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.

Testing is often an iterative process where we alter steps, individual tool speeds as well as binder amounts, and timing of the addition of the mix to evaluate if it improves the product. Our highly experienced team are experts at quickly honing in on a mixing design that gives our customers their desired product.

We observe the mixing and pelletizing progress by taking samples and visually observing if the batch is approaching the desired specification. Once we think we are within our material target specs, we stop the process and unload the batch. In this application, we will dry and screen to really evaluate how close we are to what the customer is looking for.

Contact us today to learn more about our proof of concept laboratory testing services

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717-273-2111

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

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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Improve Throughput Rates and Product Accuracy with Continuous Batch Processing

The Lancaster Products Continuous Batch Processing (system) design enjoys the benefits of both continuous and batch processing.

Designing an optimal process for bulk material mixing often requires trade-offs between high throughput rates and high product accuracy. These choices are often presented when choosing between a continuous or batch process as different applications require different types of flows through the production line. This article examines the benefits of both continuous and batch processes as well as a hybrid approach – continuous batch processing.

CONTINUOUS VS. BATCH PROCESSES

Continuous mixing processes are characterized by a consistent flow of material through the mixer where the discharge rate exactly matches the feed rate. The primary benefit of continuous mixing is steady state throughput to feed the next processing operation on the production line.

On the other hand, batch mixing processes typically are not in a steady state flow. Premeasured ingredients are added to the mixer, processed, and discharged in a single batch. The major benefit of batch mixing is the precise control of ingredient ratios, mix quality and product accuracy.

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