In the world of waste management and mineral processing, machinery durability is key. When Bunting, a leader in magnetic separation technology, partnered with Smiley Monroe, a renowned manufacturer of conveyor belts, they sought to solve a pressing issue: wear and tear on Overband Magnet cleaning belts.

Overband magnets, integral in separating ferrous metals from materials like waste and quarried rock, had long been plagued by the damaging effects of sharp, angular metal fragments. The belts used in these systems, especially in industries handling industrial and commercial waste, suffered from frequent punctures and tears. As metal separation efficiency increased, so did the belt damage.

Bunting’s customers using the ElectroMax Overband Magnet faced higher levels of metal separation, but the increased power of the magnet also accelerated belt wear. While permanent magnets had lower power and caused less damage, the need for stronger separation was undeniable.

To extend belt life in these harsh conditions, Bunting approached Smiley Monroe. Known for their expertise in producing durable, high-performance conveyor belts, Smiley Monroe’s rigorous testing ensured their products met stringent industry standards for abrasion resistance, tensile strength, and adhesion.

After evaluating several materials, Smiley Monroe recommended the ToughFlex Belt – a robust solution designed for tough applications like bulk handling and mobile crushing. Featuring a special weave of reinforced fabric plies and heavy-duty wear-resistant covers, the ToughFlex Belt was able to resist the punctures and tears caused by sharp ferrous metals.

Together, Bunting and Smiley Monroe modified the ToughFlex Belt for Overband Magnets by adding integrally moulded cleats to facilitate the transfer of captured metal. The result? Less maintenance, longer production hours, and a solution that worked as hard as the machines it served.

“We’re always looking for ways to improve,” said Adrian Coleman, Bunting’s Technical Director. “The ToughFlex Belt is a perfect fit for industries facing extreme conditions, helping our customers keep their operations running longer.”

The ToughFlex® Belt

The Powerful ElectroMax Overband Magnet