It's no surprise that the crossbelt (overband) magnet experiences the most wear and tear on the belt that transfers separated metal away from the conveyor. In order to reduce the damage to this rubber belt, Bunting has developed a special, lightweight armored belt for crossbelt magnets. Bunting is a global leader in the design and manufacture of magnetic separators, eddy current separators, metal detectors, and electrostatic separators. Its manufacturing facilities are located in Newton, Kansas, just outside Wichita in the center of the United States.

Armored Belts Protect Crossbelt Magnets from Excessive Wear and Extend Belt Lifespan

Positioned over a conveyor that transports materials like aggregate, waste, shredded wood, or mined ore, crossbelt magnets operate by creating a magnetic field—either through a permanent magnet or an electromagnetic block. This field attracts ferrous metal from the conveyed material onto the revolving self-cleaning belt. Rubber upstands on the belt catch the lifted metal and transport it away from the conveyed material into a separate collection area.

The force generated when ferrous metal strikes the self-cleaning rubber belt is considerable due to the magnetic attraction increasing as the metal approaches the magnet’s face. As a result, the metal accelerates into the belt, momentarily sandwiching the moving belt between the lifted metal and the magnetic block until the upstand catches and removes the item from the magnetic field.

Applications where self-cleaning belts experience significant wear:

• High levels of ferrous metal in the conveyed material
• Large and heavy ferrous metals
• Nails, or thin and sharp ferrous metals
• Models with additional force in their magnetic block (like the ElectroMax and ElectroMax-Plus)

To prevent excessive wear and prolong the lifespan of crossbelt magnets, Bunting’s engineers designed a lightweight yet heavy-duty armor for the belt. While alternatives such as special wear-resistant coatings and other rubber belt types exist, the armor provides unmatched protection, significantly extending belt life.

This armor consists of high-density polyethylene (HDPE) slats, each measuring 100mm in width and 10mm in thickness, tailored to fit specific crossbelt magnet models. These slats are affixed to the belt using special 304 stainless steel elevator bucket bolts and nyloc nuts.

Adrian Coleman, Bunting’s Technical Director in the UK, says, “The introduction of this armored belt design has been very popular. Other types of belt armor have not worked well, but the HDPE solution has proven exceptionally effective.”

Contact us today to discuss your application or request a quote.

Whether you're dealing with high volumes of ferrous material or working in a harsh industrial environment, Bunting’s armored belts offer the durability and reliability needed to keep your system running smoothly. With a focus on innovation and quality, Bunting continues to lead the way in magnetic separation technology.

Don’t let unnecessary wear and tear disrupt your operations. Invest in a solution that protects your equipment and improves efficiency. Contact Bunting today to find out how our armored belts can benefit your process.