Over the years, we have worked with several fertilizer manufacturers in helping them meet their required specifications to produce safe and effective fertilizer for mass consumption. These requirements have ranged from mix-only processing of sulfur to a pelletized, shelf-ready end product made from organic ingredients. In all cases, our high shear mixers outperformed alternative solutions and/or improved efficiencies from existing processes.

Fertilizer manufacturing is a process by which raw materials/nutrients, often in powder form, are mixed and agitated with a binder until pelletized for easier spreading with minimal dust dispersion. The pellets must be a homogeneous mix of nutrients to ensure maximum effectiveness without over/under saturation when applied. Furthermore, the size of the pellets will vary based on its intended application. For example, fertilizer for commercial agricultural fields will not necessarily be the same size as that used on golf course greens.

High shear mixers manufactured by Lancaster Products are the ideal machines for fertilizer manufacturers. Not only will these machines meet the requirements of a homogeneous mixture, but they also allow for multiple products to be run in the same machine on a batch-by-batch basis. Our engineering and materials processing staff will apply their experience to define the process for varying pellet sizes. This also allows for a tighter control on the yield rates for each type of fertilizer manufactured and thus a higher rate of predictability when forecasting production schedules.

Contact us today to discuss how high shear mixers from Lancaster Products can improve your fertilizer manufacturing process.

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

Full Scale Mix Recipe Optimization in Lancaster K4 Mixers

This is the third video in our lab and testing series. The Lancaster Products Lab is equipped with a production-sized K4 mixer to test and optimize mix recipes at full scale. In this video, we are testing a clay type of material for pelletization.

The K4 mixer introduces a third tool, the low-speed plow, which, along with the rotating pan, transports material to the high-speed rotor. You can see how the high shear counter-current movement creates a rolling action which agglomerates the materials into pellets. The K4 mixer has a bottom discharge; the plow allows for the rapid and complete evacuation of the mixing cavity. After the mixer is fully evacuated, the bottom discharge closes, and reseals ready for the next batch.

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Prototype Mix Recipe Optimization in Lancaster K3 Mixers

This is the second video in our lab and testing series. The Lancaster Products lab is equipped with a small production-sized K3 mixer to test and optimize mix recipes at a prototyping scale. In this video, we are testing a clay type of material for pelletization.

Looking inside of the mixing cavity, you see the counter-current mixing action. The pan rotates clockwise, and the high shear mixing tool spins counterclockwise. The mixing pan actively transports material to the primary mixing tool. Slowing the action down gives us a good view of how the Lancaster mixing action creates a tumbling that promotes agglomeration by rolling the particles much the same way as a snowball growing larger by rolling down a hill.

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