How is your Lancaster mixer performing?

Are you noticing a drop in yields or inconsistencies in product quality?

This may be an indication that your high-speed rotor needs to be repaired or replaced.

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.

The images below show examples of rotor vane wear from an abrasive mix process over time.  As you can see, it is fairly easy to identify the degree of wear by simple visual inspection in between batches.  Rotor vanes exhibiting a loss in base metal should be replaced to maintain optimum batch yields and quality of end product.

Lancaster Products’  upgraded control systems are pre-programmed to alert the operator with a maintenance reminder when it’s time to inspect the rotor based on a predetermined interval of batch cycles to ensure that your Lancaster Mixer is performing at optimal levels.

NOTE: Because every material processed in our mixers is different, we encourage all machine operators to visually inspect the rotors with regularity, so the controls can be re-programed as needed to match the wear patterns in your process.

Not sure if your rotors need replacement?  Contact us today because the Certified Service Technicians at Lancaster Products are always available to assist with any on-site or remote diagnostics, repairs, and replacements of rotors or rotor vanes.


Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

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Office Hours:
Mon - Fri: 8:00 am - 5:00 pm

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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