717. 273. 2111

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:

  1. Materials. Includes: types of raw material and binders, volume, chemistry
  2. Mix time and steps. Includes: step times, pan speed, rotor speed
  3. Type of mixing tool(s) used
  4. Order in which ingredients are added
  5. Intended results/actual results
  6. Comments
  7. Samples

This data is provided to our customers in a lab report format and is valuable as a reference for future testing.  It also has value in cases where our customers already have a process in place to pelletize or granulate their materials, but want to improve on their efficiencies and yields.  Process optimization testing follows the steps outlined below:

  1. Specifications/expected results are defined
  2. Formulate and initial recipe for testing
  3. Lab scale testing
  4. Review test results
  5. Manipulate variables (materials, run time, rotor speed, etc) based on previous test to improve results
  6. Repeat lab scale testing as needed to achieve results that meet or exceed customer specifications
  7. Customer approval. Note: we can perform additional testing using any excess sample materials in an attempt to further optimize the process.
  8. Synthesize data and provide lab reports

Our engineers may suggest alternative ingredients, such as binders, to customers who may not have strict defined formulations.  In addition to proving the concept at the small-scale laboratory level, our engineers also develop recipes that are scalable  for production which may slightly differ from the recipe developed in the lab, again, with data provided along the way.

Contact our engineers today to discuss the process for sending us your materials so we can test them in our lab and develop an optimized materials processing formulation for your company.

[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

Operational Life Expectancy of Lancaster High-Intensive K-Series Mixers

Lancaster Products High Shear Counter-Current Mixers are highly effective in their ability to mix and pelletize in one machine and one process, but Lancaster Mixers are also built to last. Many of our machines are still operating after decades of use. We continue to supply parts to many vintage year machines still in operation.

High Shear MixerLancaster Products machines are built with a robust construction that provides structural durability and are designed to allow for replacement of wear parts as needed to extend the operational life of our machines instead of total machine replacement. To our customers this translates to lower Total Cost of Ownership and higher return on investment than other mixers. With proper maintenance, Lancaster Products mixers are very long-lived machines.

read more

Infographic: Lancaster Products Materials Testing Process

materials-testing-process-infographic-thumbnailLancaster Products is dedicated to process and mix design optimization. Whether you are looking to develop a new process/product or improve on an existing process, Lancaster Products can help. From mixing to granulating or pelletizing, our experienced application engineers can design toward many objectives, including: mixing cycle times, binder and minors optimization, homogeneity, particle hardness, moisture and air entrainment, particle size distributions and yields.

read more