Binders are a key ingredient in agglomerating, granulating and pelletizing applications.  Considered an inactive ingredient, binders are critical in allowing for agglomeration and holding the structure of the pellets together.  Many of our customers are pleasantly surprised of how efficiently the Lancaster High Shear Counter-Current Mixer can pelletize utilizing low amounts of binders when compared to alternate methods of granulation.    The advantage lies in the Lancaster Mixer’s ability to rapidly homogenize tiny amounts of minor ingredients into large amounts of majors.  Because the binder is so efficiently dispersed throughout the mix, only the optimal amount of binder is used.  Less effective mixing techniques require more binder than in a Lancaster Mixer, because the binder is not as effectively dispersed throughout the mix.

There are two common ways  we work with our customers:

Process Improvement

Customers with an existing product looking to improve their process come to us with a pre-defined recipe or formula for pelletizing and work with us to optimize ingredients and mix times in our high shear counter current mixer.   In these cases, we know the baseline formulation and we are actively attempting to refine the recipe and improve the mixing & pelletizing process.  Examples of  improvement outcomes include faster mixing and pelletizing times, increased yields at specific size ranges and/or reduced binder and minor ingredient usage.

New Product Development

Other Customers have ‘active’ raw ingredients and a profitable idea, but rely on our mix engineers to help define their recipe.  In these cases, choosing the right binder is secondary to developing the optimal mix process and highest yields as the binder itself typically does not compromise the chemistry of the raw, active materials.  Most binders are inexpensive, benign, and are compatible in the high shear mixing process.  There is a long list of binders available,  they can be organic or inorganic with some of the more common binders being: water, glue, molasses, PVA (polyvinyl alcohol powder), lignosulfonate, bitumen, corn starch, sucrose, alumina silicate, and many more.

Ultimately, the choice of binder used in pelletizing applications is contingent upon the specifications for the end product and cost.  Some products require binders that have specific properties such as: burn off in a kiln for ceramic applications, non-toxic or edible requirements for animal feed, or the inability to alter the end product’s color for colorant. Often customers ask Lancaster Products to test multiple binders at various price points to calculate a cost/benefit analysis of powerful but expensive binders versus less costly but less effective binders in their end product.   The engineers at Lancaster Products draw from our extensive recipe development knowledge to suggest binder choices for every application.

              Contact our engineers today if you need assistance in formulating your ideal end product or to optimize your existing formulation.

[javascript protected email address]

717-273-2111

Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

Sitemap | Privacy Policy

© Lancaster Products

Lancaster Products Announces New Website Launch

January 4, 2019

For Immediate Release

LEBANON, Pennsylvania – The new and completely redesigned website offers visitors richer insight into the Company’s high efficiency mixing, pelletizing and crushing solutions for a wide variety of industries and materials.

read more

What to Expect from Lancaster Products High Shear Mixer Sample Testing

Our last post focused on our experience in concept testing and how it applies to our high shear mixer sample testing process. This post will dig in a little deeper and provide insight into the breadth of data we provide to our customers when they commission Lancaster Products to provide sample testing for them.

Over the past 30 years, we have collaborated with our customers to perform proof of concept testing in our K1 laboratory mixers for thousands of materials samples. The desired outcome of the testing is customer dependent but typical requirements are along the lines of pelletizing/granulating to specific size ranges and desired yields, mixing to achieve homogenization, or reduced reaction times of existing processes. Outcomes provided are 1) proof of concept in achieving the desired product, and/or 2) optimization of the current mix processes. Our engineers perform the tests in our controlled laboratory, log all key information in our database, and share all data with our customers for future reference. Below is a list that summarizes some of the information we collect during every test run we perform:

read more