A magnetic head pulley is a simple option that can be added to remove ferrous from the material stream at the discharge end of a conveyor. Remcon supplies them two ways — built into the new conveyors we fabricate, or as a retrofit, built to drop straight into a conveyor you already run.
What Is a Magnetic Head Pulley?
A magnetic head pulley is a conveyor head pulley with permanent magnets built into the drum. It takes the place of the standard head pulley at the discharge end of a belt conveyor, so it keeps doing the pulley's normal job — turning with the belt — while also working as a magnetic separator. Because the magnet is the pulley itself, there is no separate drive, no second belt, and no overhead frame to hang: ferrous separation happens inside the footprint the conveyor already occupies. Remcon builds this style of conveyor magnetic pulley with ceramic grade 8 magnets inside a replaceable 3/8"-thick aluminum shell, in diameters from 6" to 16" O.D. and face widths from 18" to 50".
How It Works
As material is conveyed off the end of the conveyor, the magnetic head pulley attracts ferrous objects and holds them tight to the belt. Non-ferrous material leaves the belt on its normal trajectory. The ferrous stays put: the belt carries it around the pulley and back underneath, out of the main stream of material, until it passes beyond the magnetic field and falls off into a chute to be collected. The separation runs whenever the belt runs — no operator, no controls, no added horsepower.
Retrofit a Magnetic Head Pulley Into Your Existing Conveyor
You don't need a new conveyor to get the ferrous out. A magnetic head pulley replaces a component your conveyor already has, so a magnetic head pulley retrofit is usually a pulley swap — the same job your crew does when a head pulley wears out — not a rebuild. Remcon builds each pulley to custom dimensions to allow drop-in replacement of the existing head pulley, whether or not the conveyor is one of ours.
To spec a retrofit, we need the measurements off your current head pulley:
- Belt width — sets the magnet face width; we build faces from 18" to 50" wide
- Pulley diameter — we match your existing O.D., from 6" to 16"
- Shaft diameter — the shaft is removable, installed in hubs welded to the pulley endplates using taper lock bushings, and is sized for each application; typical head pulley shafts run from 1-15/16" to 2-15/16"
- What's in the stream — the material you're conveying and the ferrous you're trying to pull out of it
The ferrous also has to land somewhere. If your discharge doesn't already have a divider under the head end, we can fabricate a collection chute to drop the ferrous into a drum, bin, or container. Magnetic head pulleys can be retrofitted to inclined conveyors (infeed, transfer, etc.) and horizontal conveyors (sort conveyors, etc.).
Send us your pulley dimensions for a retrofit quote →Built Into a New Remcon Conveyor
When Remcon builds the conveyor, the magnetic head pulley goes in at the design stage instead of being bolted on later. The pulley, the discharge chute, and the ferrous collection point are laid out together, so the clean stream and the ferrous each land where they should. It's a simple add to most of the belt conveyors we build — infeed, transfer, and sorting conveyors alike — and an easy line item to include in a turn-key system quote.
Magnetic Head Pulley vs. Overhead Magnetic Separator — Which Do I Need?
Both machines use magnets to pull ferrous out of the stream; they sit in different places and discharge differently. A magnetic head pulley works inside the conveyor itself — it grabs ferrous riding at or near the belt surface and drops it into a chute under the discharge end. An overhead magnetic separator is a separate machine suspended above the belt, with its own cleated belt and drive, that lifts ferrous up out of the burden and conveys it away to a bin, container, or another conveyor — in a crossbelt or parallel orientation, with permanent magnets or electromagnets.
| Factor | Magnetic head pulley | Overhead magnetic separator |
|---|---|---|
| Where it mounts | Replaces the conveyor's own head pulley | Suspended above the belt on its own frame |
| Drive | None added — turns with the existing belt | Its own belt, motor, and reducer |
| Pulls best from | Material at or near the belt surface | The top of the burden, lifting up through it |
| Ferrous discharge | Drops into a chute under the head end | Conveyed away to a bin, container, or another conveyor |
| Best fit | Simple ferrous removal at discharge; retrofits; tight headroom | Deeper burdens, higher ferrous volume, self-discharging duty |
Plenty of plants run both — an overhead magnet doing the bulk of the ferrous removal, with a magnetic head pulley downstream as a final check. If you're not sure which the job needs, describe the stream and we'll tell you.
Special Features
- Heavy-duty construction
- Replaceable aluminum shell
- Custom dimensions available to allow drop-in replacement of an existing head pulley
- Can be added to inclined conveyors (infeed, transfer, etc.) or horizontal conveyors (sort conveyors, etc.)
Magnetic Head Pulley Specifications
Below are some standard specifications that are typical for magnetic head pulleys we have built in the past. Contact us to discuss these specifications in detail.
| Specification | Remcon standard |
|---|---|
| Diameter | 6" to 16" O.D. |
| Face width | 18" to 50" wide |
| Drum | 3/8" thick, replaceable shell |
| Drum material | Aluminum |
| Magnets | Ceramic grade 8 |
| Shaft diameter | Typical head pulley range 1-15/16" to 2-15/16" — sized appropriately for each application |
| Shaft mounting | Removable shaft, installed in hubs welded to pulley endplates using taper lock bushings |
| Dimensions | Custom — built for drop-in replacement of an existing head pulley |
Magnetic Head Pulley FAQ
What is a magnetic head pulley?
A magnetic head pulley is a conveyor head pulley with permanent magnets built into the drum, so it separates ferrous metal from the material stream while doing the pulley's normal job of turning with the belt. Non-ferrous material follows its normal trajectory off the discharge end; ferrous is held to the belt, carried underneath the pulley, and dropped into a collection chute. Remcon builds them with ceramic grade 8 magnets inside a replaceable 3/8" aluminum shell.
Can a magnetic head pulley be added to my existing conveyor?
Yes — most belt conveyors can be retrofitted by replacing the existing head pulley with a magnetic head pulley built to the same dimensions. Remcon builds each pulley to custom dimensions for drop-in replacement, whether or not we built the conveyor: tell us the belt width, pulley diameter and face width, and shaft diameter, and we build the pulley to match. The removable shaft installs in hubs welded to the pulley endplates using taper lock bushings.
Do I need a magnetic head pulley or an overhead magnetic separator?
Choose a magnetic head pulley when the ferrous can simply drop into a chute at the conveyor discharge and you want separation with no added drive — it's the simpler option and the easiest retrofit. Choose an overhead magnetic separator when the burden is deeper or the ferrous needs to be carried away automatically to a bin, container, or another conveyor. Many plants run both, with the head pulley acting as a final check downstream of the overhead magnet.
What sizes of magnetic head pulley does Remcon build?
Remcon builds magnetic head pulleys from 6" to 16" outside diameter, with face widths from 18" to 50". Typical head pulley shaft diameters run from 1-15/16" to 2-15/16" and are sized appropriately for each application. Custom dimensions are available so the pulley can drop into place of your existing head pulley.
How much does a magnetic head pulley cost?
Every magnetic head pulley is quoted per job — price depends on the diameter, face width, shaft sizing, and whether Remcon is also fabricating the collection chute or building the whole conveyor. Send us the belt width, pulley dimensions, and what's in the stream and we'll quote it. Call (509) 244-9439.
Custom Designed and Fabricated
We specialize in custom designed and fabricated equipment and can work with you to design a solution that will work well for your needs. Every magnetic head pulley — and every conveyor we build one into — is designed and fabricated at our Airway Heights (Spokane), Washington shop, then shipped and installed nationwide. Contact us to discuss options or to get a quote.
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