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.

Star Rotors are composed of a shaft with blades attached in a staggered configuration.  It is considered an all-purpose tool because it can both mix or pelletize materials.  This style of rotor is excellent for blending, chopping, milling, and homogenizing of materials. The star rotor is also an excellent all-around granulation tool.    Blades can be bolted on for quicker change-outs or welded on per client specifications.   The number and size of blades vary based on the size of the mixer and specifications of the mix.  Hardfacing is often applied to the blades to reduce wear and extend the blade life.   The angle and position of the blades effects the material flow within the mix and affords an almost limitless number of configurations allowing us to optimize the mixer to satisfy processing requirements.


Pin Rotors are comprised of a shaft with a disc shaped mixing ‘head’ attached to the tip and rugged metal pins arranged around the circumference in a vertical orientation.  These rotors are ideal for pelletization processes due to the rotor shape which is specialized for processing extremely round, dense, spherical pellets.




Some projects specify additional customization based on the materials being processed such as special coatings or hard facing the blades for extremely abrasive materials.  Additionally, rotors are considered a ‘wear part’ and need periodic inspection to determine wear life.  For star rotors with bolt-on replaceable blades or pin rotors with screw in pins, replacing worn blades or pins is a quick change.  For customers that have a star rotor with welded on blades, it is recommended to have a backup rotor on hand to avoid down time while the worn rotor is being fixed.

Contact us today to discuss your high shear mixer rotor requirements and we’ll work with you to provide the correct mixing tool to optimize your mixing or pelleting results.


Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

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Case Study – High Shear Mixing of Clay Compositions

High Shear mixers are used in a wide variety of applications in many different industries. Finding the right blend and being able to produce the same mix consistently is the key to success at Highwater Clays, a clay and glaze supplier to the arts & crafts industry. The company has two locations with the main production center located in Ashville, North Carolina. Highwater Clays produces a wide range of clay bodies using fireclays, ball clays, kaolin, and stoneware clays. All the clay bodies consist of complex compositions and must be mixed into one reliable consistency.

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Lancaster Products Announces Updates to Low Shear Mixers

We are excited to announce several recent improvements to the design of our low shear mixer product line. These mixers are often pushed beyond the limits of other mixers due to their widespread use in mixing dusty, abrasive, corrosive, highly viscous or explosive materials. The enhancements listed below were designed to improve the performance of our low shear mixers and to minimize maintenance and repair costs, which lowers the overall lifetime cost of ownership for our clients.

  1. Split drivetrain: pan and tooling on separate drives

The counter-rotating pan and tooling are now operating on separate drives allowing for individual control of tool and pan speeds. This simple split drive design provides increased flexibility to customize mixing recipes for different materials as compared to a single vertical shaft. Maintenance and trouble- shooting of issues relating to the pan or tooling also become easier.

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