Mixing Process

Lancaster counter-current mixing action is the most effective mixing technique for consistent uniformity, homogeneity and rapid mix time.


All Lancaster Products Mixers utilize a counter-current mixing action where the pan rotates in a clockwise direction, while the mixing tools rotate counter-clockwise creating a shearing action within the mixing cavity that imparts a tremendous amount of focused energy into the mix.  The powerful combination of multiple mixing tools including the rotating pan, high-speed mixing tool, and the counter-rotating plow effectively eliminate all dead zones in the mixer.

The pan and the plow transport material through the mixing cavity into the path of the high-speed mixing tool ensuring that all particles pass through the high-speed mixing tool every few seconds. The plow and sidewall scraper prevent material build up on the pan bottom and sidewalls, effectively leaving no unswept surfaces where ingredients can lodge. The Lancaster Products Mixer design allows for thorough mixing – without relying on the free fall or tumbling of material. Processing times are greatly reduced compared to most conventional mixers while providing a more homogeneous batch.

In addition to a superior mixing action, Lancaster Mixers can also granulate or pelletize in a single process.  Because the tooling and pan all are independently controlled, at the proper speeds Lancaster’s Counter-Current mixing action can create a rolling action inside the mixing cavity that allows for granulation and pelletization of materials.  The combination of homogeneous mixing and granulation provides for homogenous granules and pellets with the precise amount of ingredients throughout the batch – in one process in a single machine.


Our counter-current mixing action is the most effective mixing technology for rapid and consistent homogeneity of a wide variety of materials.

  • The rotating pan efficiently conveys material to secondary mixing plows and main high-speed mixing tool – all optimally placed to deliver maximum material mixing.
  • Designed to generate increased relative particle velocities – providing countless material exchanges throughout each batch cycle.
  • High-Intensive Mixers add versatility in meeting almost any material mixing challenge by individually adjustable component speeds.
  • Ability to handle powder to slurry mixing applications
Lancaster High Shear Mixer


Lancaster High Shear Mixer

Lancaster Products counter current High Shear Mixers excel in homogenizing, agglomerating, granulating, pelletizing and densifying in a single machine with increased yields, uniform quality and better mixing productivity than traditional mixing technologies.

Our high shear mixers can:

  • Mix and pelletize in one machine and one process
  • Homogenize powdered materials of different densities quicker and more effectively
  • Create homogeneous pellets that consistently deliver precise ingredient formulations
  • Deliver pellet size range tight tolerances and higher yields than possible with most other machinery
  • Alter the pellet size range from batch to batch with no changes to formulation or equipment to create products for different markets

Decades of mixing experience

Lancaster Products combine decades of mixing experience, working across multiple industries, with the finest granulating and pelletizing mixer technology. Lancaster Products Mixers are used with diverse materials such as

  • Glass
  • Ceramics
  • Building Materials (Grout, Concrete, Clay, Ultra High-Performance Concrete)
  • Many other materials, including:
    • Fertilizers (Mineral and Organic)
    • Waste stream reclamation (Iron Oxide, Dry Scrubber Materials)
    • Carbon Black
    • Refractory
    • Coal Combustion Products
    • Foundry/Molding Sand

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