Why Machine Shops Need Dedicated Chip Handling Systems
Every machining operation generates metal chips, turnings, and swarf. Small shops might manage with manual chip removal using buckets and shovels, but once production volume increases, manual chip handling becomes expensive, messy, and potentially hazardous. Operators shouldn’t waste time shoveling chips when they could be running machines. Wet chips mixed with cutting fluid create slippery floors and disposal headaches. Accumulated chips around machines create safety hazards and interfere with proper machine operation.
Magnetic chip conveyors solve these problems by automatically removing ferrous chips from machine tool sumps and work areas, transporting them to central collection points for disposal or recycling. These specialized conveyors handle the unique challenges of machining chips—irregular shapes, sharp edges, coolant saturation, and continuous generation during operation.
At Custom Conveyor & Equipment Corporation in Cedar Rapids, Iowa, we’ve built chip and scrap conveyors for machining and fabrication operations, from a magnetic conveyor for fine shavings to steel hinged belt conveyors for machining and laser cutting cells. Our fabrication capabilities—including 3kW fiber laser cutting and 300-ton press brake forming—enable us to manufacture chip conveyors customized for specific machine configurations and production requirements. This article explains how magnetic chip conveyors work, when they make sense, and how to select and maintain them effectively.
Moving chips or scrap away from your machines
We’ve built a magnetic chip conveyor that removes fine shavings without exposing its moving parts, and a steel hinged belt chip conveyor designed to be lowered into the pit below a machining center. Tell us about your machines and your chips.
How Magnetic Chip Conveyors Work
Basic Magnetic Conveyor Design
Magnetic chip conveyors use permanent magnets or electromagnets embedded in a moving belt or chain to attract and transport ferrous metal chips. The conveyor typically mounts at an incline, lifting chips from machine sumps while allowing coolant to drain back for recirculation.
The fundamental design incorporates several key elements:
Magnetic medium: Either continuous steel belt with magnets beneath, or hinged steel plates (flight-style) with magnetic inserts. The magnetic field must be strong enough to hold chips securely during conveying but allow release at the discharge point.
Drive mechanism: Motorized drive pulls the magnetic medium up the incline at controlled speed, typically 10-30 feet per minute. Speed adjustment accommodates different chip types and production rates.
Support structure: Inclined frame providing rigid mounting for conveyor components while allowing coolant drainage. Most chip conveyors operate at 30-45 degree inclines—steep enough for effective coolant drainage yet manageable for magnetic retention.
Coolant return: Perforated or open construction allows cutting fluid to drain from chips back into machine sump. Effective designs return most of the coolant to the sump, minimizing fluid consumption and disposal costs.
Discharge mechanism: At the top of the incline, chips release from the magnetic field into collection containers. Some designs use wiper blades or scrapers to ensure complete chip removal from the magnetic surface.
Magnetic Belt Conveyors
Continuous belt magnetic conveyors employ a smooth or cleated steel belt running over permanent magnets or magnetic drum. These provide continuous chip removal with relatively compact installations. Belt widths typically range from 6 to 24 inches, with lengths from 3 to 20 feet depending on machine configuration and required elevation change.
Magnetic strength can be adjusted by varying magnet spacing or using different grade magnets. Stronger magnetic fields handle heavier chips or steeper inclines but may make chip discharge more difficult. Proper balance ensures secure transport without chip adhesion at discharge.
Hinged Steel Belt (Flight) Conveyors
Hinged belt conveyors use overlapping steel plates connected by hinges, creating a flexible yet robust conveying surface. Magnets mount beneath the flights, attracting chips to the plate surface. The hinged design navigates corners and complex paths better than continuous belts, though with higher mechanical complexity.
Flight conveyors excel with larger, heavier chips and stringy turnings that might tangle in belt-style designs. The gaps between flights allow excellent coolant drainage while the rigid plate surfaces support heavy chip loads.
Drum-Style Magnetic Separators
Magnetic drum separators use a rotating drum with permanent magnets inside. Chips-laden coolant flows over the drum, where magnetic chips adhere to the drum surface while coolant and non-magnetic materials pass through. A scraper blade positioned at the drum top removes chips for discharge into collection containers.
Drum separators work particularly well in high-volume applications with relatively fine chips. They provide continuous operation with minimal moving parts and excellent coolant recovery. However, drum separators handle stringy turnings less effectively than belt conveyors.
Coolant Recovery and Management
The Economics of Coolant Recovery
Metal cutting coolant concentrate costs $10-30 per gallon for quality synthetic or semi-synthetic formulations. Every gallon of coolant removed with chips represents direct cost plus disposal expense (often $1-5 per gallon for proper hazardous waste handling). A machine generating 50 pounds of chips daily might remove 5-10 gallons of coolant if chips aren’t adequately drained before disposal.
Over a year, this totals 1,500-3,000 gallons of lost coolant that must be replaced, plus disposal fees and environmental compliance burden. Effective magnetic conveyors with proper drainage return most of this coolant to the sump instead of sending it out with the chips.
Drainage Design Considerations
Maximizing coolant recovery requires attention to several design factors:
Incline angle: Steeper inclines promote faster drainage but reduce magnetic retention and chip capacity. Most installations use 35-40 degree inclines balancing drainage efficiency with chip handling capability.
Transport speed: Slower conveyor speed provides more drainage time before chips reach discharge. However, excessively slow speed may not keep up with chip production. Typical speeds of 15-25 feet per minute provide good compromise.
Belt or flight design: Perforations, mesh sections, or gaps between flights allow coolant passage while retaining chips. Design must prevent small chips from passing through with coolant.
Drainage dwell time: Some conveyors incorporate horizontal sections or pauses in conveying cycle allowing additional drainage time. This works particularly well with intermittent chip production.
Chip Wringer Systems
For maximum coolant recovery, chip wringers further compress chips after magnetic conveying. These mechanical presses squeeze chips, recovering additional coolant and reducing chip volume. Industrial chip wringers can extract 95-98% of coolant from chips, delivering nearly dry material for disposal while recovering maximum coolant value.
Chip wringers make economic sense in high-volume operations where coolant costs are significant and disposal costs are high. The equipment cost scales with capacity, and the return comes from reduced coolant consumption and disposal expense.
Handling Different Chip Types
Machining operations produce various chip forms, each presenting different handling challenges. Effective conveyor selection requires understanding your chip characteristics.
Chip and scrap conveyors we’ve built
Each of these was matched to a different chip or scrap stream:
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A magnetic chip conveyor that removes fine metal shavings without exposing its moving parts to the material, for long life and minimal maintenance
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A steel hinged belt chip removal conveyor for a machining cell, with a lifting eye at the center of gravity for lowering it into the pit below the machining center
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A 24 in wide × 20 ft low-profile steel hinged belt scrap removal conveyor that carries scrap from a laser cutting station into a dumpster
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A slide bed belt scrap bin conveyor that moves scrap from a processing machine into a bin placed for direct fork truck access
Fine Chips and Dust
Grinding operations, high-speed machining of cast iron or bronze, and certain milling operations produce fine chips approaching powder consistency. These require:
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Strong magnetic fields to attract and hold small particles
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Smooth belt surfaces preventing chip accumulation in crevices
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Enclosed designs preventing chip dispersion into work environment
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Consideration of pneumatic collection for very fine dust-like chips
Curly Chips and Turnings
Turning operations on ductile materials (low-carbon steel, aluminum, stainless steel) often produce long, curly chips or continuous stringers. These problematic chip forms tend to:
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Tangle in conveyor mechanisms, jamming drives and causing downtime
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Bridge across conveyors, blocking chip flow
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Retain excessive coolant due to their coiled structure
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Create disposal challenges due to high volume relative to weight
Handling curly chips effectively requires:
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Wider conveyors allowing chip spreading rather than bunching
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Hinged flight designs navigating tangles better than smooth belts
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Chip breakers on machine tools breaking turnings into manageable lengths
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Chip crushers or wringers compacting and breaking chips before disposal
Heavy Chips and Slugs
Operations like turning large-diameter steel bar stock produce heavy, chunky chips. These require:
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Robust conveyor construction withstanding impact loads as chips drop onto belt
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Strong magnetic fields retaining heavy chips on inclined sections
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Powerful drive motors moving heavy chip loads up inclines
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Structural support adequate for accumulated chip weight plus equipment mass
Non-Magnetic Chips
Machining aluminum, brass, bronze, plastics, or other non-ferrous materials produces chips that won’t respond to magnetic conveyors. These materials require alternative handling methods:
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Auger conveyors using mechanical screws to move chips
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Belt conveyors with cleats or flights
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Pneumatic chip handling using air flow to transport chips
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Scraper systems pushing chips to collection points
Shops machining both ferrous and non-ferrous materials often use magnetic conveyors for steel chips while employing separate systems for non-magnetic materials. Attempting to move non-magnetic chips with magnetic conveyors simply results in chips accumulating in machine sumps until manually removed.
Centralized Chip Handling Systems
Single-Machine Versus Centralized Collection
Small shops with one or two machines typically use individual magnetic conveyors discharging into drums or dumpsters at each machine. This approach minimizes capital investment and installation complexity but creates several disadvantages:
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Multiple collection points requiring operator attention to empty containers
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Chip containers occupying valuable floor space around machines
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Inconsistent coolant drainage depending on how long chips sit before emptying
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Difficulty capturing maximum scrap value due to small quantities per container
Shops with multiple machines benefit from centralized chip collection where individual machine conveyors discharge into a central collection conveyor system transporting chips to a single accumulation point. This centralized approach provides several advantages:
Centralized System Benefits
Reduced labor: Operators no longer empty individual chip containers. Chip removal becomes a single task at the central collection point, perhaps daily or weekly depending on volume.
Improved scrap value: Larger volumes of segregated chips command better scrap prices. Scrap dealers pay premium rates for clean, well-drained steel chips versus mixed materials or coolant-saturated waste.
Better coolant recovery: Central chip wringers or centrifuges process all chips consistently, maximizing coolant recovery across the facility rather than depending on individual machine handling.
Floor space recovery: Eliminating chip containers at each machine frees valuable floor space for productive equipment or material staging.
Improved housekeeping: Enclosed conveyors moving chips away from work areas reduce mess and safety hazards compared to open containers sitting at machines.
Central System Design Considerations
Effective centralized systems require careful planning:
Conveyor routing: Main collection conveyor must route to all machines needing chip removal. This often requires overhead or under-floor installation to avoid interfering with material flow and machine access.
Discharge coordination: Individual machine conveyors must discharge smoothly onto central conveyor without jamming. Proper angle and positioning at discharge points ensures reliable transfer.
Capacity planning: Central conveyor must handle peak chip generation when multiple machines discharge simultaneously. Undersized central conveyors create bottlenecks and spillage.
Segregation requirements: Shops machining different materials may need separate collection systems to maintain scrap material segregation for maximum recycling value.
Coolant management: Central systems should include proper coolant collection and return preventing cross-contamination between machines using different coolant types.
Maintenance Requirements and Best Practices
Preventive Maintenance Essentials
Magnetic chip conveyors operate in harsh environments—coolant exposure, metal chips, continuous duty cycles. Proper maintenance ensures reliable performance and long service life.
Daily maintenance:
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Visual inspection for chip jams, unusual noise, or coolant leaks
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Check discharge chute for chip accumulation blocking flow
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Verify proper chip release at discharge point
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Observe coolant drainage ensuring efficient return to machine sump
Weekly maintenance:
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Check belt or chain tension, adjusting per manufacturer specifications
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Inspect magnetic surface for chip buildup or damage
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Examine drive components (motors, reducers, couplings) for proper operation
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Clean coolant return areas preventing restriction of drainage flow
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Verify structural bolts remain tight under continuous vibration
Monthly maintenance:
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Lubricate drive components per manufacturer specifications
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Inspect belt or chain for wear, damage, or elongation requiring replacement
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Check magnetic strength ensuring adequate chip retention
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Examine structural components for corrosion or damage from coolant exposure
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Test safety interlocks and emergency stops
Common Problems and Solutions
Chips not releasing at discharge: Usually indicates excessive magnetic strength, worn wiper blade, or chip buildup on magnetic surface. Solutions include adjusting magnet spacing, replacing wiper blade, or cleaning magnetic surface thoroughly.
Chips falling off during transport: Indicates insufficient magnetic strength, excessive conveyor speed, or too-steep incline angle. Strengthen magnetic field, reduce speed, or decrease incline angle as appropriate.
Coolant not draining adequately: Often results from excessive conveyor speed, insufficient incline, or plugged drainage openings. Reduce speed to allow more drainage time, verify incline angle, and clean any obstructed openings.
Drive motor overload: Typically caused by heavy chip accumulation, jammed mechanisms, or mechanical binding. Clear chip jams, inspect for binding components, and verify proper lubrication of drive components.
Chip jams: Usually involve long stringy turnings tangling in conveyor mechanisms. Implement chip breakers on machine tools, consider chip crusher at conveyor discharge, or switch to hinged flight design better handling stringy chips.
Extending Service Life
Chip conveyors exposed to constant coolant require corrosion-resistant materials and protective coatings. Stainless steel construction provides maximum corrosion resistance but costs significantly more than painted carbon steel. Many installations use stainless steel for wetted components (belt, flights, drainage areas) while using painted steel for structural elements less exposed to coolant.
Regular cleaning prevents coolant residue buildup that accelerates corrosion. Monthly washdown of accessible surfaces extends equipment life substantially. Pay particular attention to coolant sumps and drainage areas where concentrated coolant can pool.
Selecting the Right Magnetic Chip Conveyor
Capacity Determination
Proper conveyor sizing starts with estimating chip production rate. Calculate expected chip volume based on material removal rates, number of machines, and operating schedule. A rough estimate: removing one cubic inch of metal per minute produces approximately 0.3 pounds of steel chips. A machine averaging one cubic inch of material removal per minute over a 16-hour day generates about 300 pounds of chips per day.
Start with real chips
Before sizing a conveyor, collect a shift’s worth of chips from each machine, weigh them, and photograph the sump and the space around the machine. Real samples show the shape, weight and coolant load the conveyor has to handle. We offer on-site or remote engineering consultations and help gather this kind of data to validate a concept before it is built.
Conveyor capacity must handle peak production, not average. If three machines might discharge simultaneously, the conveyor must handle triple the single-machine rate without overloading.
Installation Considerations
Available space: Measure space beneath and around machines determining maximum conveyor dimensions. Account for access requirements to machine sumps and other equipment.
Discharge height: Collection container location determines required conveyor discharge height. Higher discharge may require longer conveyors or steeper inclines.
Power availability: Ensure adequate electrical service for conveyor motor. Most chip conveyors use 1-3 HP motors at 208-480V three-phase, though smaller units may operate on single-phase power.
Coolant compatibility: Verify conveyor materials are compatible with coolants used. Some cutting fluids are more aggressive toward certain materials and coatings.
Custom Versus Standard Designs
Standard chip conveyors suit many applications and offer lower cost with shorter delivery. However, custom designs often provide better solutions when:
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Machine sump geometry doesn’t match standard conveyor dimensions
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Space constraints require non-standard configurations
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Multiple discharge points are needed along conveyor length
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Integration with existing central collection systems is required
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Specialized materials or coatings are necessary for corrosion resistance
Custom Conveyor & Equipment Corporation builds custom chip and scrap conveyors engineered to match machine configurations and production requirements. Because design, fabrication and assembly happen in one facility, we run and adjust each design before shipment, while changes are still easy to make.
Return on Investment Analysis
Cost Components
Magnetic chip conveyor investments range from compact single-machine units to centralized systems serving multiple machines, with cost driven by length, width, construction and controls. Custom designs, stainless construction, and specialized features increase costs.
Installation labor adds to equipment cost depending on complexity and required utility connections.
Savings Calculation
ROI comes from several sources:
Direct labor savings: Operators spending 30 minutes daily on chip removal represent substantial cost. At $30/hour loaded labor rate, 30 minutes daily equals $3,750 annually. Eliminating this manual handling through automated chip removal provides clear, quantifiable savings.
Coolant recovery: As discussed earlier, effective chip conveyors return coolant to the sump that would otherwise leave with the chips. Counting both fluid and disposal costs, this often represents the largest single savings component.
Scrap value improvement: Clean, well-drained steel chips typically bring a better price from scrap dealers than mixed, contaminated material. Ask your dealer for both prices and multiply the difference by your annual chip volume to see what drainage and segregation are worth to your shop.
Housekeeping and safety: Automated chip removal reduces slip hazards, improves shop cleanliness, and decreases time spent on cleanup activities. While harder to quantify precisely, these benefits contribute real value.
Typical Payback Periods
Payback for a well-specified chip conveyor comes from a combination of labor savings, coolant recovery, and improved scrap value, and it depends on your own labor rates, coolant costs and chip volume. High-volume shops generally see the fastest payback.
Beyond financial return, chip conveyors improve shop environment and free operators to focus on productive work rather than chip handling—benefits extending well beyond simple cost calculations.
Making Chip Handling Work for Your Shop
Magnetic chip conveyors transform chip handling from labor-intensive manual task to automated background process. Proper selection, installation, and maintenance deliver years of reliable service while recovering coolant value, improving scrap returns, and freeing operators for productive work.
Success requires matching conveyor type and capacity to specific chip characteristics and production volumes. Standard designs suit many applications, while custom engineering addresses unique configurations and requirements. Either way, investing in proper chip handling pays dividends through reduced costs and improved shop operations.
Chip Conveyor FAQs
Related Resources
Explore related industries, equipment and guides from Custom Conveyor.
Industries:Machining Laser Cutting
Equipment:Scrap, Chip & Dust Collection Conveyors Specialty Conveyors
Project examples:Magnetic Chip Conveyor Chip Removal Conveyor Scrap Removal Conveyor
Related guides:Drag Chain Conveyors
Custom Chip Handling Solutions from Cedar Rapids
Custom Conveyor & Equipment Corporation has built specialty conveyors since 1984, including chip and scrap conveyors for machining, laser cutting and fabrication operations, combining material handling expertise with in-house fabrication capabilities. Our Cedar Rapids, Iowa facility includes 3kW fiber laser cutting and 300-ton press brake equipment, enabling us to manufacture chip conveyors precisely matching your machine configurations. We engineer chip and scrap conveyors for individual machines and collection conveyors that gather material from multiple drop points, handling everything from fine shavings to heavier chips and scrap. Our team helps you select appropriate conveyor types, optimize coolant recovery, and integrate chip handling seamlessly with your production operations. Whether you need a single magnetic conveyor for a new machine tool or a complete centralized chip handling system for your facility, we provide engineering expertise and manufacturing capability to deliver practical solutions matching your requirements and budget. Ready to automate chip handling in your shop? Contact our engineering team at (319) 449-3322 or visit our contact page to discuss your application. We’ll help you evaluate options and develop chip handling solutions that reduce costs while improving your shop operations.
Chip and scrap conveyors built to fit your machines, from Cedar Rapids, Iowa.