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

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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Mix-Granulating with a Lancaster K-Series High Shear Mixer

Many reasons compel industrial operations to enlarge solid particles for handling. Some objectives may be: enhancing flow properties, recycling, de-dusting, densifying, freezing ingredient distribution, improving mold filling properties, etc. Size–Enlargement in the powder technology context include: agglomerating, pelletizing, granulating and briquetting. This article deals with particle enlargement generally through a snowballing mechanism, with some shear action, but without the application of high pressure or extrusion.

Most powders having the ability to fuse, or slightly dissolve in the presence of a liquid, can be granulated quite easily. Others may be coaxed to form granules by the introduction of some suitable binders. The binders may act as a medium for the solid particles to adhere to each other by modifying interfacial activities. Some may form a matrix to capture the particles. Others may involve chemical reactions to achieve the objective.

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