RELIABLE FX-series air recycling separator — air classification equipment for separating light materials (plastic films, sawdust, fibres, light dust) from heavy materials (metal, glass, stone, dense granules) through a controlled air stream, without mechanical contact. Available in five models FX600–FX1500, with a separation efficiency above 95%.
This air recycling separator is the air-classification stage in the recycling lines of the metallurgy, mining, cement, chemical, construction and power-generation industries — wherever separating materials of different density and aerodynamic resistance is the central operational requirement.
The aerodynamic principle of this air recycling separator — fundamentally different from electrostatic, magnetic or gravity separation — uses the air stream as the separation medium. Light materials with high aerodynamic resistance (films, fibres, dust, sawdust) are entrained by the air stream and collected in the light fraction; heavy materials with low aerodynamic resistance (metal, glass, dense granules) are not entrained by the air stream and fall by gravity into the heavy fraction. No mechanical part comes into contact with the processed material — zero abrasive wear, zero contamination and zero damage to fragile materials. Key Advantages of the RELIABLE FX Air Recycling Separator
• 95% efficiency for light/heavy separation — optimised aerodynamic performance: The optimised design of the air-classification chamber and the air-stream profile of the FX series produce a separation efficiency above 95% for the light fractions versus the heavy ones. This means that out of 100 kg of mixed material (plastic films + metal), 95 kg of the light fraction are collected cleanly, without contamination by heavy material — and vice versa for the heavy fraction.
• Zero mechanical contact — zero damage and zero contamination: The air stream is the only active agent of the separation — no roller, no blade, no magnet comes into contact with the processed material. This eliminates damage to fragile plastic films, contamination of metals with mechanical-wear particles and the impact noise specific to crushers and mechanical separators. The recovered materials have their properties intact, saleable at the prices of quality secondary raw materials.
• Low energy consumption — efficient aerodynamic design: The optimised aerodynamic design of the air-stream channels maximises separation efficiency at minimal stream velocities and air flow rates. Compared with mechanical or electromagnetic separators of equivalent capacity, the energy consumption of an FX air recycling separator is significantly lower — a direct advantage in the operating cost per tonne of material separated.
• 5 models FX600–FX1500 — scalable by capacity and belt width: The model number indicates the working width of the classification chamber — from 600mm for small and medium installations to 1500mm for high-volume industrial lines. All models use the same aerodynamic principle and the same simple maintenance structure, easing operator training and the common spare-parts stock across models.
• Simple structure — minimal maintenance and reduced downtime: The absence of mechanical parts in contact with the material (rollers, blades, hammers) eliminates the main sources of wear and maintenance of conventional separators. The service components of an FX air recycling separator are limited to the fan, the motor and the dust-capture filters — standard parts with extended maintenance intervals and reduced replacement costs compared with the blades and liners of mechanical separators.
• Purely physical process — no reagents, no water, no secondary waste: Air separation is completely dry and generates no wastewater, sludge or chemical emissions. The air used is recirculated through the integrated filtration system, with no dust emissions into the workshop atmosphere — direct compliance with workplace air-quality standards and the environmental regulations applicable to recycling lines.
• Applicable in 5 major industries — metallurgy, mining, cement, chemicals, construction: The versatility of the aerodynamic principle allows the use of this air recycling separator in any industry where mixtures of materials of different density and aerodynamic resistance require separation: removing light impurities from mineral aggregates, separating plastic films from production waste, particle-size classification of cement and powdered materials and the air-based cleaning of metal fractions from WEEE recycling lines.
• Environmentally friendly — compliant with international ecological standards: Low energy consumption, the absence of water and reagents and zero emissions of liquid or chemical pollutants make the FX series the separation equipment with the lowest environmental footprint in the RELIABLE range — a direct argument for ISO 14001 certification and for recycling companies' sustainability reports.
Specifications and Models — RELIABLE FX Air Recycling Separator
| Available models | FX600 / FX800 / FX1000 / FX1200 / FX1500 |
|---|---|
| Separation principle | Air classification — controlled air stream |
| Separation efficiency | ≥95% for the light fractions versus the heavy ones |
| Mechanical contact | Zero — no part in contact with the processed material |
| Separation type | Dry separation — no water, no reagents |
| Processed light materials | Plastic films, sawdust, fibres, light dust, textile material, plant waste |
| Processed heavy materials | Metal, glass, stone, dense granules, ceramics, sand |
| Applicable industries | Metallurgy, mining, cement, chemicals, construction, power generation, recycling |
| Energy consumption | Low — optimised aerodynamic design |
| Maintenance | Minimal — no wear parts in contact with the material |
| Emissions | Zero dust in the workshop — air recirculated through integrated filtration system |
| Customisation | Available on request |
Applications — Where the FX Air Recycling Separator Is Used
An FX-series air recycling separator is the air-classification stage in metal recycling lines where light fractions (plastic films, labels, textile insulation from cables) must be removed from heavy metal fractions before the magnetic or eddy-current separators. Plastic films and textile fibres remaining in the metal granulate after crushing disrupt the magnetic separators and reduce the purity of the recovered metal — the FX air separator removes these light fractions efficiently, at 95% efficiency, before entry into the magnetic separation stage.
Tyre recycling lines use this air recycling separator to separate rubber powder from textile cord fibres — the light fractions (fibres) are entrained by the air stream and collected separately, while the dense rubber granules fall by gravity into the heavy fraction. Granulated rubber cleaned of fibres has a higher market value and is directly accepted by synthetic-turf lines and rubber-flooring production without additional sorting. Explore the full range of Uzinex industrial equipment for integrated solutions for recycling and separating mixed materials.
The cement, construction-materials and mineral-aggregate processing industries use FX-type air recycling separator systems for the particle-size classification of powders and granules — separating fine fractions from coarse ones through an adjustable air stream, with greater precision than mechanical screens at higher processing rates and without the screen-mesh clogging specific to wet or sticky powders, in line with international standards for processing industrial materials. The RELIABLE Separators from UZINEX — Complete Comparison
The RELIABLE range of separators available from Uzinex covers all physical separation principles — the correct choice depends on the differentiating property of the materials to be separated:
• FX air separator (density + aerodynamic resistance): Light vs. heavy — plastic films + metal, fibres + granules, light dust + heavy aggregates. 95% efficiency. No strict particle-size limit for larger materials.
• DF electrostatic separator (electrical conductivity): Metal vs. non-metal at ultra-fine particles 0,04–1mm. 99% dual-stage efficiency. PCB, aluminium-plastic, titanium chips, pharmaceutical blister.
• Eddy-current separator (variable magnetic field): Non-ferrous metals (aluminium, copper) from non-magnetic mixtures. Particles 5–100mm. Radiators, WEEE, non-ferrous fractions.
• Gravity separator (density + controlled air stream): Materials of different density at similar particle size. Rubber + steel wire, mixed granulates of equal size but different density.
Operating Mode — Air Classification with the FX
• Feeding the mixed material into the classification chamber: The mixture of light and heavy materials is fed uniformly onto the FX separator's distribution belt. The speed and feed rate of the feeding belt are adjusted to ensure a thin, uniform layer of material in the active classification zone — a layer that maximises the exposure of each particle to the air stream.
• Activating the controlled air stream: The fan generates the air stream with a velocity adjustable according to the densities of the materials to be separated. The optimal air-stream velocity is set so that it entrains the light materials without entraining the heavy materials — a balance point determined experimentally for each specific combination of materials.
• Separation along differential trajectories: Light particles (films, fibres, light dust) with a high surface/mass ratio are entrained by the air stream and follow the stream's trajectory towards the light-fraction collector. Heavy particles (metal, glass, dense granules) with a low surface/mass ratio are not entrained by the stream and fall by gravity into the heavy-fraction collector, without touching any moving part.
• Collection and air filtration: The light fraction is separated from the air stream in a cyclone or bag filter and collected in a dedicated bunker. The cleaned air is recirculated in the system — zero dust emissions into the workshop atmosphere. The heavy fraction falls directly into the separator's lower bunker.
• Adjusting the stream velocity for optimisation: The operator monitors the purity of the collected fractions and adjusts the air-stream velocity for continuous optimisation against composition variations in the fed material. The adjustment is made from the control panel without stopping the production line.
Frequently Asked Questions about the RELIABLE FX Air Recycling Separator
How does it differ from the gravity separator — both use physical principles without chemical reagents?
Both are dry separators with a physical principle, but with different mechanisms. The RELIABLE gravity separator combines fluidisation by an upward air stream with vibration and the stratified movement of the material bed — optimal for materials of similar particle size but different density (rubber vs. steel wire at the same size). This FX air recycling separator uses a horizontal or oblique air stream to selectively entrain light materials based on the surface/mass ratio — optimal for plastic films, fibres and light lamellar materials versus heavy compact materials, regardless of particle size. Can the FX separate plastic films from plastic granules of the same density?
Not efficiently — the FX air separator separates materials with significant differences in surface/mass ratio (light vs. heavy) or aerodynamic resistance. Two materials of the same density but different shapes (film vs. granule of the same polymer) can be partially separated if the aerodynamic-resistance difference is sufficient, but efficiency will be lower than 95%. For the precise separation of plastics of the same density, the DF electrostatic separator or the density separator are the more suitable machines. What particle sizes does the FX process and is there a minimum limit?
The FX air separator has no strict minimum particle-size limit — it works on any size, from fine dust to pieces a few centimetres across, as long as the difference in surface/mass ratio between the fractions to be separated is sufficient. For particles under 0,1mm, more efficient air filtration (cyclone + bag filter) is recommended for the complete capture of the fine light fraction and the prevention of dust emissions. The UZINEX team configures the capture system appropriate to the specific particle size. How is the FX integrated into a tyre recycling line with the RELIABLE shredder?
The standard flow is: Tyre shredder → 50mm rubber granulate → fine mill → 1–5mm granulate → FX air recycling separator to remove textile cord fibres → clean rubber granulate → magnetic separator for residual steel wire → clean rubber powder ready for sale. The FX separator is the mandatory air-cleaning stage for fibres before rubber is sold — textile fibres reduce the market value and the performance of rubber powder in end applications (synthetic turf, flooring). What is the typical energy consumption compared with a mechanical separator of equivalent capacity?
Mechanical separators (vibrating screens, roller sorters) consume energy to drive the movement mechanisms in contact with the material — multiple motors, transmissions and bearings. The FX air separator consumes energy only for the fan and the feeding belt — with no other mechanical drives. At equivalent processing capacity, the FX's energy consumption is 30–50% lower than a comparable mechanical sorter, according to standard estimates for air classification versus mechanical classification. Why Buy the RELIABLE Air Recycling Separator from UZINEX?
• Free consultation for model selection and stream velocity: The UZINEX team analyses the materials to be separated, the densities and aerodynamic resistance of the fractions and recommends the FX model and the stream parameters for maximum separation efficiency in your specific application.
• Delivery, commissioning and air-stream calibration included: Every FX air recycling separator delivered through UZINEX includes complete installation, calibration of the stream velocity for your specific materials and operator training for adjusting parameters across different material batches.
• Extended 60-month warranty and technical support under 36 hours: The 60-month warranty and the guaranteed response time under 36 hours ensure the continuity of the air-classification line — with priority delivery of the service components (fan, filters, belts) from UZINEX's own stock.
• The lowest maintenance cost in the RELIABLE separator range: The absence of parts in contact with the material makes the FX the separator with the lowest maintenance costs in the entire RELIABLE range — no blades, no wear rollers, no liners to replace. The 5-year cost of ownership is calculable and documentable to justify the investment against alternative mechanical separators.
• Integrated into the complete RELIABLE ecosystem from UZINEX: The FX connects natively upstream of the magnetic, eddy-current and electrostatic separators from the RELIABLE range distributed by UZINEX, completing the full separation line with the air-based pre-cleaning stage needed for the maximum efficiency of the separators in the following stages.
RELIABLE FX600–FX1500 air recycling separator — air classification at 95% efficiency, zero mechanical contact, low energy consumption and minimal maintenance, for separating plastic films, fibres and light materials from the metals, glass and dense granules in the recycling lines for tyres, metals, WEEE and mixed industrial materials, in any industry that needs a dry and efficient air recycling separator for fractions of different density and aerodynamic resistance.