Everyone remembers from grade school that if you mix a bunch of colors together you get black.  But in the world of manufacturing and mass production making products black isn’t so simple.  Black pigments that satisfy specified requirements must be used to achieve the desired color, and when it comes to making black pigments, there’s no better place to start than the residual by-product of refineries appropriately known as “Carbon Black”.

Challenge: In its raw form, carbon black is a very fine powder, so fine that it has liquid-like properties which makes it difficult to handle when transporting between and within facilities.  It is also classified as a Group 2B carcinogen and becomes airborne easily when in its raw, powder form.

Background: Carbon black is a waste product generated in large volumes by petroleum refineries around the world.  Rather than dispose of it, refineries will opt to sell it to materials processors who process it so it can be incorporated into pigments and fillers with a wide variety of uses, particularly in the steel, rubber, and plastics industries.

Converting carbon black powder to a pelletized form significantly reduces the risk of releasing carcinogens into the air when handling.  The pellets are also much easier to store and transport due to the lower flow rate of pellets vs. powder.

Solution: High shear mixers manufactured by Lancaster Products are the perfect solution to meet the critical specifications of pelleting carbon black powder.  Our mixers are the heart of carbon black processing facilities as this is where the transformation from powder to pellet takes place.

It is of the utmost importance to select high shear mixers that meet all of the critical demands required for both the physical and performance specifications inherent across all materials processing facilities, which commonly include 1) homogeneity of materials, 2) uniform pellet size, 3) high processing efficiencies, 4) minimal use of binders, and 5) high yields.

Furthermore, most materials processors work with a diverse array of materials and prefer to run them separately through one processing line when appropriate.  The versatility of Lancaster Products’ high shear mixers allows them this luxury which further increases their overall efficiencies.

Lastly, the process itself must be formulated and tested prior to production of the high shear mixer.  Lancaster Products will run samples of your carbon black through in our in-house lab using our laboratory mixers.  Our experienced engineers work hand-in-hand with our customers to help define the ‘recipe’ for processing your materials as well as ensuring that all specifications are met and the final product is satisfactory.

Benefits: The demand for pelletized carbon black is much higher than the powder version, but only if the pellets maintain the same properties as the powdered form.  Additionally, the pelletized form is not prone to becoming airborne which significantly minimizes the levels of airborne carcinogens.

Contact us today to discuss your next materials processing requirement.

717-273-2111

 

Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

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Office Hours:
Mon - Fri: 8:00 am - 5:00 pm

Maintenance Bulletin: Rotor Wear and Replacement in Industrial Mixers

The high-speed rotor is the primary mixing and pelletizing tool in industrial high shear mixers and in many ways, it is the most utilized part of the machine. But rotor wear is also a good leading indicator of your machine’s overall operating condition as it is a direct result of material processing. Chances are, if the rotor is worn, there is other preventative maintenance to be done.

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What Preventative Maintenance Will Prolong the Life of My Mixing Equipment?

Industrial mixers are built to run and withstand a great deal of abuse, however, regular preventive maintenance efforts can help keep your mixer running like new. The two most critical components that can affect the life of your mixer are lubrication and inspection of working tools. Below is an overview of the in-depth information provided in our full maintenance schedule available for download below.

 

Lubrication: Proper lubrication can encompass multiple areas on your mixer, not just the shaft seals of the mixing tool. Lubrication of all seals as well as drive gears, discharge valves and other locations where bearings are utilized is the best way to extend the life of your mixer. Automated lubrication systems on larger production mixers help maintain proper lubrication intervals, but regular visual inspection should be scheduled to assure the system is working properly.

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