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

Email: [javascript protected email address]

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

Proof of Concept Testing in Lancaster K1 Lab Mixers

Lancaster Products is dedicated to optimizing our customers’ mixing processes and recipes. This 3 part video series will focus on our on-site lab and testing capabilities. In this first video, we demonstrate proof of concept testing with a chicken litter material for a fertilizer product.

We use our K1 lab mixer during these initial tests. We load the K1 mixer with the test material and then program the steps and feeds. After the mixer begins, we add a liquid binder to it to allow the material to agglomerate into granules or larger pellets.

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Rotary Table Feeders Turn Batch Processing to Continuous Batch Processing

Rotary table feeders act as a critical piece of equipment in Lancaster Mixers continuous batch processing lines. They provide a mechanical conduit to continuously meter and feed materials from each batch of material processed to the next process in line. The cone and cylinder over the table is used as a surge hopper to temporarily store the material batch while the table feeder continuously discharges the material. Their role may seem simple compared to the processing equipment they’re connected to, but is significant to maintaining continuous throughput and ensuring overall system performance.

Lancaster Products’ high shear mixers process materials in batches which allows for tight control over the physical properties of the end product and thus, higher on-size, homogeneous yields. Most batches are processed completely and ready for discharge in a matter of minutes. By positioning a Lancaster rotary table feeder under the mixer’s discharge chute and feeding product downstream to the next piece of equipment, the batch processing is converted to a continuous process.

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