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
  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 an 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.


Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

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Press Release: Bradley Pulverizer Acquired By Lancaster Products Owner

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


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.

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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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