissible levels governed by BIS and other international standards, particularly in the food processing industry.

Iron Removal System

One of the most common methods to mechanically separate iron is through magnetic equipment. All food processing units rely on these systems, which can use either permanent magnets or electromagnets. Several types of magnetic devices, such as magnetic drums, pulleys, grills, plates, and over-band magnets, are employed for iron separation.

While these devices are used by various industries, they are often deployed in isolation. Until recently, no comprehensive system combined the strengths of these various devices into an efficient iron separation solution.

Application in Tea Processing

This iron removal machine is designed specifically to remove iron from tea. The system is installed between the tea storage areas and the blending station and is capable of processing up to 4,500 kg of tea per hour. The machine ensures that the processed tea contains no more than 30 ppm of pure iron or 400 ppm of iron mixed with tea.

However, it should be noted that the output quality depends on factors like the input quality, flow rate, iron contamination size, and the magnetic systems used. Therefore, it is recommended to calculate a cleaning ratio to measure the system's efficiency.

System Specifications

The machine occupies approximately 15 square meters of floor space and is 5.5 meters in height. It comprises several components including an input bin, vacuum feeding system, magnetic drum separators, a geared motor drive, and a control panel.

Tea is fed from 35 kg bags into the input bin at ground level. A vacuum feeding system transports the tea to a hopper, from where it is released onto a series of magnetic drum separators. As the tea passes over the drums, iron particles adhere to the drum surface due to the powerful internal magnets. The iron is then separated and collected in designated trays, while the cleaned tea proceeds for further processing.

This system is not suitable for materials with high viscosity or large particle sizes by volume or weight.

Schematic Diagram of Working System of IFR

Advantages of the Iron Removal System (IFR)

• Comprehensive system ensuring efficient iron separation down to 30 ppm.
• Equipped with PLC controls for flexible flow rates and enhanced safety features.
• Production capacity can be scaled from 3.5 to 4.5 tons per hour.
• The three-drum separator design, combined with a magnetic grill, offers superior iron removal performance from input levels of 400 ppm to output levels as low as 30 ppm.