Home » MPI Products Inc » Products » Metal Separation and Metal Sorting Solutions » Magnetic Separation for Bulk Gravity Applications » Intell-I-Mag Products
Intell-I-Mag® Products
MPI's Intell-i-Mag® App and Controller revolutionize magnetic separator management by enabling real-time monitoring of magnetic performance, cleaning cycles, and equipment conditions through Bluetooth® or network integration. Compatible with most MPI separators, it features user-friendly dashboards, maintenance alerts, and downloadable compliance logs to simplify adherence to industry standards like HACCP, FSMA, and GFSI. As the first sensor-enabled magnetic separator, Intell-i-Mag® allows operators to optimize cleaning schedules, drastically reducing downtime and labor costs. It automatically tracks cleaning history and saturation trends, providing valuable insights for quality assurance. Early adopters have seen significant efficiency improvements, such as cutting cleaning stoppages by over two-thirds, leading to substantial savings. The system enhances metal control by detecting tramp metal, ensuring optimal equipment function, and facilitating compliance through automated data logging, while boosting productivity by minimizing unnecessary maintenance tasks.
Intell-I-Mag® Controller and App
Intell-I-Mag® is an advanced sensor upgrade for magnetic separators, designed to monitor ferrous metal saturation levels in real-time. This controller, which operates independently from the magnetic separator, allows users to view saturation data through a mobile app, PLC integration, or a computer dashboard. Setup is easy via the mobile app and only takes minutes. The Intell-I-Mag® mobile app is available for both Apple and Android devices. The app facilitates configuring device settings, monitoring magnet saturation, and establishing alert thresholds. Once set up, users can access a dashboard remotely or through an HDMI-linked display. The system can be monitored and controlled via Bluetooth or Ethernet, ensuring comprehensive data visibility and integration with existing plant control systems.
View Intell-i-mag® controller and app
Self-Clean Inline Pneumatic Drawer Magnet
Intell-I-Mag® Compatible Products for Pneumatic Applications
Self-Clean Plate Magnet with Housing (Inline Plate)
Intell-I-Mag® Compatible Products for Pneumatic Applications
Quick-Clean Plate Magnet with Housing (Inline Plate)
Intell-I-Mag® Compatible Products for Pneumatic Applications
Intell-I-Mag® Compatible Magnetic Separator Comparison Chart
Unique Benefits and Considerations
Industries, Applications and Regulations
For assistance in selecting the most suitable Electro & ElectroPermanent Magnetic Chucks and Controller for your application or for additional customization options, contact Magnetic Products Inc. today to speak with our team of experts!
Industry Type
Intell-i-Mag® Setup
MPI’s Intell-i-Mag® system offers flexible configuration options tailored to various operations and user preferences. Setup can be performed locally via the unit’s onboard interface or remotely using the free Intell-i-Mag mobile app (available on iOS and Android). During the initial configuration, users can assign custom names to each magnet (e.g., “Unload Pit 1”), define alert thresholds for magnet saturation (e.g., 25% yellow, 50% red), and configure IP addresses for PLC integration.
Using the mobile app, users can:
Identify nearby Intell-i-Mag controllers via Bluetooth
Configure new or existing magnets
Assign PLC settings and network IP addresses
Initiate recalibration (MPI technician only)
Set up alert and performance thresholds
The system automatically loads a local dashboard interface for ongoing display when connected to a user-provided touchscreen through the HDMI input. Ethernet-enabled devices can also be viewed through a standard web browser within the facility's network.
Processing Application
Intell-i-Mag® Monitoring
Once configured, Intell-i-Mag® supports continuous, real-time monitoring of magnetic separators through several interfaces. Operators can view data locally via the HDMI-connected display, through the mobile app while within Bluetooth range, or remotely via an in-network browser dashboard.
Key dashboard features include:
Percentage Full Dial: Indicates magnet saturation in real time
24-Hour Historical Graph: Visualizes magnetic loading trends
Current and Max Temperature Readouts
Magnet Profile: Includes name, serial number, IP address, sensitivity, and calibration data
Restart Flow Button: Reboots the display in case of error
Page Selection: Navigate to the setup or diagnostic menus
The Customer Setup section allows quick access to editable magnet names, saturation indicators, and manual calibration functions to ensure quick, accurate adjustments when necessary.
Regulations and Requirements
Using Intell-i-Mag® Data for Continuous Improvement and Compliance
Intell-i-Mag®’s intelligent monitoring platform transforms magnetic separation into a fully traceable, performance-optimized process. By collecting, storing, and visualizing real-time performance data, operators can easily:
Identify trends in metal contamination
Adjust cleaning schedules to optimize performance
Document separator activity for HACCP, FSMA, and GFSI audits
Improve preventive maintenance scheduling and reduce unplanned downtime
Users can connect the Intell-i-Mag® controller directly to their PLC system for advanced integration. Required setup includes the IP address of the PLC and the Intell-i-Mag® serial number. MPI provides detailed Ethernet/IP communication instructions, supporting various controller types.
The result is a seamless, scalable system that enhances operational visibility, maximizes separator effectiveness, and streamlines compliance across food, pharmaceutical, plastic, and powder processing industries.