Maggie Magnetic Separator

The ZGF Maggie is an innovative and patented magnetic separation technology.  Maggie is an effective, efficient and environmentally responsible solution that can optimize life-cycle cost and minimize the environmental footprint of industrial operations where ferrous (magnetic) contaminants are present/introduced.

The fully automatic, in-line, high intensity, self-cleaning, patented magnetic separator is the best available technology for separating magnetic contaminants from process fluids.  Maggie can remove particles down to 1 micron without damaging critical process fluids such as machining coolants, cleaning / degreasing solutions or polymer quench fluids. 

Media filters such as cartridge filters and roll media create a physical barrier which captures all particles larger than the micron opening.  You don’t want to remove everything!  For example, you don’t want to remove defoamer particles, surfactant micelles or emulsion droplets. You want to remove the contaminants, the ferrous fines and particles that deteriorate the process fluids, negatively impact quality and productivity, and drive up maintenance costs. 

Maggie has a stainless-steel body that houses our proprietary magnetic cores.  The magnetic cores are thin walled, seamless stainless tubes that seal magnetic shuttle assemblies.  Each magnetic core contains several magnet/pole combinations that generate a magnetic field greater than 10,000 Gauss at the surface of the tube.  The magnetic cores are assembled into different Maggie sizes/models to best accommodate the flow and loading characteristics of the application/process.

The five Maggie models (MG100, MG300, MG600, MG1200 & MG2600) are designed to handle flow rates from 1 gpm to 250 gpm.  Multiple Maggie's can be assembled in a manifold arrangement to meet any flow requirement.   The Maggie product family also includes the Smart Drum and Smart Drum PLUS (SD) fluid recovery devices.  The purpose of the SD is to physically remove the magnetic fines from the Maggie purge fluid and return the fluid back to the process.  Click on the Maggie and Smart Drum animation to see a simplified process flow.

To learn more about this best-in-class technology, watch the Maggie video. The video shows and explains how our Maggie technology works. After watching the video, I am sure you will be thinking of many processes and applications in your facility where ZGF magnetic separation technology could provide value.

 

Maggie Family

MAGGIE FAMILY OVERVIEW

Model Product Flow Rate (gpm) Inlet / Outlet / Purge
Water-based Oil

MG100

Maggie 1-core

12

8

0.75”/ 0.75”/ 0.75”

MG300

Maggie 3-core

35

25

1”/ 1”/ 1”

MG600

Maggie 6-core

70

50

1.25”/ 1.25”/ 1.25”

MG1200

Maggie 12-core

125

85

2”/ 2”/ 1.5”

MG2600

Maggie 26-core

250

175

3”/ 3”/ 1.5”

Manifold Arrangement

MG1200 or MG2600

unlimited

unlimited

user determined

Smart Drum

Fluid Recovery

Batch Process

1.5”/ 1.5” (2” vent)

Smart Drum PLUS

Fluid Recovery

Batch Process

1.5”/ 1.5” (2” vent)

All of Maggie’s wetted components (other than elastomers) are stainless steel.  Maggie is compatible with a wide range of liquids and operating conditions up to 200oF and 100 psi.  Maggie is available with four valve seat materials (Viton, Buna, EPDM and Teflon) and four O-ring materials (Viton, Buna, EPDM and ETP).  Valve Seat and O-ring material selection is based upon compatibility with the process fluid.

Click on the desired Maggie or Smart Drum model MG100, MG300, MG600, MG1200, MG2600, Smart Drum or Smart Drum PLUS for a detailed product specification sheet. For a comprehensive overview of ZGF Maggie technology, click on the Maggie Product Data Sheet.  If you are looking for more information, go to Documents. You can download and access drawings, installation, operation & maintenance (IOM) manuals, as well as other technical and reference documents.

Maggie is available with three control options:

  • Analog Timer – for use with MG100, MG300, MG600 & MG1200. ZGF’s most basic control system.  The analog timer has minute dial for setting the purge interval and second dial for setting the purge duration.  The timer is also equipped with a push button for initiating a manual purge.  The analog timer is mounted directly on the Maggie valve assembly.  There is no control enclosure to mount.
  • Proprietary, Solid-State, Printed Circuit Board (PCB) control system – for use with all stand-alone, individual models, and when an individual Maggie is used in conjunction with Smart Drum or Smart Drum PLUS.  The PCB controls are housed in a NEMA 4, painted steel enclosure with a membrane keypad and LCD display that allows the user to configure timers and displays operational status.
  • Logic Module (Siemens LOGO!) – for use with any single Maggie, multiple Maggie systems, when adding Maggie Watch, or when the operator requires greater range of control.  The controls are housed in a NEMA 4, painted steel enclosure or a NEMA 4X stainless steel enclosure.  A door mounted user-interface allows the user to configure timers and displays operational status.  An LED stack light provides system status (i.e. power on, purge and fault / alarm).  The LOGO! controls also provide some interface capability with other control systems.

All control system options feature automatic purge (i.e. self-cleaning cycle) based on time interval and manual override.

ZGF also offers "Maggie Watch" fault monitoring system.

Maggie Watch continuously monitors for all potential Maggie faults: 

  • Low or loss of air pressure,
  • Magnetic Shuttle does not move,
  • Magnetic Shuttle Air Leak (Internal Air Leak Detection),
  • Tube Seal Leak (Internal Process Fluid Leak Detection),
  • Purge and/or discharge valve does not open or close. 

Click here for the Maggie Watch Product Data Sheet to learn more about a product that improves process reliability, reduces total operating costs and makes your job easier. 

Smart Drum fluid recovery system saves valuable fluids

Machining coolants, metalworking fluids, quench fluids, wash solutions and many other fluids processed through Maggie are extremely valuable.  These fluids are expensive to purchase and expensive to treat or dispose.  When the Smart Drum (SD) and Smart Drum PLUS are used with Maggie, virtually none of these valuable fluids are lost.  The SD is a fluid recovery device.  The SD is a fully automatic, batch process, magnetic separator that is used in conjunction with Maggie in-line separators. The purpose of the SD is to physically remove the magnetic fines from the Maggie purge fluid and return the fluid back to the process.  Click on the Maggie video to see how the SD works in tandem with Maggie to separate out the solids from the purge fluid and return the valuable fluid back to the process.

Purge fluid from Maggie flows to the SD at system pressure.  The inlet diffuser and upper tank serve to reduce the pressure and act as a surge tank.  The fluid drains via gravity from the upper tank into the lower pan and across the magnetic drum before exiting the system.  All fluid must pass across the magnetic field prior to discharging from the front of the unit.  There is no by-pass flow. Click on the Smart Drum video to see how the drum rotates and captures the chips/fines. As the drum continues to rotate, the fines/chips are removed by the plastic scraper, and they drop onto the tray situated at the front of the drum.  The fines/chips fall off the tray and into a customer supplied chip bin located below (ZGF can also provide a chip hopper to collect the chips / fines).  The fluid from the SD is directed back to the process.  Flow out of the SD is via gravity. 

A wringer roller is available.  The wringer roller is designed to reduce the liquid/moisture content of the solids/sludge that is removed by Maggie.  The wringer roller is spring tension adjustable.

Smart Drum versus Smart Drum PLUS

 

MG100

MG300

MG600

MG1200

MG2600

Multiple
Maggie’s

Smart Drum

 

 

 

Smart Drum PLUS

 

 

Click on the Maggie and Smart Drum animation to see a simplified process flow of the Maggie and Smart Drum.

Click on the desired model - Smart Drum or Smart Drum PLUS for a detailed product specification sheet.  For a comprehensive overview of ZGF Maggie technology, click on the Maggie Product Data Sheet.  If you are looking for more information, go to Documents. You can download and access drawings, installation, operation & maintenance (IOM) manuals, as well as other technical and reference documents.

To learn more about this best-in-class technology, watch the Smart Drum video. The video shows how the solids are captured by Smart Drum.

When the Maggie and Smart Drum products are configured together as a system, ZGF can provide the best available & most environmentally responsible technology with the lowest 10-year lifecycle cost in the industry.

Maggie is the ideal solution in several industries for many applications.

Simplicity, consistency, reliability and the lowest life-cycle cost make Maggie the only choice when you need to remove magnetic contaminants from your process. Click on the link life-cycle cost spreadsheet to see how ZGF Maggie technology can provide value to you.

Click on the links to watch the Maggie video and the Maggie / Smart Drum animation or download the Maggie Product Data Sheet to learn more about this innovative technology.

Our Maggie automatic, self-cleaning, in-line magnetic separators are primarily utilized in the Automotive / Heavy Truck and Steel / Tube industries.

Whether you are a:

  • Paint Center Manager with weld ball contamination in your paint pre-treatment system
  • Manufacturing Engineer with honing, grinding or machining issues
  • Galvanizing Line Supervisor trying to improve strip cleanliness
  • Cold Mill Maintenance Planner dealing with issues due to dirty mill coolant
  • ERW Tube Mill Maintenance Manager trying to extend impeder life and improve mill productivity
  • Metallurgist wrestling with part quality and coil life issues due excessive scale in your induction hardener quench fluid
  • Quality Engineer that must improve process reliability and component cleanliness in several parts washers

The table below outlines the features and benefits of ZGF Maggie technology.

After reviewing Maggie’s Features & Benefits you will understand why Maggie is:

  • THE BEST AVAILABLE TECHNOLGY FOR REMOVING FERROUS CONTAMINANTS FROM PROCESS FLUIDS,
  • THE MOST ENVIRONMENTALLY RESPONSIBLE TECHNOLOGY FOR REMOVING FERROUS CONTAMINANTS FROM PROCESS FLUIDS,
  • AND HAS THE LOWEST 10 YEAR LIFECYCLE COST

Click on the link Success Stories to learn more about how our customers were able to realize value via implementation of ZGF Maggie technology.  We’ve probably helped somebody that has the same challenges as you! 

FEATURE BENEFIT
High intensity magnets generating >10,000 gauss Captures particles as small as 1 micron
Selective contaminant removal  Will not strip any components or ingredients from the process fluid
Consistant and reliable performance  Creates steady-state conditions reducing process variability resulting in improved quality and lower operating costs
Full 1-year warranty on Maggie assembly  Reduces operating and maintenance costs
Fully automatic, self-cleaning operation  Requires no regular manual intervention freeing up labor for other value-added plant services and reducing maintenance and operating costs
Pressure fed, zero by-pass design  Provides a three-dimensional magnetic field that increases particle capture efficiency and allows for particle removal down to 1 micron
In-line design  Eliminates need for additional pumps, motors and controls reducing maintenance and operating costs
Compact design Saves valuable floor space
Low energy requirement  Reduces load on plant utilities and lowers operating costs. It uses less energy than a light bulb
Efficient and environmentally responsible design 

It uses <0.50% of total volume for purge.

Creates no additional waste (i.e. no disposable media, no packaging for new media, etc.).

It uses less energy than a light bulb.
Secondary batch processing system (Smart Drum) 
Allows for recovery of valuable process fluids and reduces waste
Permanent media, stainless steel body and cores
Does not require replacement, thereby reduces labor and disposal costs, and increases productivity
Minimal moving parts through simplicity of design Increases reliability, thereby reducing maintenance and operating costs

Simplicity, consistency, reliability, and lowest cost of ownership make Maggie technology the only choice when ferrous contaminants are present in your process fluid!

Click on the link to read more – Maggie / Smart Drum – Basic Description & Operation

Maggie is simple, effective and reduces your total operating costs. Click on the Maggie animation link for a narrated animation that provides a basic explanation of Maggie technology.

Maggie – Filter Mode

  • Dirty fluid enters in top
  • Magnetic shuttle assembly in lower position
  • Particles are trapped on the outside wall of tube
  • Clean fluid is discharged through the outlet port
  • Purge port closed, discharge port normally open

Maggie – Purge Mode

  • Dirty Fluid enters in top
  • The discharge port is closed, purge port is opened
  • Using compressed air, the magnets are shuttled to the upper position
  • The solids have nothing to cling to and are easily washed away through the purge port

The purge (automatic, self-cleaning) process is:

√   Quick:             4 to 6 seconds

√   Efficient:         < 0.50% of the process volume

√   Effective:       100% clean with each purge

√   Simple: No mechanical scrapers or wipers. No media. Compressed moves the magnetic shuttles up and down

 

ZGF is your preferred partner.

 Filtration should not be a burden.

 Filtration should be a tool that improves quality and reduces cost.

Let us help you meet your objectives and make your job easier!

 

 Please contact us today for a free consultation or request a quote.

 We are always available by phone too.  Give us a call!