Traditional processes for manufacturing fertilizer require many steps and different types of equipment. It is common for systems to include multiple dryers, a mill/pulverizer for size reduction of dried material, pin mixer/pug mill for mixing of additives and raw materials, a pelletizer and multiple conveyors to facilitate the process. If this seems like a complex process that requires high levels of work, energy and maintenance, we agree.

Lancaster Products engineers can optimize existing complex fertilizer pelleting processes or design new streamlined systems to help you realize multiple benefits, including a reduction in physical footprint and an improvement in the characteristics and reproducibility of your pelletized product. By utilizing a Lancaster Products K-Series High Shear Mixer to replace a mill and disc pelletizer, you not only reduce system complexity but also gain the ability to begin processing with raw materials at higher moisture levels. The counter-current mixing action in a Lancaster Mixer allows for one-step mixing and pelletizing with rapid mix times.

Our counter-current, high shear mixers have several product and operating advantages over complex, traditional systems.

PRODUCT ADVANTAGES:
Counter-current, high shear mixing strategically imparts a higher amount of well-dispersed energy into the mixing process resulting in a well-defined final product in a fraction of the time. The individually controlled mixing tools allow for variation of pellet sizes to meet different product specifications. This results in:

    • More homogeneous pellets
    • Better control of fertilizer pellet size from batch-to-batch
    • Higher yields of on-size pellets

OPERATING ADVANTAGES:
The ease of use and versatility of a Lancaster Products High Shear Mixer provides many operational benefits to reduce operating and raw material costs. Replacing several pieces of equipment with a single Lancaster Mixer offers the following advantages:

    • Reduced system complexity
    • Reduced equipment maintenance
    • Less energy use
    • Reduced physical footprint
    • Reduced waste output and binder use
    • Ability to operate with high moisture raw materials

Contact our engineers today to discuss how we can help to optimize your fertilizer pelletizing process.

717-273-2111

Maintenance Bulletin: Rotor Wear and Replacement in Industrial Mixers

The high-speed rotor is the primary mixing and pelletizing tool in industrial high shear mixers and in many ways, it is the most utilized part of the machine. But rotor wear is also a good leading indicator of your machine’s overall operating condition as it is a direct result of material processing. Chances are, if the rotor is worn, there is other preventative maintenance to be done.

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What Preventative Maintenance Will Prolong the Life of My Mixing Equipment?

Industrial mixers are built to run and withstand a great deal of abuse, however, regular preventive maintenance efforts can help keep your mixer running like new. The two most critical components that can affect the life of your mixer are lubrication and inspection of working tools. Below is an overview of the in-depth information provided in our full maintenance schedule available for download below.

 

Lubrication: Proper lubrication can encompass multiple areas on your mixer, not just the shaft seals of the mixing tool. Lubrication of all seals as well as drive gears, discharge valves and other locations where bearings are utilized is the best way to extend the life of your mixer. Automated lubrication systems on larger production mixers help maintain proper lubrication intervals, but regular visual inspection should be scheduled to assure the system is working properly.

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