The Most Essential Innovation in Magnetic Separation Since 1860 - Now in an App
Magnetic Products Inc. (MPI) is the first to bring reliable, intelligent automation to industrial magnetic separation since the technology’s commercialization began in the 1860s in manufacturing. Intell-I-Mag® is the industry’s first and only sensor-enabled, app-accessible magnetic separator that tells operators much metal is on the magnet in real-time. Intell-I-Mag®
eliminates unnecessary blind manual magnet checks and downtime while ensuring optimal performance.
Magnetic separators play a crucial role in industries like food processing, pharmaceuticals, and manufacturing, where the removal of tramp metal is vital for maintaining product quality and safeguarding machinery. Traditional magnetic separators depend on blind manual checks, resulting in operational inefficiencies.
This robust magnetic separation technology conveniently tells plant operators and personnel exactly when a magnet needs to be cleaned—and when it does not. Intell-I-Mag® self-monitors and provides real-time performance alerts, eliminating unnecessary maintenance downtime while protecting the product from metal contamination. This allows operators to optimize their magnet cleaning schedule, reduce downtime, and maintain the performance of their metal control system.
The Intell-I-Mag® dashboard can be accessed from a factory-integrated PLC, local HMI display, through a secure online link from an on-site or remote computer, or on-the-move via the smartphone mobile app.
The Intell-I-Mag® mobile application (available for Apple and Android) empowers operators and managers to monitor, control, and access data from magnetic separators in real-time via their mobile devices. With user-friendly graphics and alerts, the app allows for on-the-go monitoring of each magnet within a facility. Users can configure and manage their magnetic separators directly from their smartphones—collecting, processing, and analyzing real-time data. The app also provides customizable alert settings to ensure optimal performance of the separators. Additionally, operators and managers can remotely track key performance metrics such as metal capture volume, current and maximum temperature.
Solving an Industry-Wide Challenge
According to a 2023 study in Science Direct titled Food Contaminants and Their Pathways Within Food Processing Facilities, 48% of operational risks for food and beverage manufacturers are due to chemical or physical food contamination pathways. The National Food Standards Agency (NFS) has
long confirmed that metal is the number one physical contaminant cited in incidents globally, causing 32% of all category shutdowns and recalls.
Keeping metal contaminants out of feed and other bulk materials is an ongoing challenge—one that, if not appropriately planned for and prioritized, can cost a company millions of dollars in rejected products and expose them to recall risk and brand reputation damage. Not to mention, it reduces the longevity of processing equipment that is damaged by metal in the product stream.
Most food processing plants have magnetic separators that remove ferrous tramp metal from raw materials at various locations throughout the production process. However, without a reliable method for knowing when these magnets are saturated with metal, plants must temporarily shut down their production lines at set intervals for regular magnet cleaning, whether needed or not. This inefficient practice has led to lost production time, unnecessary increased plant operational costs, and damage to brand reputation and consumer confidence.
Intell-I-Mag® empowers operators with sensor technology that detects the magnet’s metal level and alerts personnel when the magnet reaches a plant-defined capacity level. This ensures they know precisely when the magnet needs to be cleaned and, equally as important, when it doesn't.
Key Features
Intell-I-Mag® is a patented technology exclusively available from Magnetic Products, Inc. Intell-I-Mag® tells operators exactly when a magnet needs to be cleaned. The Intell-I-Mag® controller and mobile app monitor metal levels on the working surface of the magnetic separator in real-time. The magnetic separator has embedded sensors that measure the strength of the magnetic field. These sensors report data collected in real-time to the Intell-I-Mag® controller and app. Intell-I-Mag® can be customized with user-defined capacity levels. Easy-to-read graphics visually alert operators when the magnetic separator reaches user-defined capacity levels and high-temperature thresholds. Intell-I-Mag® boosts productivity, minimizes downtime, and enhances overall efficiency in facilities where controlling metal contamination is essential.
Simple Set-Up and Reliable Usability
- The Intell-I-Mag® App makes controller set-up simple and quick. The app is available for Apple and Android and can be downloaded for free.
- A user-friendly setup wizard guides users in adding new devices, assigning magnet names, configuring IP addresses and PLC integration, calibrating capacity alert levels, and establishing operational capacity limits.
- The app o ffers portable, in-hand monitoring of each individual magnet, a summarized metal control snapshot of all in-range magnets, and features user-friendly, customizable, color-coded graphics with easy-to-read metrics for quick interpretation.
Engineered for Efficiency, Performance, and Peace-of-Mind
- Intelligent Engineering - Internal sensors continuously monitor tramp metal levels, alerting operators of potential issues before they occur. When the magnet reaches a pre-set threshold, it notifies plant personnel about necessary cleaning, or a predefined self-cleaning cycle can be initiated from a distance.
- Remote Access and Flexibility - The industry 4.0-compliant controller supports communication and integration with factory PLCs or control systems, and MPI’s Intell-I-Mag® mobile app enables remote monitoring and control of the magnet. Users can view a summary of all connected Intell-I-Mag® controllers, displaying critical data such as separator metal capacity levels, temperature, and magnet strength over Bluetooth, allowing oversight of any in-range location and by
multiple users. - Enhanced Accountability - Oversee vendors during material unloading, resulting in earlier metal detection and reduced product damage in the production process.
- Risk Mitigation - Prevent complications from equipment failures, inadequate cleaning intervals for magnets, or hard-to-reach equipment.
- Increased Efficiency - Intell-I-Mag® eliminates unnecessary blind manual magnet checks and reduces unnecessary downtime by providing precise, real-time alerts and predictive maintenance tools, enabling operators to act before significant failures occur.
- Improved Uptime - Real-time monitoring and data analysis allow operators to swiftly respond to full-capacity alerts or temperature anomalies, improving separator eff ectiveness, maintaining magnet strength, and increasing uptime.
Real-Time Alerts and Labor-Free Performance Monitoring
- As metal is captured and magnetic performance declines, Intell-I-Mag® sensors are triggered, LED indicators signal the separator’s tramp metal capacity on the controller and push data to the mobile app.
- Alerts can be viewed in-app, through the dashboard, and on physical indicators on the separator.
- The mobile app allows users to establish custom alert thresholds (e.g., at 40% full) to trigger notifications when the separator reaches a set capacity.
- Configurable parameters are segmented into thirds of 100% magnet capacity. Alert levels are user defined. For example:
- Green – 0 - 50%
- Yellow – 51% - 99%
- Red – >100%
- Real-time temperature monitoring eliminates one of the primary causes of magnetic separator degradation and enables users to better understand potential causes of temperature spikes.
Detailed Reporting, Analytics, and Predictive Maintenance
- Intell-I-Mag® aggregates data from multiple sensors within the separator and automatically generates maintenance and performance reports to ensure accurate records for audits and compliance with operational standards.
- Maintenance activities, such as cleaning cycles and temperature changes, are logged automatically with timestamps, and operators have the option to add notes for more robust quality management,
guarantee precise records for audits, and adherence to operational standards and compliance, like HACCP, ISO, BRC, IFS, and SQF. - Data collection enhances analysis of magnetic separator performance and maintenance by tracking key metrics, including metal capture levels, cleaning alerts, temperature fluctuations, and cleaning cycles. The system retains historical data so operators can better predict maintenance requirements, allowing for proactive management to prevent downtime.
- All data is pushed to the controller and can be accessed locally or remotely for user ease and accessibility.
Designed for Versatility and Compatibility
- Intell-I-Mag® is available for gravity, pneumatic, and liquid applications.
- The system, including the controller, is rated NEMA 4X, making it suitable for liquid-tight designs, wet environments, or areas requiring high-pressure washdown.
Intell-I-Mag® adds value at multiple points in the production process.
Primary magnet installation: enhance plant protection against tramp metal, vendor monitoring documentation, and improve receiving throughput.
Facilities oversee vendor unloading to detect ferrous metal presence. The most eff ective way to prevent metal from contaminating the final product is to stop it before it enters the plant. The Intell-I-Mag® can be tailored to meet specific user requirements, allowing users to enhance product quality
and strengthen documentation at receiving locations. If a strict no-metal policy is enforced upon receipt, the Intell-I-Mag® actively monitors captured metal in real-time, enabling immediate cessation of the unloading process.
In some facilities, while metal presence may be acknowledged, the user mandates its removal prior to product entry. In such cases, the Intell-I-Mag® can alert the user to halt the unloading to clean the magnet before it
reaches its full metal capacity.
Regardless of the scenario, users can be assured that tramp metal has not infiltrated the facility from vendors, and they can maintain improved quality documentation supported by Intell-I-Mag® data. With metal absent, the receiving process can continue unimpeded, thereby increasing throughput.
Secondary magnet installation: lower maintenance costs and increase uptime.
The Intell-I-Mag® protects downstream processing equipment—such as hammer mills, airlocks, or mixers—from damage inflicted by metal in the product stream. To ensure optimal protection, it is crucial that the magnet does not become overly saturated, impeding its ability to capture additional
metal.
Intell-I-Mag® allows operators to set targets for metal alerts or enable automatic cleaning of the magnet. For eff ective protection, the magnetic separator should not exceed 50% saturation, preserving 50% of its capacity to capture more tramp metal. Users can configure Intell-I-Mag® to notify them once saturation hits 50%, allowing time to shut down operations or plan for a scheduled shutdown to clean the magnet. This proactive measure prevents unplanned maintenance costs and minimizes downstream damage, helping to maintain product integrity.
If the magnet does not meet the designated saturation threshold, users might avoid shutting down the system for cleaning. This information aids users in maximizing their processing uptime. With multiple Intell-I-Mag® sensors positioned at key control points throughout a facility, users can
swiftly identify equipment failures and limit metal contamination in the final products.
Finishing magnet installation: enhance product quality, documentation, and consistency, while reducing downtime.
It is vital to document and guarantee exceptional final product quality. An eff ective upstream metal control program may leave weakly magnetic work-hardened stainless steel as a significant threat to product quality. The Intell-I-Mag® amplifies the ability to capture diffcult-to-detect tramp metal that even metal detectors might miss. It ensures that the magnetic separator operates at peak efficiency, quickly eliminating captured metal from the product stream before it is "washed off ."
To e ffectively utilize Intell-I-Mag® in such configurations, the controller should be set to a low threshold for capacity alerts, such as 10%. Once this level is reached, the user is notified to clean the magnet. The system can also be configured to remotely trigger a self-cleaning cycle when user-defined alert levels are met.
This setup is optimal for ensuring that the finishing magnet collects small and weakly magnetic tramp iron that metal detectors or X-ray machines may struggle to identify.
Rapid cycling of the magnet after capturing metal ensures that contaminants do not re-enter the product flow, protecting the final product. In case of any metal recalls or reports of contamination, users can confidently assert that the metal either lacks ferrous properties or likely originates from external sources, such as transportation vehicles. Incorporating Intell-I-Mag® data into quality reports provides an additional layer of assurance that customers receive uncontaminated products.
Utilizing Intell-I-Mag® at the finishing magnet means that the packaging or load-out systems do not need to be halted for unnecessary cleanings. When Intell-I-Mag® confirms that no metal has been captured, the system can continue operating without interruption, leading to greater uptime.
Proven Benefit and ROI
Intell-I-Mag® is patented technology exclusively available from Magnetic Products, Inc. Magnetic Product Inc.’s intelligent magnet design self-monitors its performance in real time 24/7 to maintain peak performance.
The Intell-I-Mag® Controller monitors tramp metal saturation levels on the working surface of the magnetic separator in real time. The magnetic separator has sensors embedded into the separator that measure the strength of the magnetic field. These sensors report data collected in real time to the Intell-I-Mag® Controller. The controller can be programmed to automatically alert operators to clean the magnetic separator remotely when it reaches industry-designated saturation levels.
Intell-I-Mag® is engineered with versatility and compatibility in mind:
- The Intell-I-Mag® Controller and App monitor within a 25m (80ft.) radius.
- The Intell-I-Mag® system can be rated NEMA 4X for wet applications or where high-pressure washdown is required.
- Suitable for high-temperature applications. Good for operating temperatures up to 105C (221F). With intermittent temperatures < 30 seconds for cleaning up to 125C (257F).
- The permanent magnet will continue to capture tramp metal if the controller is disconnected or not working for any reason.
- Intell-I-Mag® can be added to any self-clean unit at any time.
Before Intell-I-Mag®, there was no way for an operator to know the saturation level of their magnetic separator other than by shutting down the production line to check.
Intell-I-Mag® changes that. One Intell-I-Mag® early-adopter was able to reduce their total number of magnet cleaning stoppages by more than 2/3rds in the first year of piloting the system, and, as a result, reduced downtime and human resource expenditures required to maintain their magnetic separators, increasing revenue by more than $1.5M. That’s the power of an intelligent magnet.
In addition to capacity alerts, Intell-I-Mag® automatically collects and logs cleaning history and collection trends, letting the operator – and QA/QC personnel – know when it was cleaned, when there was a spike in saturation, and what events – for example, deliveries – were the most significant
contributors to metal in the product stream. The improved production quality and e fficiency won Intell-I-Mag® Best of Show at The International Association of Operative Millers (IAOM) and Best in Supplier Plant Effi ciency at the International Baking Industry Exposition (IBIE) in its inaugural year.
Magnetic Products, Inc is Leading an Evolution in Metal Control with Intell-I-Mag®’s disruptive technology
- Improved confidence that the magnetic separator is performing at peak, capturing the most challenging tramp metal in, including work-hardened stainless steel.
- Assurance that vendors are not unloading tramp metal into your
facility at receiving locations. - Earlier metal detection, which protects equipment throughout the production line.
- Reduced downtime by only shutting down a line to clean a magnet when needed.
- Increased equipment e fficiency and monitoring reduces maintenance costs.
- Prolonged magnetic viability and protection against degradation with the built-in temperature monitoring.
- Optimized labor productivity - employees can perform duties besides checking magnets.
- Confidence that plant operators have cleaned the magnet through the data validation of the Intell-I-Mag® sensors.
- Decreased staff hours required for maintaining magnetic separators.
- Automated QC data collection and improved data quality for internal QA programs, auditors, and customers.
- Elimination of paper cleaning records through automatic data logging.
Industry Legacy
Magnetic Products Inc. (MPI) has revolutionized the industry for 43 years with its unwavering commitment to R&D and the core value of high-performance engineering by introducing the world’s first quick-clean permanent magnetic separators with the self-cleaning chute magnet in 1983, the patented magnetic can-laner conveyor in 1989, and the patented reciprocating drawer magnet in 1991.
Magnetic Products, Inc. (MPI) is a Michigan-based OEM focused on developing and manufacturing cutting-edge magnetic separation and material handling equipment for food and bulk material processors, metal stamping companies, and related industries.
Combining advanced manufacturing with over 40 years of industry experience, the company is pioneering new sensor-enabled product lines to complement its proprietary shakers and conveyor systems. In addition, MPI conducts audits on metal control systems and sets the industry standard for system maintenance requirements.