Achieving uniformity and consistency while preserving the integrity of materials is critical in many powder processing applications. Counter-current low shear mixing is a leading technology offering a gentle yet effective method to blend powders without compromising their properties. Counter-current low shear mixing is ideal for applications that require intensive mixing with lower energy processing, including the manufacture of clays, adhesives, refractory materials, and concrete.
What Is Low Shear Mixing?
Low shear mixing involves the careful blending of powders at a controlled speed and intensity, minimizing the force exerted on the particles. Unlike high shear mixing, which applies significant energy to rapidly and thoroughly mix powder materials, low shear mixing prioritizes controlled agitation to maintain the integrity of materials.
Low energy mixing is ideal for diverse powder applications, effectively mixing abrasive, corrosive, highly viscous, and shear thickening or non-Newtonian materials.
This mixing method is also particularly suitable for fragile or heat-sensitive substances that may degrade under harsh conditions as well as mixing slow or delayed chemical reactions.
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Lancaster L-Series Mixers Capacities range from: 0.1 cu ft to 80 cu ft
The Lancaster Mixing Action
The counter-current mixing action featured in all Lancaster Products mixers occurs when the pan rotates in one direction, while the mixing tools rotate in the other. The rotating mixing pan conveys the material to the counter-rotating tool assembly. This results in countless cross-over of layers with maximum particle travel both vertically and horizontally.
Lancaster Products L-Series mixers are equipped with high-torque, low shear rotating plow blades with the option for custom tooling configurations, such as mullers and/or plows. Muller assemblies deliver the kneading, rubbing, and smearing action of a mortar and pestle, while plow action alone offers gentle kneading.
Advantages of Lancaster Low Shear Mixers
Preservation of Material Integrity
A primary benefit of low shear mixing is its ability to achieve homogeneity without compromising the characteristics of the ingredients. By exerting minimal force on the particles, it reduces the risk of attrition, abrasion, or heat generation. Preserving material integrity results in a higher final product quality with minimal process losses.
Consistent Batch-to-Batch Quality
In many applications, ensuring consistent product quality is crucial. Low shear counter-current mixing reduces powder agglomeration and ensures uniformity across batches, minimizing variations and enhancing overall product reliability. This consistency is vital for industries where product uniformity directly impacts performance and compliance with industry standards. Low shear mixers consistent quality translates to cost-effective batching and improved operational efficiencies for manufacturers.
Controlled Mixing Process
Lancaster Mixers provide better control over the mixing process, allowing for precise adjustment of mixing parameters to achieve the desired outcome. All mixing tools plus the counter-current rotating pan are independently controlled to provide custom mix designs to meet low-energy mixing challenges.
Effective Mixing of Hard-to-Mix Applications
Lancaster Mixers counter-current low shear action allows for effective homogenization of viscous, sticky, heavy, or other hard-to-mix applications. The high-torque, low shear counter-rotating action provides for an effective, consistent mix for the thickest and most difficult to mix of materials.
Ideal for Research, Testing, or Production
Lancaster Products low shear mixers offer superior mixing and versatility, accommodating a wide range of batch sizes and formulations with consistent results. The L-Series mixers are available in capacities ranging from 0.1 cu ft to 80 cu ft. and are ideal for material testing, mix optimization and proof of concept development. Lancaster Mixers can be found in research and material test labs or production environments.
By minimizing the need for post-processing steps such as sieving or re-blending, these mixers streamline production workflows, saving time and resources.
Harness the Power of Low Shear Mixing
Low shear mixing offers a reliable solution for achieving precision and efficiency in powder blending applications.Whether enhancing product quality in refractory applications or optimizing research in university or DOT material testing labs, customers worldwide rely on the thorough mixing action and consistent batch results produced by Lancaster L-Series mixers.
For more information on how low shear mixing could be a good fit for your application, contact Lancaster Products.
