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

Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

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Full Scale Mix Recipe Optimization in Lancaster K4 Mixers

This is the third video in our lab and testing series. The Lancaster Products Lab is equipped with a production-sized K4 mixer to test and optimize mix recipes at full scale. In this video, we are testing a clay type of material for pelletization.

The K4 mixer introduces a third tool, the low-speed plow, which, along with the rotating pan, transports material to the high-speed rotor. You can see how the high shear counter-current movement creates a rolling action which agglomerates the materials into pellets. The K4 mixer has a bottom discharge; the plow allows for the rapid and complete evacuation of the mixing cavity. After the mixer is fully evacuated, the bottom discharge closes, and reseals ready for the next batch.

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Prototype Mix Recipe Optimization in Lancaster K3 Mixers

This is the second video in our lab and testing series. The Lancaster Products lab is equipped with a small production-sized K3 mixer to test and optimize mix recipes at a prototyping scale. In this video, we are testing a clay type of material for pelletization.

Looking inside of the mixing cavity, you see the counter-current mixing action. The pan rotates clockwise, and the high shear mixing tool spins counterclockwise. The mixing pan actively transports material to the primary mixing tool. Slowing the action down gives us a good view of how the Lancaster mixing action creates a tumbling that promotes agglomeration by rolling the particles much the same way as a snowball growing larger by rolling down a hill.

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