Granulation Process

Lancaster Products high-intensity K-series mixers can mix and granulate in a single machine in a single operation.


Our proprietary mixing knowledge and technology, our counter-current mixers are a high-value, high-throughput granulation solution for many applications.

ideal tool to granulate powdered materials

Because our mixers can mix and granulate in the same process, there are no segregation problems during handling and it ensures a homogeneous granule. Powders granulated in a Lancaster K-Series mixer provide uniform mixtures and flow. The granulation process in a Lancaster Mixer optimizes the overall mix quality and reduces the use of binders, water and minor ingredients due to the efficient dispersion of ingredients throughout the mix. The granulation process also allows for a dust free product for handling, bagging and transportation. In addition to working with powders, for certain applications, the mixer can act as a rough milling device, using the high speed rotor to break down non-uniform or lumpy materials into a powder in order to build the material back up into a granule.

ONE MACHINE ONE PROCESS

We are a solutions company dedicated to improving material mixing and granulating. Our versatile Lancaster High-Shear Counter Current Mixer can mix and granulate in one machine and in one process. We have acquired extensive mixing expertise that allows us to advise on mix design and outcome improvements. Our experienced engineers work with our customers to understand their requirements and then design a mix recipe that achieves or exceeds their goals.

We address granulation-related objectives including mixing & granulating cycle times, reduction of binders or minor additives, particle size & size distribution, yields at specific size ranges, particle shape or sphericity, and crush strength all can be achieved. The key benefit mixing and granulating in a single process is the ability to create a homogenous mix that is transformed into granules which are consistent in their composition throughout the batch and from batch to batch.

Lancaster Products High Shear Mixer
Lancaster Products

The Lancaster Difference: Counter-Current Mixing Technology

Using our proprietary mixing knowledge and technology, Lancaster Products high-intensity K-series mixers can mix and granulate in a single machine. Within each mixer, the pan rotates clockwise and the tooling rotates counterclockwise, imparting a tremendous amount of energy into each batch.

Each piece of tooling in the mixer is independently controlled and the counter-current shearing action creates a rolling motion at the proper settings – allowing granules to form. Like a snowball rolling down a hill, granules and pellets can grow larger with additional time in the mixer – all completely at your control.

GRANULATION APPLICATIONS:

  • Recovery of waste streams and dust from a steel mill.

These waste streams can include floor sweeping, dust collected from the cupola and other general bag house dust collected throughout the process. These materials can then be combined and blended with a binding agent to allow reintroduction into the melting furnace.

  • Blend and granulation for production of iron ore pellets.

Blending the iron ore with the bentonite prior to entering the standard balling drum ensures a more homogeneous mixture, thus resulting in a reduction in the amount of bentonite required to create the iron ore pellets. A reduction in bentonite usage resulted in a significant cost saving in the production of green iron ore pellets.

  • Creation of Granulated Fertilizer

Lancaster Products works with many fertilizer companies, mixing and granulating both mineral and organic fertilizers to create a range of products for residential, farming and golf course usage.  Our fertilizer customers enjoy the ability to alter the size ranges to create different product granule sizes for different markets and the ability to create a homogenous all in one granule.

  • Granulation of Carbon Black for De-dusting and Material handling

Carbon black in its milled process form is extremely flighty and difficult to handle. Granulating in a Lancaster Mixer is optimized by allowing for a minimal amount of binder. The granulated product is much easier to handle and because it is densified, dust from handling is nearly eliminated.

Call 1-800-447-7351 or [javascript protected email address] to talk to a Lancaster Products Representative about your granulation needs.

Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

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Lancaster Products Announces New Website Launch

January 4, 2019

For Immediate Release

LEBANON, Pennsylvania – The new and completely redesigned website offers visitors richer insight into the Company’s high efficiency mixing, pelletizing and crushing solutions for a wide variety of industries and materials.

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What to Expect from Lancaster Products High Shear Mixer Sample Testing

Our last post focused on our experience in concept testing and how it applies to our high shear mixer sample testing process. This post will dig in a little deeper and provide insight into the breadth of data we provide to our customers when they commission Lancaster Products to provide sample testing for them.

Over the past 30 years, we have collaborated with our customers to perform proof of concept testing in our K1 laboratory mixers for thousands of materials samples. The desired outcome of the testing is customer dependent but typical requirements are along the lines of pelletizing/granulating to specific size ranges and desired yields, mixing to achieve homogenization, or reduced reaction times of existing processes. Outcomes provided are 1) proof of concept in achieving the desired product, and/or 2) optimization of the current mix processes. Our engineers perform the tests in our controlled laboratory, log all key information in our database, and share all data with our customers for future reference. Below is a list that summarizes some of the information we collect during every test run we perform:

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