Automation in part separation: how to optimize management in industrial processes

Industrial automation: one of the main levers of industrial efficiency. At every stage of the production process, the ability to manage flows in a rapid, continuous and controlled manner is a competitive factor, decisive in the eyes of customers, partners, competitors and suppliers.

A major boost to automation in handling in manufacturing processes has been given at the part separation stage. A crucial but often underestimated moment, where the use of automated separation systems makes it possible to improve productivity, reduce waste, and ensure consistent quality and on-time performance.

The importance of automated part separation

Plastics, rubber, metallurgy, mining. In all these sectors, raw materials and finished products proceed inexorably through the production chain, continuously and simultaneously, often joined together or still conjoined with scrap (production waste). This goes all the way to the crucial stage of separation: separating parts efficiently, without damaging surfaces or compromising quality, is essential.

Years ago separation was left to operators or manual systems, whereas today automated separation systems offer a much faster, reliable and replicable solution. The ability to integrate separation systems with conveyor belts and handling and storage systems enables continuous part handling, eliminating stagnation between production stages.

Advantages of automation in industrial separation systems

Automating the separation of raw materials, parts, and products means achieving constant control of the process and speed up production activities. Through technologies using sensors, ballistic separation systems, and magnetic separation, these automated mechanisms enable materials and objects to be separated from one another without the need for human intervention.

What are the main advantages of automatic separation systems?

• Time reduction: automated systems operate continuously, eliminating the “dead” or slower times that characterize manual activities.
• Increased accuracy and repeatability: speed, inclination and separation methodology are adjustable, constant and predictable, ensuring consistent results over time.
• Reducing scrap and damage to parts: separation is done with controlled movements, avoiding impact and abrasion.
• Increased safety and protection of human input: operators no longer have to intervene manually in potentially dangerous areas, being able to devote themselves to more value-added activities.
• Integration with automated lines: separation systems easily connect to conveyor belts or storage systems, thus enabling fully automated management of the production flow at all stages.

What types of automated separation systems exist?

There are several solutions for automatic separation of raw materials and parts, each of which is adapted to specific product, material and production line configuration requirements within industries. The main technologies used today are based on rotary drum systems, rotating roller systems and End-mounted rotating roller systems.

Let's look in detail at similarities and differences between the various existing solutions in separation systems.

DRUM SEPARATORS

The rotary drum systems represent one of the most popular solutions for automatic separation.
The operating principle of rotating drum systems is very simple but extremely effective: parts that need to be separated are fed into a cylindrical drum that rotates on a horizontal axis. The surface of the drum, equipped with calibrated holes, only allows ready or finished parts to pass through, while retaining scrap or separating raw materials according to gauge or weight.

In fact, the constant rotation promotes the separation by size and mass difference, without the need for manual intervention. These systems are particularly suitable when parts differ significantly from scrap in size or weight, as is often the case in plastic injection molding.

The main advantages of rotary drum systems are:

• High productivity, due to the ability to operate continuously;
• Reduced maintenance, because of the mechanical simplicity of the system;
• Adaptability, with drums that can be customized according to the shape and size of the pieces.

ROLLERS SEPARATORS

The rotating roller systems take advantage of a series of parallel rollers that rotate on themselves. Among the different types of rotating roller separation systems, 2-roller separators with millimeter adjustment and spiral roller systems deserve mention. Both solutions allow for a extremely precise selective separation, which is why they are mainly used in applications where the following is required a gentle but careful separation, for example, in the field of aluminum die casting.

The main advantages of rotating roller systems are:

• Adjustable and modular separation;
• Excellent handling of irregularly shaped parts;
• Possibility of integration with sensors For in-line quality control.

END OF CONVEYOR SEPARATORS

A particularly efficient solution for continuous production lines are the End-mounted rotating roller systems. In this case, the separation system is integrated directly at the end of the conveyor belt: outgoing parts are automatically conveyed to the rollers, which proceed to separation based on the set criterion (size, weight or geometry) or functionality.

This configuration makes it possible to Optimize production space as much as possible and simplify line layout, reducing intermediate handling and lowering the reliance on manual operations. It also enables synergistic management of transportation and separation, improving the overall efficiency of the production process.

Thanks to their flexibility and compactness, end-of-belt rotating roller systems are ideal for automated lines with high production runs, where every second translates into a competitive advantage.

Increasingly efficient production: factory automation with separation systems

By integrating automated separation systems within your manufacturing operation, you can improve productivity, optimize cycle times and reduce waste, contributing to more sustainable, high-performance production.

Choosing to rely on automated separation solutions means taking a long-term view. Improving this delicate phase has direct repercussions on the workflow by making it smoother, significantly lowering unscheduled maintenance and keeping the quality of operations constant.

Crizaf: experience and innovation in parts separation and handling

For more than 50 years, Crizaf is an international benchmark in the design and production of Conveyors, separation systems and automated storage solutions.

The proposal of Drum systems, roller systems, and integrated end-of-belt modules, allows us to support companies in building increasingly efficient, flexible and automated lines.
For a dedicated project, please contact us!