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One of the world's leading manufacturer of toys attaches greatest importance to the subject of quality in all areas. Where quality is concerned, the toy manufacturer does not make any compromise, neither with respect to the safety of their products, nor with respect to their responsibility towards customers, manufacturers, consumers, and the environment. Quality is a fundamental criterion that is a central theme in corporate philosophy and business politics. Quality assurance measures are defined in a global quality assurance system.


For the plastics that are used in toys, the manufacturer not only applies the same stringent standards that also are applicable for packagings in the food sector, but makes even further demands concerning the properties of the raw materials. The company operates its own plastics development laboratory and a test laboratory.


All toys bear the CE mark of the European Union. The toy manufacturer thereby guarantees that the respective product complies with the regulations of the EU directive for toys. Products for the American market must comply with the 'Code of Federal Regulation' and with the ASTM standard F963.


When experiences problems in the production process that were caused by metal contaminations in the plastics granulate, this was the starting point for the installation of magnet systems. Plastics recycling material from the grinding mill was considered to be the source of contamination. Metal particles had deposited in the plastifying screw and in the nozzles and were responsible for costly downtimes of the injection moulding machines. In certain cases the metal contaminations even could have damaged the injection moulds or - in the worst case - a metal part even could have stuck out of a finished toy.

The SAFEMAG magnet system installed into the injection moulding machine of a toy manufacturer. 


S+S Separation and Sorting Technology, Schönberg, has developed a magnet system that can be installed directly on the material inlet of injection moulding machines, beneath the dosing unit. As a "Last Chance Controller" this magnet system allows metal separation to be performed as late as possible in the production process. One important advantage is that for the installation directly on the processing machine, only one magnet system is needed per machine.


Since the magnet system had to be integrated in an already existing line, the toy manufacturer demanded a very flat design. Changing the course of the pipes above the machine would have been very difficult and would have caused immense costs. A space of approximately 80 millimetres was available for installation.


S+S has successfully designed a highly efficient and with only 60 millimetres a very flat magnet system. The compact and sturdy aluminium-block design of the SAFEMAG allows the installation of conveyor, mixing, and dosing units directly on the inline magnet.


The magnet system had to provide outstanding ease of handling, and quick and efficient cleaning also had to be ensured. For this reason the magnet system features a pull-out at the front. Opening two quick-release locks is all that is required for pulling out the aluminium block with the magnet rods for cleaning purposes. Metal contaminations can then be manually removed from the magnet rods.

Following a test phase with ten SAFEMAG magnet systems, which yielded excellent results, the toy manufacturer decided to install magnet systems at all the 600 injection moulding machines.

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