Process Plant Optimization Services

Audit and improve the performance of ANY existing materials processing lines

The team at Lancaster Products always welcomes the opportunity to visit with you at your processing plant to fully understand your existing materials processes operation and provide a comprehensive audit with suggested enhancements and clearly defined cost/benefit analyses for suggested upgrades.

Comprehensive Audit & Process Analysis

In our initial audit, our engineers will evaluate your entire operation to thoroughly calculate and document your current performance metrics. We then analyze the data to assess overall Quality, Throughput, Cost and most importantly the Safety of your current processing system. These results are used to identify potential areas of improvement within the mixing and pelletizing process itself and their impact on the overall process line. Lastly, we develop an easy to understand plan that provides a prioritized list of improvements from suggested enhancements to critical requirements.

Our audits can be conducted on ANY materials processing equipment regardless of equipment brands and focus on the four key aspects of your materials processing operation shown below:

Checklist Graphic

Recipe Optimization

  • Yield improvement
  • Process time reduction
  • Liquid and binder reduction

Process Optimization

  • Process redesign for increased efficiency
  • Automation opportunities to eliminate operator variability
  • Overall cost reduction –
    • Reduced cycle times
    • Increased yield
    • Reduced maintenance cost
  • Bottleneck identification and resolution
  • Document best practices
  • Safety review

Controls Upgrades

  • Hardware upgrades and conversions
    • PLC, HMI, SCADA, etc.
  • Identify opportunities for automation upgrades and overhauls

Machine Refurbishment

Cost analyses calculate long term ROI of purchasing new equipment vs. machine updates:

  • Mixers overhauls
  • Tooling replacement
  • Motors upgrades – VFD
  • Gear replacement
  • Grease line replacement
  • Upgrade to auto lubrication system
  • Controls upgrades
Contact us to talk to a Lancaster Products Representative

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

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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