Introducing Lancaster Products High Shear Counter-Current Mixer Recipe Development, the first in a category of posts designed to provide insight into our deep experience in developing  thousands of pelletized and granulated formulations over the past 30 years.

We develop custom recipes or mix designs for our customers that are rooted in our deep mixing and pelletizing experience.  Because every customer’s materials, parameters and processes are different, each requires a unique mix design. In performing proof of concept testing, we have worked with our customers on a wide variety of materials and binder combinations across many different industries.  While specific formulations belong to our customers, we have learned a tremendous amount from our experiences with various materials and we wanted to highlight the science that goes into every formulation developed by our materials processing engineers.

Custom Mix Designs

The mix designs developed by Lancaster Products’ engineers require a high level of precision to meet each customer’s specifications.  Our customers provide us with major ingredients (most commonly powder(s)), sometimes a desired binder and then physical specifications for their end product with regard to homogeneity of the mix, granule size, sphericity, moisture level and hardness.  Our engineers then work through the mix design, initially designating the number of steps involved, the tooling and pan speeds as well as time at each step, quantities of ingredients, and when to add liquids and binders and timings of ingredient additions.  We often go through a trial and error process to home in on the exact recipe to produce the desired product specifications.  After we hit the target criteria, we then move to phase 2 of the product development to refine the recipe.  We work to optimize the process to:

  • reduce the amount of additives, liquids and/or binders,
  • reduce times at each step and
  • increase yields at targeted size range

Because the development of mix designs is often a complex and iterative process,  these factors must be thought through prior to performing testing and we rely on our experience from many years of testing a vast number of materials in our High Shear Counter-Current mixers.

In 30 Years of Mixing Trials, We Have Seen A Lot

Our experience has been codified into a  guide that draws from many years of mixing and pelletizing tests performed under controlled conditions in our laboratory.  Our guidebook gives Lancaster Products an excellent proxy to begin a new mix design for our customers.  Our materials processing engineers reference this guide as a starting point whenever a customer presents us with a new opportunity.  In many cases, we have deep experience with material similar to their application so lab testing becomes fairly predictable exercise.  Occasionally, we are presented with totally new materials/applications that we have never experienced that requires more extensive proof of concept testing and new mix designs to be developed, but we can reference our experiences with proxy materials to expedite development and improve on existing formulas/processes before going to mass production.

Contact our engineers today to discuss how we can apply our experience to help optimize your current materials processing application.

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

Press Release: Bradley Pulverizer Acquired By Lancaster Products Owner

For Immediate Release Contact:
Curt Snyder 717-273-2111
[email protected]

BRADLEY PULVERIZER ACQUIRED BY LANCASTER PRODUCTS OWNER

Allentown, Pennsylvania, January 17th, 2020 – Bradley Pulverizer is pleased to announce new ownership. Lancaster Products & Kercher Enterprises’ owner Curt Snyder acquired the assets of Bradley Pulverizer through an affiliate effective on January 14th, 2020. Bradley Pulverizer specializes in the design, manufacture, and supply of pulverizing systems for fine and semi-fine grinding of hard, friable, abrasive materials for various applications throughout the world.

read more

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.

read more