Quality products start with quality materials. Lancaster Mixers improve material processing and  achieve better results than conventional mixing or pelletizing machines in a single machine and process.   Exploring how to  achieve better material results starts in the Lancaster Products laboratory.   Whether our customers are looking to improve an existing process, or define a new method for processing materials, the high shear mix design for producing the end product is iterative.  It starts as a proof of concept, and scales up to a production mixer run along the way refining the optimal mix program.  Many Lancaster customers consider the process through a K-series high shear mixer the secret catalyst to make their products extraordinary and give them an advantage in an ever more competitive marketplace.

Buying a key piece of equipment without knowing exactly how it will perform is a risky proposition, so Lancaster Products will work hand-in-hand with clients to establish a level of comfort with the K series mixer before ever committing to a purchase order.  For a small investment in time and money, Lancaster Products provides a complete scope of testing services. This important activity allows our customers to hit the ground running with an established mix design and knowledge on mixer operation.   

Lancaster Products makes it easy to get started.  Our Engineering staff works with  our customer to arrange a mutually convenient test date prior to the shipment of test materials.  Even though the Lancaster Products staff can perform the R&D to qualify the material outcome, clients are strongly encouraged to actively participate in the tests.  Testing can be done to target a customer predefined set of material outcomes, criteria/properties or to maximize a specific outcome such as processing time, yield, or target pellet size.    After  testing is completed, the Lancaster staff provides a complete  report of the testing results along with the associated mix design.   Lancaster even offers a money back guaranty for proof of concept testing if the predefined material outcome cannot be achieved.

The Lancaster Testing Process:

STEP 1Proof of Concept: Begins by  testing in a Lancaster K1  Mixer with  2000-3000 grams of material.  This test will determine if the Lancaster Mixer is an appropriate piece of equipment for the process.   Testing can take place in the Lancaster Products testing facility in Lebanon, PA or at the customer site with a rental K1-Lab Mixer.

STEP 2–  Production Scale: Going beyond proof of concept, the next round of testing is typically done in a K4 or K5 production mixer.  The Lancaster Products Engineering staff works to scale the K1 mix design to a production scale.

STEP 3Mix Optimization:  Once the mix design achieves the desirable material properties, the Lancaster Staff will work to improve the process to achieve results that exceed customer defined acceptable material outcomes such as improved yield rates, reduced processing times and enhanced material properties.

Benefiting from decades of mixing knowledge, Lancaster Products has built a deep database  of mixing data across multiple industries. We are happy to apply our knowledge and expertise to your application. Lancaster Products is proud to work with our customers to provide the solution for better material outcomes.

Contact us today to discuss how a Lancaster Mixer can improve your material outcome and schedule a time to test.


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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