MicroMag Stabilises EDM Drilling and Heat Treatment Performance at HepcoMotion

A magnetic filtration system from Eclipse Magnetics has helped HepcoMotion improve machining stability, reduce maintenance requirements, and enhance overall production efficiency at its manufacturing facility in Tiverton, Devon. 

HepcoMotion is a global engineering company specialising in linear motion and automation components used in manufacturing, guidance, and transfer applications. Headquartered in the UK, the company operates internationally with offices across Europe and Korea, supplying precision-engineered products to a wide range of industrial sectors. Its portfolio includes linear guides, curved rail and track systems, driven track systems, linear actuators, and gantry systems. 

Manufacturing these components requires tightly controlled production processes, including induction and flame hardening as well as electrical discharge machining (EDM) drilling. In both applications, the cleanliness of quench and deionised water systems plays a critical role in maintaining consistent product quality and reliable machine performance. 

An Ongoing Challenge

Prior to installing magnetic filtration, HepcoMotion relied on conventional paper and cartridge filtration to manage contamination within these systems. Despite regular maintenance, contamination remained an ongoing challenge that affected both process stability and operating costs. 

In the deionised water system used for EDM drilling, contaminants caused electrical sparking that disrupted machining performance and led to increased scrap and rework. At the same time, contamination within the quench system reduced the effectiveness of the hardening process, creating inconsistent hardness across components. 

These issues required frequent intervention from the maintenance team. Machine cleanouts were typically carried out on a monthly basis and sometimes more often. Each machine used multiple cartridge filters, and the cleaning process resulted in approximately two hours of downtime per machine while maintenance engineers completed the work. 

The combined impact of downtime, consumable filter costs, and inconsistent production quality affected machine availability and overall manufacturing efficiency. Scrap and rework also extended production lead times. 

High-Intensity Magnetic Solution

To address these challenges, HepcoMotion installed an Eclipse Magnetics MicroMag magnetic filter on a trial basis to determine whether magnetic separation could provide a more effective and lower-maintenance solution. 

The MicroMag generates a high-intensity magnetic field that captures and retains ferrous particles circulating within process fluids. By continuously removing fine iron and magnetite contamination from the system, the filter helps maintain fluid cleanliness, protect critical equipment, and reduce long-term wear. 

Improvements were visible immediately after installation. The magnetic filter began capturing fine ferrous particles at the point of flow, preventing them from recirculating through the system. The success of the trial led HepcoMotion to adopt magnetic filtration as a long-term solution. 

Since installing the MicroMag, the company has significantly reduced maintenance requirements and process disruption. Machine cleanouts, previously carried out monthly, are now typically required only every three months. Cartridge filters have also lasted considerably longer, with no replacements required for more than six months following installation. 

Matt Winiarski, Maintenance Manager at HepcoMotion, explained that contamination had previously been a persistent operational challenge. Since installing the MicroMag, contaminants are removed immediately from the system, significantly reducing downtime and delivering more consistent process performance. 

Matt added that installation was straightforward and the results were visible almost immediately, making the value of magnetic filtration clear. The MicroMag has proven to be a simple but highly effective solution that has delivered measurable operational improvements while also supporting sustainability goals. 

Stabilising EDM Drilling

Improved fluid cleanliness has stabilised EDM drilling processes by reducing instances of electrical sparking and lowering scrap and rework. Heat treatment performance has also become more consistent, improving product quality and reducing variability across components. In addition, machine reliability has improved and unplanned downtime has decreased, increasing overall equipment availability. 

HepcoMotion estimates that reduced maintenance, labour, and consumable filter costs have generated annual savings of approximately £600, resulting in an expected return on investment of around twelve months. 

Maintenance requirements have also been simplified. Operators now perform a quick weekly routine to remove collected contaminants from the magnetic filter, significantly reducing the maintenance effort previously associated with traditional filtration systems. 

The installation has also supported HepcoMotion’s environmental objectives. Lower contamination levels have extended the usable life of both quench and deionised water, reducing fluid change frequency and disposal requirements. The elimination of disposable filter cartridges has reduced waste, while the captured ferrous material can be recycled.