When Not to Use a Magnetic Conveyor

Magnetic conveyors are one of the most reliable and low-maintenance solutions for moving ferrous scrap in stamping and machining operations. When applied correctly, they deliver consistent performance, reduce downtime, and support clean, controlled scrap handling.

That said, magnetic conveyors are not the right solution for every application. Understanding when not to use a magnetic conveyor is just as important as knowing when to use one.

Material Type Is the First Limitation

The most obvious limitation is material type. Magnetic conveyors only work with ferrous materials such as steel and iron. If your operation involves non-ferrous materials like aluminum, brass, copper, or certain grades of stainless steel, a magnetic conveyor will not move that material.

This becomes especially important in mixed-material environments. If you plan to run both ferrous and non-ferrous scrap through the same conveyor and expect it to handle both, that is usually a clear sign that a magnetic conveyor is not the right choice.

In these cases, a mechanical system such as a steel hinge belt conveyor is typically a better fit.

Long or Stringy Material Can Create Movement Issues

Another important consideration is the shape and length of the material being conveyed. Magnetic conveyors rely on internal magnets moving beneath a sealed slider surface. The scrap above the surface follows the magnetic field as the magnets travel underneath it.

A simple way to think about this is a paperclip following a magnet underneath a table. The magnet is not physically pushing the paperclip forward. It is pulling it along through magnetic attraction.

Because of this, part shape and magnet spacing matter.

Problems can occur when handling long, narrow parts or stringers. In machining operations, this often means long, continuous chips that look like thin wires or strands. In stamping applications, it may be long, narrow scrap pieces that are lightweight but extended in length.

If these pieces are long enough to span across multiple magnetic zones at the same time, one magnet may be trying to move the part forward while another magnet is still holding it in place. When that happens, the part may not advance properly. It can sit stagnant on the conveyor surface, leading to buildup, inconsistent flow, or eventual blockage.

Magnet Spacing Should Be Compared to Scrap Length

A good way to identify this risk is to compare the length of the scrap to the spacing of the magnets inside the conveyor.

If the scrap is long enough to bridge across multiple magnetic zones at once, the conveyor may experience inconsistent movement or complete stoppage of material flow. This is especially common with long stringers that have not been broken down before entering the conveyor.

If there is no method in place to control, cut, break, or reduce the length of these materials, a magnetic conveyor may not perform reliably.

High-Volume Applications Can Increase the Risk

High-volume applications can also create challenges. In stamping environments where scrap is being produced at a very high rate, the conveyor must be able to keep up with the flow of material.

If the system requires higher conveyor speeds, such as 60 to 75 feet per minute, and the scrap includes a wide range of shapes and sizes, the risk of bridging increases. Multiple pieces can overlap, span across magnets, or interfere with each other’s movement.

In these situations, the issue is not simply whether the material is magnetic. The issue is the combination of speed, volume, and scrap geometry.

Even though the material may be ferrous, a magnetic conveyor may not be the best fit if the scrap stream is too inconsistent or the volume is too aggressive for reliable magnetic carry. A mechanically driven system, such as a steel hinge belt conveyor, may be better suited for the demand.

Scrap Consistency Matters

Magnetic conveyors perform best when the material being conveyed is relatively consistent in size, shape, and flow rate. The more predictable the scrap stream, the easier it is to match the conveyor design to the application.

When there is a high level of variation, especially with long, irregular, or oversized pieces, the system becomes less predictable. This does not mean the conveyor will fail immediately, but it does increase the likelihood of issues over time.

For this reason, reviewing sample scrap, peak load conditions, part geometry, and required conveyor speed is important before selecting equipment.

When a Magnetic Conveyor May Not Be the Best Choice

There are relatively few scenarios where a magnetic conveyor is not a strong option, but the warning signs are important to recognize.

A magnetic conveyor may not be the best choice if:

• The material is non-ferrous
• The scrap stream includes aluminum, brass, copper, or non-magnetic stainless steel
• The application includes long stringers that cannot be controlled
• Scrap pieces are long enough to bridge across multiple magnetic zones
• The system requires high speeds with highly varied scrap shapes
• The material flow is extremely inconsistent or oversized
• The application requires one conveyor to handle both ferrous and non-ferrous material

In these cases, another conveyor style may provide more reliable performance.

Final Recommendation

Choosing the right conveyor is about matching the technology to the reality of your process. When a magnetic conveyor fits the application, it can provide excellent performance with minimal maintenance. When it does not fit, the issues tend to show up quickly.

If your operation involves non-ferrous materials, long stringers, high-volume scrap flow, or highly varied part geometry, it is worth reviewing the application in more detail before selecting equipment.

Taking the time to evaluate these factors early can help prevent costly downtime and ensure your scrap handling system supports production instead of working against it.

FAQ: When Not to Use a Magnetic Conveyor

Q: Can a magnetic conveyor move aluminum?

A: No. Magnetic conveyors are designed to move ferrous materials such as steel and iron. Aluminum is non-ferrous, so it will not be carried by the magnets.

Q: Do magnetic conveyors work with stainless steel?

A: It depends on the grade of stainless steel. Some stainless steel is magnetic, but many common grades are not magnetic enough for reliable conveying. The material should be tested before assuming a magnetic conveyor will work.

Q: Are magnetic conveyors good for long stringy chips?

A: Not always. Long stringers can create problems if they span across multiple magnetic zones at the same time. This can cause the material to stall, build up, or stop moving consistently.

Q: When is a steel hinge belt conveyor better than a magnetic conveyor?

A: A steel hinge belt conveyor is often better when handling non-ferrous materials, mixed scrap, long stringers, oversized parts, or high-volume applications with inconsistent scrap shapes.

Q: How do I know if my scrap is too long for a magnetic conveyor?

A: Compare the length of the scrap to the magnet spacing inside the conveyor. If the scrap can bridge across multiple magnetic zones, there is a higher risk of inconsistent movement or blockage.

Written by the engineering and applications team at Storch Magnetics, specializing in magnetic conveyors and industrial magnetic solutions.