Lancaster Products has newly engineered their popular K-Lab Mixer. The K-Lab has been one of their fastest selling machines for testing, experimentation and development of new processes. It can beneficially add a new dimension to a mixing / pelletizing process that companies may not even know exist. The K-Lab mixers have proven for many companies to be a minimal investment with maximum dividends in product development.

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The New K-1 Lab Mixer

The New K-1 Lab Mixer
The K1-Lab’s enhanced mechanical design features a shorter, lighter, easier to handle and clean pan. The view port is larger than its predecessor and has a provision for sampling the material. This enables real-time adjustments to the mix. The K1-Lab also has a vastly improved, touch screen control allowing very specific electronically controlled speeds. A thermal probe gives a numerical report of temperature, again in real-time, permitting a better means of assessing whether temperature increase is due to friction or chemistry. There is a re-settable mix phase time that reads out in seconds. Total mix cycle times and a pre-programmable mix design are also provided. Motor speeds and power are recorded as well. The new control can also store and repeat mix cycles, as well as communicates with other devices.

Many companies have successfully used the Lancaster Products K-Lab mixers as “proof of concept” in product development, opening up new processes and markets for them. Once a mix is perfected in the K1-Lab mixers, we invite customers to come to our testing lab and replicate the results achieved in the K1-Lab using the K-4 production mixer.

The new K1-Lab mixer has now streamlined the mixing process of blending, pelletizing or granulating with much quicker times. Whether it is a ½ cu. Ft. capacity K1-Lab or a 210 cu. Ft. K-10, Lancaster Products is proud to be able to “take a tiny amount of this . . . add it to a lot of that . . . and have it result into something great!”

Come see us and the New K1-LAB at the Ceramics Expo in Cleveland, Ohio — April 26-28 —Booth #615

Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

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The Effect of Rotor Styles on High Shear Mixing

In addition to the rotating pan, all high shear mixers manufactured by Lancaster Products larger than a K3.5 have two independently motor driven mixing tools inside the pan which are responsible for proper mixing, pelletizing, and granulating of materials: the plow and the high speed rotor.  The plow continually sweeps the entire surface of the pan bottom to prevent material from accumulating on the bottom and enhances the overall mixing action.  However, the most important tool of all is the high-speed rotor, which rotates counter direction to the pan causing a shearing action inside of the mixing cavity.  This high-speed rotor not only agitates the mixture, but significantly influences the control of the entire process.  While there are just two main style of standard rotors, we can custom configure the rotor to optimize all mixing processes.

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Infographic: Optimize Your Fertilizer Pelletizing Process

Traditional processes for manufacturing fertilizer require many steps and different types of equipment. It is common for systems to include multiple dryers, a mill/pulverizer for size reduction of dried material, pin mixer/pug mill for mixing of additives and raw materials, a pelletizer and multiple conveyors to facilitate the process. If this seems like a complex process that requires high levels of work, energy and maintenance, we agree.

Lancaster Products engineers can optimize existing complex fertilizer pelleting processes or design new streamlined systems to help you realize multiple benefits, including a reduction in physical footprint and an improvement in the characteristics and reproducibility of your pelletized product. By utilizing a Lancaster Products K-Series High Shear Mixer to replace a mill and disc pelletizer, you not only reduce system complexity but also gain the ability to begin processing with raw materials at higher moisture levels. The counter-current mixing action in a Lancaster Mixer allows for one-step mixing and pelletizing with rapid mix times.

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