Part 1 of a 4-part blog series: “Enhanced Mix-Granulation in a Single Machine

Download the Full ArticleThe precision mixing and granulation of mineral and organic fertilizer ingredients are essential to meet growing market demand for high-value, complex crop fertilizers. Furthermore, the ability to mix and granulate in a single machine offers fertilizer manufacturers both operational and product quality advantages over traditional granulation methods.  Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International May|June 2022, issue 508, pp. 34-37.


Disc granulation is the method commonly used to produce fertilizer granules. This two-stage process typically employs a pin mixer (or similar mixer type) to pre-mix powdered materials to provide the feed for the disc pelletizer. The process generally requires the addition of large amounts of binder and water to create the finished product. This traditional type of granulation process is often not ideal as it generates lower yields of on-size pellets (1-3 mm) leading to high recycle loads.

In comparison, high shear, countercurrent mixers – unlike most granulation options – can rapidly mix and granulate materials in the same machine as a single stage process. In mix-granulation equipment, such as those offered by Lancaster Products, the pan rotates in a clockwise direction, while the mixing tools rotate counter-clockwise direction. This design results in efficient counter-current mixing by creating the necessary shearing action within the mixing cavity.

The mixing tool’s variable speed capability achieves the desired output by enabling different sized granules and densities to be created. A wide spectrum of granule sizes – from the micron range to as large as 8-10 millimeters – are possible depending on the feed materials. Mix-granulation is completed in batches and excels at producing highly repeatable homogeneous mixes and granules (Figure 1).

Contact us to learn more about the benefits of mix-granulation.