Sand Separation System SandFlo by BlakerTech

SandFlo™ Fluidised Bed Separator

The SandFlo fluidised bed separator provides efficient, low-cost dry separation of secondary metals and minerals according to their density. SandFlo is ideal for the recovery of aluminium, zinc, copper and brass fractions from mixed non-ferrous metals in processing plants.

Metal recovery technologies

The sorting of non-ferrous metals from mixed scrap residues warrants a careful selection and costing of technology.

The replacement of hand sorting by automatic equipment can be difficult to justify economically for such varying and mixed feed materials. Expensive systems using, for example, x-ray fluorescence, have not been taken up generally by the industry.

The use of wet separators also presents challenges, creating effluents that are becoming more difficult and costly to treat. SandFlo is a simple, robust and cost-effective solution to these metal recovery issues.

The SandFlo is handmade in the UK at BlakerTech’s manufacturing facility in the South East of England. They also provide full installation, training and support.

Cost effective dry separation

A cost-effective system with high recovery performance
An environmentally friendly, dry process with no contaminated effluent to treat
The carbon footprint is less than 25% of an optical sorter
A proven, commercial solution for upgrading non-ferrous fragmented scrap
Requires a single operator and can recover 2-2.5 tonnes of material per hour
By saving costs on manual pickers, SandFlo typically pays for itself within 12 months

The SandFlo process

The system is based on an annular trough around which sand and metal are continuously circulated by vibrating the trough. Air is fed into a section of the trough base, creating a buoyant fluidised bed of sand into which scrap particles sink according to their density.

After magnetic separation of any residual ferrous material, mixed crushed scrap from a fragmentiser is screened to improve its uniformity. Non-metallics are removed using the MagThro™ eddy current separator and the mixed non-ferrous metals are then fed into the annular trough up-stream of the fluidised bed.

As the scrap is carried across the fluidised region by the continuously circulating sand, the less dense materials (aluminium and magnesium) remain near the surface and are conveyed out of the sand by an inclined perforated flight, fixed across the width of the trough.

The heavier metals (zinc, brass, copper and any residual stainless steel) sink deeper as they travel through the fluidised zone and are conveyed out of the trough by a second lower perforated flight, downstream of the fluidised zone.

The sand particles pass through the perforated flights and end up back at the feed point, re-circulating continuously around the annular trough.

Low-cost operation

The SandFlo is simple to operate and has a low capital cost. More than one unit might be needed to process the scrap output of a conventional fragmentiser. To process to a dedicated size, a trommel screen is often included with each unit.

The SandFlo system is a dry process. It doesn’t create any by-products for disposal, e.g. contaminated liquid effluent and the sand can be constantly cleaned.

Your Questions, Answered

Q:How does SandFlo’s fluidised bed technology work?

A:

SandFlo is a fluidised bed separator that uses a carefully controlled flow of air through a vibrating bed of fine media, often sand, to separate materials by particle density and characteristics.

In this fluid-like environment, lighter non-ferrous metals such as aluminium float, while denser materials like copper, brass, stainless steel, and zinc sink and are directed to a separate outlet. This makes SandFlo ideal for handling nonferrous metal separation tasks where magnetic separation alone is not effective.

The system offers a clean, dry alternative to water-based separation, with no contaminated water to manage or dispose of. We are also actively developing heavy duty sand separation systems to meet the growing demand for higher-volume, industrial-scale applications.

Q:What are the advantages of using a fluidised bed for metal separation?

A:

Fluidised bed separators like SandFlo offer several key advantages for non-ferrous metal separation and metal recovery:

No water waste: Unlike water table systems, SandFlo™ uses air, removing the need to treat or dispose of contaminated water
Lower investment cost: Significantly more affordable than colour sorters or X-ray-based systems
Low running costs: With few moving parts, it offers easy maintenance and low operating overheads
Straightforward to use: There are no complicated user manuals to digest — SandFlo™ is designed for simple, intuitive operation
Reliable and scalable: Ideal for both standalone and integrated systems, especially where dry separation is essential

This dry separation process is particularly beneficial in environments where water usage is restricted or sustainability is a key consideration.

Q:Can SandFlo remove plastics or coatings from metal particles?

A:

No, SandFlo is not designed to remove bonded materials such as plastics. It separates materials based on density, not material composition.

Q:What materials are best suited for metal separation with SandFlo?

A:

SandFlo separates non-ferrous metals that have been screened for consistent particle size. Ideal materials include aluminium, copper, zinc, tin, and brass, particularly where density differences allow for clean separation.

For best performance, input material should be dry, relatively clean, and fall within a defined size range to ensure optimal metal recovery.

Q:How is SandFlo different from magnetic or eddy current separators?

A:

While magnetic separators and eddy current separators rely on electromagnetic properties to extract ferrous and non-ferrous metals, SandFlo takes a different approach.

As a fluidised bed separator, SandFlo operates purely on density and fluid dynamics, using air to suspend and separate materials based on weight rather than magnetic response.

Q:Why is SandFlo called a ‘sand separation system’ if it doesn’t only use sand?

A:

While SandFlo is often described as a sand separation system, it doesn’t rely exclusively on sand. The term refers to the fluidised bed separator process, which uses fine media that, when aerated, creates a fluid-like environment for density-based separation.

This aerated medium allows lighter non-ferrous metals to float while denser materials sink, enabling clean, dry separation without the need for water. Depending on the application, the system can operate with a variety of media to suit specific metal recovery requirements.

Q:Do you have a SandFlo™ density separator for sale, also known as a fluidised bed separator?

A:

Yes, our SandFlo™ density separator is available to purchase directly from BlakerTech. Designed for dry separation of non-ferrous metals from mixed materials, SandFlo™ is a robust and reliable solution built in the UK and tested in operational recycling environments.

It’s particularly well suited for applications where water-based systems are not ideal, offering a cleaner, simpler alternative with zero sludge or liquid waste

A simple, low-cost solution

The SandFlo process is simple to operate and has a low capital cost. One or more units may be needed to process the scrap output of a conventional fragmentiser. A trommel screen is often included with each SandFlo processing to a dedicated size. SandFlo is a dry process and produces no contaminated liquid effluent. The sand can be constantly cleaned and therefore does not present a disposal problem.

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A proven cost-effective dry separation solution

A dry process with no contaminated effluent to treat

High recovery performance of secondary metals and minerals

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