Intell-I-Mag® - Intelligent Magnetic Separation

The only magnets that tell you when they need to be cleaned.

Intell-I-Mag® is a patented technology designed for intelligent magnetic separation. It features an innovative design that self-monitors performance continuously, with an Intell-I-Mag® Controller providing real-time tramp metal saturation levels on magnetic separators. Embedded sensors measure the magnetic field strength and communicate real-time data to the controller, which can alert operators remotely when cleaning is needed, based on predefined saturation thresholds. Operators can also check performance using a built-in LED indicator. This system allows uninterrupted processing by eliminating the need to stop production to inspect magnets, significantly reducing maintenance interruptions. Early adopters have seen over a two-thirds reduction in cleaning shutdowns, resulting in cost savings and higher throughput, translating into increased revenue. Additionally, the Intell-I-Mag® system logs cleaning history and saturation trends, offering insights for better operational management. The technology has received notable awards for its contributions to production quality and efficiency in the milling and baking industries.

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Built for Versatility and Compatibility

The Intell-I-Mag® platform monitors tramp metal saturation on the working surface of the magnetic separator in real time with embedded sensors that continuously measure the strength of the magnetic field. These sensors report data to a hardwired control box near the separator. That data is transmitted via Bluetooth to a mobile app or through a direct connection with the internal plant control system, alerting the operator that the magnet requires cleaning. Even without access to the digital platform, an operator can view the built-in LED indicator light to know if the magnet is working at peak, is filling up, or needs immediate attention.

Intell-I-Mag PLC Controller Box

Intell-I-Mag® enhances production through its primary, secondary, and finishing magnet installations. At the primary level, it monitors vendor unloading to prevent tramp metal from entering the facility, thus improving product quality and documentation by allowing operators to stop unloading when metal is detected. The secondary installation protects downstream equipment by alerting when magnets are 50% saturated, preventing maintenance costs and damage. At the finishing stage, Intell-I-Mag® targets weakly magnetic metals that typical detection methods may miss, ensuring high-quality final products by cleaning the magnet before it reaches saturation. This system boosts efficiency by reducing unnecessary downtime during cleaning, confirming that customers receive contamination-free products. Intell-I-Mag® provides real-time monitoring and enhances metal control, improving quality and reducing maintenance.

  • Available on drawer, plate, chute, and pneumatic inline plate magnets, as well as magnetic rotary feeders
  • Can be rated NEMA 4X for wet applications or where high-pressure washdown is required
  • Suitable for high-temperature applications – up to 105C (221F) with intermittent temperatures (<30 seconds) up to 125C (257F)
  • Can be added to most compatible models at any time
  • Permanent magnet continues to function even if the Intell-I-Mag® platform is offline

Proven ROI

4 Sisters Product

Your Magnets are Costing You Millions

When 4 Sisters and a Rice Farm in Louisiana added Intell-I-Mag® to their Kennedy Rice Mill, they reduced magnet maintenance-related downtime and increased throughput and, as a result, earned more than $1.5M in additional revenue in one year of use. The Mill reduced the total number of magnet cleaning stoppages by 2/3rds from once a day to once every three days without increasing their risk for metal contamination.

Key Benefits

  • Only Smart Magnet in the World

Patented technology, unique in magnetic separation. Permanent magnet functionality continues even if the Intell-I-Mag® platform is offline.

  • Real-Time, Constant Monitoring

Provides alerts for cleaning needs and optimizing maintenance. Monitors real-time product flow, ensuring vendor accountability.

  • Decreases Operator Effort

Reduces human effort and error in monitoring and cleaning equipment. Simplifies on-floor processes and responsibilities. Enhances operational efficiency with reduced labor, downtime, and improved results.

  • Increases Vendor and Plant Accountability

Monitors in real-time as the product comes into and moves through your facility. Increases plant accountability and process accuracy.

 

  • Better Quality Control

    Ensures peace of mind and quality assurance for customers. Facilitates better decision-making with real-time monitoring and data trends. Eliminates paper cleaning records through automatic data logging.

  • 100s of Compatible Configurations

It is available for drawer, plate, chute, pneumatic inline plate magnets, and magnetic rotary feeders. It is compatible with most MPI models and can be added anytime.

  • Suitable for Wet Applications

Rated NEMA 4X, suitable for wet applications and high-pressure washdown.

  • Works in All Harsh Environments

Hazard Location Certified model available. Handles high temperatures up to 105°C (221°F), with intermittent temperatures up to 125°C (257°F) for short durations.

 

Intell-I-Mag® Compatible Products

Intell-I-Mag® Literature