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Maintenance Bulletin: Rotor Wear and Replacement in Industrial Mixers

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.

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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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Synergies Between Lancaster Products, Bradley Pulverizer, and Kercher Industries Lead to Improved Efficiencies and Market Growth

In January of 2020, Lancaster Products/Kercher Enterprises owner, Curt Snyder, acquired the assets of Bradley Pulverizer and we are thrilled to add over 130 more years of complementary industry experience to our 70+ years. While each will continue to operate as 3 separate businesses, we are already leveraging the benefits of the new acquisition. When Snyder first explored this opportunity he immediately identified 5 primary synergies between the businesses that would benefit from cross-company collaboration and improve efficiencies to benefit our organizations as well as our combined pool of clients.

In just a short amount of time a strategic plan has been instituted to align the best of all 3 companies with a focus on the following:

    1. Product Line Synergies
    2. Overlap in Customers and Industries Served
    3. Expansion of Manufacturing and Fabrication Capabilities
    4. Leverage Existing Global Sales Channels
    5. Enhanced Business Efficiencies
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Benefits of High Shear Mixing in Ferrite Processing

Ferrite materials have a dark grey to black color, possess strong magnetic properties and are categorized into ‘Hard’ and ‘Soft’ sub-classes. They are actually classified as ceramics due to their composition being a combination of metallic oxides. Hard ferrites have strong coercivity, showing relatively permanent magnetic properties. Soft ferrites have low coercivity, hence their magnetization can switch direction without much energy requirement or heat generation. This characteristic can be very useful. For this reason soft ferrites find wide applications in electronic industries.

Ferrites are generally synthesized using an iron oxide based powder through a solid phase reaction incorporating other metals, such as magnesium, zinc, manganese, nickel, cobalt etc. to achieve various desired properties. One critical requirement in the synthesis is a high degree of mix homogeneity which impacts on microscopic composition, consequently product quality. Typical processing sequence in the manufacture of ferrite products are: mix powders–>freeze recipe (by granulation)–>dry–>calcine–>mill–>spray-dry–>form and sinter to achieve the desired magnetic properties (see figure below). Calcination at sub-sintering temperatures (800°C – 1100°C) is considered beneficial in pre-consolidating metals for subsequent sintering which occurs generally between 1200°C – 1400°C. Calcination also eliminates carbonates.

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Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

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Maintenance Bulletin: Rotor Wear and Replacement in Industrial Mixers

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.

read more

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.

read more

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