Blog-News
Save Time & Increase Yields by Mixing & Granulating in One Machine
After more than 75 years in business and hundreds of installations worldwide, we still get excited when we demonstrate Lancaster Mixers ability for homogenous powder mixing and granulating in a single batch operation. With an average batch runtime under ten minutes for most applications, Lancaster Mixers ability to granulate produces high on size yields in a repeatable and predictable process. These “one-step mix-granulate” processes are utilized across a wide variety of applications including the production of fertilizer, technical ceramics, lightweight aggregates, beneficial re-use of waste, and more.
A typical Mix-Pelletizing Cycle looks like this:
- Feed dry ingredients into mixer from weigh hopper(s)
- Dry mix and de-lump
- The de-lumping capability means the raw material does not have to be dry
- Add liquid or binder from separate weigh hopper(s)
- Wet mix and pellet formulation
- Dusting (optional – to stop pellet growth and clumping)
- Discharge
Effective Homogenization and Densification of Powders of Differing Densities
As published by Powder & Bulk Solids March 2023, pp. 13-14.
A common challenge faced by many customers is mixing two or more materials of differing densities into a uniform and homogenous mixture. Insufficient mixing can lead to particle segregation and de-mixing during transport or storage.
The Lancaster line of high-shear counter-current mixers excel at the rapid homogenization of bulk powders, including those of differing densities. For some applications, dry mixing operations can be as brief as 30 seconds or less.
This case study will demonstrate how Lancaster Products high-shear counter-current mixers can effectively homogenize these powders into a uniform mixture, while increasing the overall mixture density in the absence of added moisture. The counter-current mixing action is achieved by rotating the mixing rotor and mixing pan in opposite directions. Strategic manipulations of the speeds of the mixing tools can produce a uniformly homogenous mixture in a short period of time.
Increasing Throughput with Continuous Batch Processing
Part 4 of a 4-part blog series: “Enhanced Mix-Granulation in a Single Machine“
The 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.
Batch processing of complex fertilizers offers both greater product accuracy and high yield outputs. The other key advantages of a batch process are recipe optimization and mix homogeneity. In fact, there are no real downsides because – with a continuous batch configuration – these important benefits can be realized simultaneously with the consistent throughput and high production rates of a continuous production line.
Enhanced Product Characteristics and Reproducibility
Part 3 of a 4-part blog series: “Enhanced Mix-Granulation in a Single Machine“
The 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.
In complex fertilizers, thorough mixing of individual nutrients (e.g., N, P and K macro-nutrients plus secondary nutrients and micronutrients) is required to ensure maximum agronomic effectiveness without over/under application to the field. The multi-tool mixing action in counter-current technology delivers this, providing homogeneous mixing with rapid mix times.
Because the pan, high speed rotor and plow are individually controlled, the mixer can create exact and repeatable conditions within the mixing cavity to produce specific products – e.g., granules of a specific size within a tight tolerance. Valuably, even slight adjustments to tooling speeds can produce different sized granules, shapes, densities, and yields.
Reduced System Complexity
Part 2 of a 4-part blog series: “Enhanced Mix-Granulation in a Single Machine“
The 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.
Traditional fertilizer manufacturing typically requires multiple steps and many different pieces of machinery for drying, milling, mixing and agglomeration. Additionally, initial drying of high moisture raw materials is often required prior to processing – adding extra time and energy costs to the manufacturing process. Mixing and granulating in the same step in a high shear, counter-current mixer is advantageous as it reduces system complexity in several ways (Table 1):
Disc Granulation versus Mix-Granulation
Part 1 of a 4-part blog series: “Enhanced Mix-Granulation in a Single Machine“
The 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.
NEW Heated Pan Option for K-1 Laboratory Mixers
The K-1 Laboratory mixer from Lancaster Products is now available with a heated pan option, and K-1 mixers currently in the field can be retrofitted with a heated pan as well. The heated pan provides consistent, controlled heat throughout the mixing chamber, and is ideal for recipes that require a very viscous binder such as molasses, wax, or tar. The addition of heat directly to the mix recipe increases the flow rates of viscous materials (particularly binders) which can prevent premature binding and incomplete mixing.
High Intensity Explosion Proof Mixers
Lancaster Products offers explosion proof mixers for high intensity mixing applications where the potential for explosions is present, such as mixing powders for 3D metal printing. Most of our Lancaster Mixers can be designed to meet explosion proof requirements such as:
- The ability to pump inert gas (such as Nitrogen or Argon) into the mix chamber to replace the Oxygen and eliminate the potential for spark caused by the presence of Oxygen.
- Instrumentation added to verify the removal of Oxygen in the mix chamber.
New, Integrated Clean-in-Place Option for Lancaster Mixers
We are excited to announce the addition of integrated Clean-in-Place systems as an available option for all new Lancaster Mixers. Customer demand has been high for this feature as more materials processors are expanding their product offerings and running a greater diversity of recipes through our mixers, thus increasing the need for regular, complete cleaning between products. The ability to automate the cleaning process also helps to satisfy the need to improve efficiencies and counteract recent trends in labor shortages.
The Lancaster Mixer clean-in-place (CIP) system incorporates rotating nozzles permanently mounted in an optimal configuration that allows for 360-degree coverage of the mixing chamber without interfering with normal machine operation such as loading ingredients and discharging processed materials. High pressure pumps power the system to accomplish complete coverage with average cleaning cycles as short as 5-10 minutes. The ability to automate the process at pre-determined intervals ensures greater reliability and consistency of cleanliness and maintenance.
Owner Interview: How to Grow by Design with Curt Snyder
Re-published by permission from Value Prop and the Revenue Throughput Podcast.
Jose Palomino: Welcome again to the Revenue Throughput podcast. This is Jose Palomino, your host and our guest today is a CEO, owner, operator of a really fascinating company. He’s Curt Snyder, CEO of Lancaster Products based in Lebanon, PA, and they are a solutions company dedicated to improving material mixing and processing. They design and build complete mixing pelletizing and crushing systems for a wide range of industries and different materials and applications.
I’ve known Curt for years, and I’ve seen firsthand how he’s applied some best practices and principles to grow and thrive in a number of highly competitive markets. Well, let’s welcome Curt Snyder to the Revenue Throughput podcast. Hi Curt, glad to have you here.
Curt Snyder: Thanks for having me Jose, I appreciate it.
Jose Palomino: Yes, so Curt, in my introduction I mentioned how I just focused on one business right now. The Lancaster Products that I’ve certainly grew to know you best through initially, could you just provide a brief background how you came to to become the owner of Lancaster product?
What drew you into the world of heavy industrial manufacturing?
Curt Snyder: I had been working in mergers and acquisitions for probably close to 15 years prior, part of that was in aerospace, so it’s fairly complex, highly engineered heavy manufacturing type of product. I had been traveling the world, making acquisitions, and had a young family and quite frankly was tired of being away. So much so, when the opportunity presented itself, I was able to go out on my own and I found Lancaster Products, and Lancaster Products seem to be really interesting. A heavier manufacturing company with proprietary products with some really interesting technology. Also the owner was ready to retire. So, I was able to step in and and take it over about five years ago.
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
