Lancaster Products has deep experience blending, mixing and pelletizing materials in the ceramics industry. Our High Shear Counter-Current Mixers excel in homogenizing powdered materials of different densities. Lancaster Products Mixers provide high-intensity mixer preparation of glazes for ceramics.
Our mixing action produces reduced process times and improved productivity, and produces a more homogeneous solution for glazes and other applications.
- Granulation of the raw material for improved quality and strength for pressed tile.
- Preparation of the slip for use in the casting process for sanitary ceramics and technical ceramics.
- Preparation of plastic bodies for extrusion and formable bodies.
- The ability to prepare the dry raw materials and the plastic body in a single mixer.
- Excellent distribution of additives even in very small quantities.
- Simple corrections in moisture when required.
- Reduced processing time allows higher throughput from a smaller machine.
Lancaster Mixers provide high intensity slip preparation for castable shapes. Our mixers result in reduced processing times versus the standard preparation in a blunger. Reduced aging times for the slip occur because of the high shear and desalination of the clay particles during processing. This results in the ability to cast the slip immediately after preparation without the typical 8-12 day aging period.
Lancaster Mixers are used extensively in ceramic proppant preparations that include the mixing of raw materials and the graduation of the materials for green pellet production. This process can be completed with clay-based proppants, fly ash based proppants and many other materials that can be fired into a final proppant product.
Traditional processes for manufacturing fertilizer require many steps and different types of equipment. It is common for systems to include multiple dryers, a mill/pulverizer for size reduction of dried material, pin mixer/pug mill for mixing of additives and raw materials, a pelletizer and multiple conveyors to facilitate the process. If this seems like a complex process that requires high levels of work, energy and maintenance, we agree.
Lancaster Products engineers can optimize existing complex fertilizer pelleting processes or design new streamlined systems to help you realize multiple benefits, including a reduction in physical footprint and an improvement in the characteristics and reproducibility of your pelletized product. By utilizing a Lancaster Products K-Series High Shear Mixer to replace a mill and disc pelletizer, you not only reduce system complexity but also gain the ability to begin processing with raw materials at higher moisture levels. The counter-current mixing action in a Lancaster Mixer allows for one-step mixing and pelletizing with rapid mix times.
Since the introduction of the original K-series mixer in 1986, Lancaster Products High Shear Mixers have been designed to produce the best mixing and pelletizing results for our customers. Lancaster Mixers superior performance is due to our multi-tool configuration, counter current mixing action and variable tooling speed capability.
Multi Tool Configuration
Lancaster Mixers can be configured with three independent variable speed mixing tools: the mixing rotor, the plow and the rotating pan. These three tools work in concert to provide the best mixing results. The primary mixing tool is the high-speed rotor. The plow and rotating pan both work to move material into the main rotor’s path. The three mixing tools are so efficient at mixing, there are no dead spots inside of the mixing cavity and every piece of material passes through the mixing rotor every few seconds. Additionally, a sidewall scraper is positioned against the pan sides to prevent caking and buildup of material on the pan itself.