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

Proof of Concept Testing in Lancaster K1 Lab Mixers

Lancaster Products is dedicated to optimizing our customers’ mixing processes and recipes. This 3 part video series will focus on our on-site lab and testing capabilities. In this first video, we demonstrate proof of concept testing with a chicken litter material for a fertilizer product.

We use our K1 lab mixer during these initial tests. We load the K1 mixer with the test material and then program the steps and feeds. After the mixer begins, we add a liquid binder to it to allow the material to agglomerate into granules or larger pellets.

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Rotary Table Feeders Turn Batch Processing to Continuous Batch Processing

Rotary table feeders act as a critical piece of equipment in Lancaster Mixers continuous batch processing lines. They provide a mechanical conduit to continuously meter and feed materials from each batch of material processed to the next process in line. The cone and cylinder over the table is used as a surge hopper to temporarily store the material batch while the table feeder continuously discharges the material. Their role may seem simple compared to the processing equipment they’re connected to, but is significant to maintaining continuous throughput and ensuring overall system performance.

Lancaster Products’ high shear mixers process materials in batches which allows for tight control over the physical properties of the end product and thus, higher on-size, homogeneous yields. Most batches are processed completely and ready for discharge in a matter of minutes. By positioning a Lancaster rotary table feeder under the mixer’s discharge chute and feeding product downstream to the next piece of equipment, the batch processing is converted to a continuous process.

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