Removing Iron Contamination from Foundry Sand & Metal Recycling
Fine iron and tramp metal are removed from foundry sand and metal recycling streams using a magnetic drum separator for continuous bulk flow, or an eddy current separator where non-ferrous metal like aluminium or copper needs to be recovered as well. After shot-blasting or processing, sand and recycling streams often carry residual metal fragments that damage downstream machinery or fall short of strict reuse purity targets. Below is how one PML customer solved exactly this, and which equipment fits your line.
Why It Matters
- Downstream equipment damage — tramp metal reaching crushers, grinders or moulding machinery causes wear and unplanned failures.
- Strict reuse/purity targets — regulated and public-sector facilities in particular often require a specific, auditable contamination removal rate before material can be reused.
- Continuous, high-volume flow — foundry and recycling lines typically can't stop for manual cleaning, so self-cleaning equipment matters more here than in most applications.
Which Equipment Fits Your Line
Magnetic Drum Separator — a self-cleaning rotating drum that continuously pulls ferrous fines, shot-blast residue and tramp metal out of high-volume sand or recycling flow, with no downtime for manual cleaning. The primary fix for foundry sand recycling.
Eddy Current Separator — where the recycling stream also needs non-ferrous metal (aluminium, copper, brass) recovered rather than just ferrous contamination removed.
Magnetic Cross Belt Separator and Magnetic Roller Separator are also part of PML's foundry and recycling range, suited to different conveyor and volume configurations — tell us your line and we'll recommend the right one.
Where This Has Already Worked
Rail Wheel Factory
- Problem
- After shot-blasting, Rail Wheel Factory's foundry sand carried heavy iron contamination — residual shot balls and fine metal fragments. As a public sector unit, the reuse target was strict: at least 95% metal removal.
- Solution
- PML advised against a single-stage setup and designed a double-stage Drum Separator system instead, running a live material trial to prove it could handle the mix of sand and shot-blasting balls.
- Result
- The trial exceeded the 95% target for iron contamination removal. Rail Wheel Factory validated the technology, secured a reliable way to recycle its foundry sand, and protected its downstream moulding machinery. See the full Drum Separator case studies →
Frequently Asked Questions
How much iron contamination can be removed from foundry sand?
PML's Rail Wheel Factory installation exceeded a strict 95% removal target using a double-stage Drum Separator configuration — tell us your material and target purity and we'll confirm what's achievable for your line.
Can this recover non-ferrous metals like aluminium or copper too?
Yes, but that needs an Eddy Current Separator rather than a standard magnetic drum, which only captures ferrous (magnetic) material. Many recycling lines run both in sequence.
Is this suitable for continuous, high-volume recycling lines?
Yes — the Drum Separator is self-cleaning by design, built specifically for continuous flow without stopping for manual cleaning.
Does this work for a government or regulated public-sector facility?
Yes — PML's Rail Wheel Factory installation was for a Government of India enterprise with a strict, auditable purity requirement, validated through a live material trial before installation.
Need to hit a specific purity target for sand reuse or metal recycling? Enquire now and our engineering team will size the right solution.