Engineered for High-Gradient Solid Waste Processing and Metallurgical Sorting Operations
Industrial magnetic separation of metals involves the selective extraction of ferrous, paramagnetic, and non-ferrous metallic contaminants from bulk material streams. The physics of sorting rests upon manipulating three core components: magnetic flux density (Gauss), magnetic field gradient (force over distance), and the physical property characteristics (such as electrical conductivity and mass density) of target materials.
As a premier OEM manufacturer, Zhejiang Laysun Magnetics Ltd. designs customized rare earth assemblies to generate critical high-gradient magnetic fields. By customizing the layout of neodymium-iron-boron (NdFeB) blocks, we optimize the magnetic circuit to project fields deeper into conveyor cross-sections. This is essential for overbelt magnetic separators, magnetic drums, and eddy current separator rotors.
In eddy current separation of non-ferrous metals like aluminum and copper, the alternating magnetic fields induce localized eddy currents inside the target metals. This creates a repulsive Lorentz force that ejects them from inert non-conductive streams. Achieving high separation efficiency requires permanent magnets with exceptional remanence ($B_r$) and thermal resistance ($H_{cj}$), preventing demagnetization under continuous, high-rpm operational friction.
A trusted National High-Tech Enterprise supplying rare earth permanent magnet solutions globally since 1999
Founded at the turn of the millennium, Zhejiang Laysun Magnetics Ltd. has evolved from a visionary startup into a major force in high-performance permanent magnet production. Our state-of-the-art facility, spanning over 100,000 square meters in the Suining Industrial Zone of Sichuan, houses automated vacuum induction melting furnaces, hydrogen decrepitation systems, jet mills, and advanced sinter furnaces.
Our primary research, development, and production focus centers on sintered Neodymium-Iron-Boron (NdFeB) materials. By integrating the entire manufacturing process—from raw alloy preparation to slicing, grinding, electroplating, and multipole magnetization—we supply highly consistent and customized magnetic solutions to the global separation machinery, electric vehicle, wind energy, and heavy industrial markets.
Unrivaled Supply Chain Integration, Material Access, and Advanced Metallurgical Engineering
China accounts for over 70% of global rare earth extraction and refining. Our production facility in Suining, Sichuan, provides direct logistical access to neodymium oxide and dysprosium/terbium inputs. This proximity stabilizes our pricing structures and ensures raw material security.
By utilizing state-of-the-art Grain Boundary Diffusion (GBD) technology, we reduce heavy rare earth (Dy/Tb) consumption while simultaneously increasing coercivity. This process allows us to produce high-temperature magnets (up to 220°C operational limit) without sacrificing peak remanence.
Industrial separators operate in humid, corrosive, and dusty conditions. Our vertically integrated electroplating and epoxy coating lines guarantee that all pot magnets, blocks, and arcs receive uniform Ni-Cu-Ni or organic barrier coats, yielding salt-spray resistance exceeding 72-120 hours.
Our ISO9001 and IATF 16949 registered manufacturing processes are backed by rigorous quality assurance checkpoints. Every production batch of NdFeB magnets undergoes quantitative analysis using industrial B-H loop tracers to verify magnetic characteristics, including remanence ($B_r$), intrinsic coercivity ($H_{cj}$), and maximum energy product ($(BH)_{max}$).
We use coordinate measuring machines (CMM) and laser scanners to check mechanical dimensional tolerances. This guarantees that our segment and block magnets fit precisely into target rotor and pulley geometries without gaps. Additionally, fluxmeter-connected Helmholtz coils measure magnetic moment consistency across single production lots to prevent localized flux variations in finished separator assemblies.
Custom NdFeB Configurations Engineered for Global Heavy Machinery Manufacturers
Providing high-reliability magnetic cores for complex industrial assemblies
Custom OEM Component Supply for Global Machinery Integrators
In municipal solid waste (MSW) sorting and e-waste recycling facilities, Eddy Current Separators isolate valuable non-ferrous metals like aluminum, copper, and brass from non-metallic residues. The separator uses a rapidly spinning rotor lined with alternating NdFeB arc or block magnets. This creates a high-frequency, alternating magnetic field that induces repulsive forces in conductive materials. Zhejiang Laysun Magnetics manufactures highly precise arc and block configurations to dynamic balance specifications, ensuring structural stability under rotor speeds up to 3,000 RPM.
These systems extract tramp iron and ferrous contaminants from conveyor-transported coal, aggregates, minerals, and grain crops. Suspended magnets generate deep-penetrating magnetic fields capable of capturing heavy steel shards from thick material burdens. We supply high-volume sintered NdFeB blocks with deep field profiles to maintain extraction efficiency across conveyor drop points and high dust zones.
Operating as head pulleys in conveyor setups, magnetic drum separators continuously isolate ferrous particles from raw feed. As materials reach the conveyor discharge, magnetic items cling to the belt until they pass outside the static magnetic sector. Our high-coercivity Neodymium blocks are engineered to prevent thermal demagnetization in heavy mining and slag processing environments.
In food processing, chemical treatment, and pharmaceutical manufacturing, even micro-sized metal particulates present critical contamination risks. Magnetic grid tubes, housing high-intensity NdFeB cylinder magnets, extract fine iron oxides and wear debris from liquid pipelines and gravity chutes. We supply stainless-steel encased magnetic bar assemblies with surface fields exceeding 12,000 Gauss to capture sub-millimeter contaminants.
Zhejiang Laysun Magnetics Ltd. coordinates global shipping and technical compliance from our headquarters in Hangzhou, Zhejiang. We specialize in supply chains that demand comprehensive product traceability, manufacturing process approvals (PPAP), and strict material certifications. Our components comply with the EU RoHS Directive, REACH regulations, and international standards for rare earth permanent magnets.
We offer flexible OEM and ODM services, accommodating tailored dimensions, specialized plating, and magnetic performance profiles. Whether you require standard blocks for overbelt setups or complex arc segments for high-speed separation rotors, our engineering team provides customized magnetic field simulations (FEA) to optimize separation performance before mass production.
Certified Quality Management Systems for International Industrial Sourcing
We manufacture rare earth permanent magnets according to API 6D, API 607, CE, ISO9001, ISO14001, and IATF 16949 standards. For detailed testing parameters, material sheets, or compliance declarations, contact our global service team.
Engineering and Sourcing Insights for Metallic Separation Equipment
Eddy Current Separator (ECS) rotors typically use high-energy permanent NdFeB block magnets ranging from N42 to N52. In applications subject to elevated operating temperatures caused by high rotation rates and continuous material impact, we recommend higher thermal stability grades such as N42SH, N45UH, or N40EH, which prevent thermal demagnetization.
GBD technology targets the distribution of heavy rare earth elements (like Dysprosium and Terbium) along the grain boundaries of the NdFeB alloy microstructure, rather than dispersing them through the main grains. This localized placement increases the magnet's intrinsic coercivity ($H_{cj}$) and thermal tolerance while reducing heavy rare earth usage. This process helps lower overall material costs.
For mineral processing and outdoor municipal waste sorting, we recommend multi-layer coatings such as Nickel-Copper-Nickel (Ni-Cu-Ni), high-durability Zinc (Zn), or specialized Epoxy resin. In wet or chemically corrosive environments, we apply Teflon (PTFE) or spray-coated Everlube finishes, which shield the underlying sintered NdFeB matrix from oxidation and mechanical wear.
Yes. We design and manufacture custom multipole magnetization profiles, including alternate radial, axial, and complex Halbach array configurations. Using Halbach array configurations allows us to concentrate the magnetic field on the active working face of the separator drum while minimizing stray magnetic flux on the interior shaft, maximizing separation efficiency.
Zhejiang Laysun Magnetics Ltd. operates under ISO9001 quality management, ISO14001 environmental management, and IATF 16949 automotive standard systems. Our materials are fully compliant with RoHS and REACH regulations, ensuring compliance for export to North American, European, and Asian markets.
Because our production facility is located in Suining, Sichuan—near rare earth mining and refining centers—we secure stable direct-purchase allocations of Neodymium and Praseodymium oxides. We offer long-term pricing agreements to our strategic OEM customers, shielding them from the price fluctuations of the global rare-earth spot market.
The effective separation depth depends on the grade and dimensions of the internal NdFeB block assembly. Our high-gradient block designs project magnetic fields that penetrate materials up to 450 mm from the conveyor surface. This ensures the extraction of heavy tramp iron even when buried beneath thick layers of aggregate or coal.
When supplying complete magnetic roller assemblies, we run dynamic balance tests using multi-plane balancing machines before shipment. We ensure that our NdFeB segment blocks are weighted and arranged symmetrically, keeping residual dynamic imbalance below ISO G2.5 standards. This minimizes structural vibration during high-speed operation.
Ensuring High Structural Stability and Field Uniformity for Industrial Sourcing Projects
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Laysun Magnetics