A Guide to the Best Magnetic Separators for Brewery Contamination Challenges

Brewery contamination issues can significantly affect the brewing process, with damage to upstream and high impact machinery delaying production and resulting in high maintenance and replacement costs.

This guide explores the best magnetic separators for brewery applications, compares them with traditional methods, and provides actionable insights for beer processors and brewers.

How Advanced Magnetic Separation Differs From Traditional Methods

Magnetic separation technology offers a distinct approach to contaminant removal. Unlike traditional methods that rely on plate magnets and destoning processes, advanced magnetic separators attract and capture ferrous and even some non-ferrous metal contaminants, such as work-hardened stainless steel, tramp metal and magnetic stone, using powerful magnetic fields.

Self-cleaning separators and liquid line magnets have proven very effective in brewery applications for both machine protection and product quality purposes.

Advantages of Advanced Magnetic Separators in Brewery Settings

Implementing magnetic separators in a brewery setting comes with several benefits:

Superior Contaminant Removal

Magnetic separators are highly effective in removing even the smallest ferrous and paramagnetic particles from the brewing process, including magnetic stone and work-hardened stainless steel. They help reduce risk to machinery and damage caused by metal fragments, as well as increase product purity and compliance with industry regulations. Unlike traditional plate magnets and destoning machinery, advanced magnetic separators provide a more thorough and reliable solution.

The Mag-Ram® Self-Cleaning Magnet can be utilized at multiple stages of the brewing process, including raw material grain intake areas, to ensure the incoming grain is free from metal fragments and magnetic stones. For de-hulled or broken grain, the Mag-Ram can be positioned upstream of high-impact machinery to protect against damage, reduce wear from stones, and prevent potential grain dust explosions caused by metal sparks.

For syrups and malt extracts, inline Pressure Pipeline Separators effectively remove fine metal fragments before final packing or processing.

Cost-Efficiency

By minimizing damage to machinery caused by metal fragments, magnetic separators contribute to overall cost savings. Self-cleaning magnets, such as the Mag-Ram®, require less maintenance and downtime for cleaning compared to other separation methods, decreasing labor costs and operational expenses. Their durability also translates to a long-term investment with significant return value.

Enhanced Product Quality

Metal contaminants, even in trace amounts, can affect compliance for manufacturers. For brewers, products such as syrups require adequate magnetic separation equipment to ensure safety for consumers. By incorporating magnetic separators, breweries can manufacture a consistently high-quality product that meets consumer expectations and regulatory standards. This level of quality control enhances brand reputation and customer trust.

Wear and Tear Protection 

Magnetic separators play a crucial role in protecting brewing equipment from excessive wear and tear particularly caused by stone and tramp metal contamination. By implementing magnetic separation technology along with destoner machinery, breweries can effectively capture these contaminants before they reach critical processing equipment, reducing mechanical stress and extending the lifespan of machinery such as mills and high impact machinery. In addition, adequate magnet protection can protect against dust explosion.

To address the abrasiveness of grain on magnetic separation equipment, Magnattack® Dura-Slik® surface technology is available, which enhances the durability of magnet surfaces and reduces wear.

Scenarios Where Advanced Magnetic Solutions Outperform Traditional

Advanced magnetic separator designs are particularly advantageous in the following scenarios:

High-Risk Contamination Points & Final Quality Control

In areas where metal contamination is the biggest risk to product security and consumer safety, such as the final location prior to packing of syrups magnetic separators provide an added layer of security.

Processing of Raw Materials

Grains and other raw materials can carry metal fragments from harvesting equipment, storage and transportation, as well as magnetic stone contamination. Magnetic separators efficiently remove these before further processing and brewing begins. Magnetic separators for malted barley assist with machine protection and product purity control.

Equipment Protection

By removing metal particles early in the process, magnetic separators help prevent severe equipment damage, reducing repair costs and downtime.

Choosing the Right Magnetic Separator for Your Brewery

Selecting the right magnetic separator involves evaluating multiple factors to ensure maximum efficiency and effectiveness in contaminant removal. 

Here are the critical considerations:

Type of Contaminants

Understanding the specific contaminants present in raw materials, brewing equipment, and final packaging will help determine the most suitable magnetic separator.

Stage of the Brewing Process

Magnetic separators can be installed at different stages of production, including grain intake, upstream of high-impact machinery, and prior to final packing or processing. Identifying the most vulnerable points in your brewery optimizes contamination control and improves overall efficiency.

Flow Rate and Volume

The separator must be capable of handling the brewery’s production volume without impeding the brewing process. A unit with the appropriate flow rate capabilities ensures contaminants are effectively removed while maintaining production efficiency.

Ease of Maintenance

Regular cleaning and maintenance are essential to keeping a magnetic separator functioning optimally. Choosing a model that allows for easy cleaning will minimize downtime and enhance operational efficiency.

Compliance With Industry Standards

Food safety regulations require breweries to maintain stringent contamination control measures. Ensure that the magnetic separator complies with industry-specific hygiene and safety standards, such as those set by the FDA, HACCP, and other regulatory agencies.

Customization Options 

Every brewery is unique, and having a magnetic separator tailored to specific needs can significantly improve contamination control. Custom configurations, such as different magnetic separator designs and installation flexibility, ensure seamless integration into the brewing process.

FAQs

How often should magnetic separators be cleaned in a brewery?

Cleaning frequency depends on the contamination load and production volume. Regular inspections will help determine the optimal schedule.

Do magnetic separators require special training to operate?

Most magnetic separators require some training to ensure operator safety to prevent accidents and safety hazards. Understanding proper installation and maintenance is crucial.

Are magnetic separators safe for food-grade applications?

Yes, food-grade magnetic separators are designed to meet stringent safety and hygiene standards, making them ideal for brewery applications and other food and beverage industries.

What is the lifespan of a magnetic separator in a brewery?

With proper maintenance, careful handling, suitable product, and other factors, magnetic separators can last for a very long time, offering a cost-effective solution over time.

Ramp Up Your Brewery Contamination Control Method With Our Magnetic Separators 

Ready to take your brewery’s contamination control to the next level? Magnattack’s advanced magnetic separators are designed specifically for brewery applications, providing unmatched efficiency in removing ferrous contaminants while ensuring your products maintain their exceptional quality. Our state-of-the-art technology not only protects your product but also enhances equipment longevity and operational efficiency.

Discover how Magnattack can transform your brewing process with superior contaminant removal solutions. Explore our brewery-specific magnetic separators and take the first step toward safer, cleaner, and higher-quality beer production.