Bunting Partners with Smiley Monroe to Improve ToughFlex® Belt for Overband Magnets

Bunting has teamed up with Smiley Monroe to enhance the ToughFlex® conveyor belt for Overband Magnets, addressing issues related to excessive wear in demanding environments. This collaboration aims to increase the durability of belts used in applications that handle tough materials like industrial waste, household waste, and quarried rock.

The Challenge of Belt Wear in Harsh Conditions
Overband Magnets, which use a magnetic field to separate ferrous metals from various materials, typically have a cleaning belt running underneath the magnet. This belt transfers the captured metal from the magnetic field into a separate collection area. However, materials like sharp-edged, angular metals found in industrial and commercial waste tend to damage the rubber cleaning belt over time.

In particular, the powerful ElectroMax Overband Magnet—known for its high magnetic separation efficiency—has led to a greater amount of metal separation. This increased metal extraction has resulted in faster wear and tear on the cleaning belts. In contrast, traditional permanent magnets produce lower magnetic power and separate less metal, leading to less damage to the belt.

ToughFlex® Belt: A Durable Solution for Harsh Applications
To tackle this issue, Bunting reached out to Smiley Monroe, a renowned manufacturer of conveyor belts. After testing various options, Smiley Monroe recommended the ToughFlex® Belt, which is designed to withstand the toughest applications. The belt is made with a special weave of two fabric plies and an additional binder warp. These features make the belt more resistant to puncturing and wear, even in the presence of sharp, angular metals commonly encountered in waste processing.

The ToughFlex® Belt is designed with heavy-duty covers that resist wear and extend the lifespan of the system. Its reinforced structure helps prevent damage from ferrous metal piercing and tearing, making it more durable in applications with high levels of metal contamination. By adopting this improved material, the new belt offers less maintenance and more extended operation times before needing to be replaced.

Modifications for Enhanced Performance with Overband Magnets
Once the belt material was selected, the engineering teams of Bunting and Smiley Monroe worked together to further modify the ToughFlex® belt for use in Overband Magnets. The design included the addition of integrally moulded cleats, which help efficiently transfer captured ferrous metals away from the magnetic field and onto the collection area.

Strengthening Customer Solutions
“We are constantly looking to make improvements that will help our customers,” said Adrian Coleman, Bunting’s Technical Director. “With the increased use of ElectroMax Overband Magnets, we identified a need for a more durable belt that could handle the higher metal separation rates. This collaboration with Smiley Monroe allowed us to meet that demand and enhance the longevity of the systems.”

Conclusion: A Key Advancement in Recycling and Metal Separation
The partnership between Bunting and Smiley Monroe results in a more robust solution for the recycling and waste processing industries. With the ToughFlex® belt, Bunting is able to offer a long-lasting solution to customers facing the challenge of metal-induced wear in Overband Magnets. The modification increases operational efficiency, reduces maintenance needs, and ultimately extends the service life of the equipment used in recycling and waste processing.