From proof-of-concept testing to large-scale toll processing, Lancaster Products provides full-scale process lab services.
Lancaster Products is dedicated to process and mix design optimization. Whether you are looking to develop a new process or simply improving existing production, Lancaster Products can help. Our experienced application engineers can design a solution that meets many objectives, including mixing cycle times, binder and minors optimization, homogeneity, particle hardness, moisture, and air entrainment, particle size distributions and yields.
With decades of mixing and pelletizing knowledge that spans across multiple industries coupled with our staff’s knowledge and expertise, Lancaster Products can provide a customized solution for you. Quality products need quality materials, and our proof of concept testing provides our clients with a more innovative and efficient process, allowing them to gain a competitive advantage in more ways than one.
We work with our customers to create an optimized mix design by identifying their product & process goals as well as discussing possibilities for improvements with a Lancaster Mixer over other mixing or agglomerating equipment. From granulating or agglomerating to pelletizing, our extensive product testing process ensures our mixer testing will deliver the end results to your exact process specifications. Once the parameters have been defined and proof of concept testing is completed, you’ll receive a testing results report in addition to the associated mix design.
The Lancaster Products Guarantee for proof of concept K1-LAB testing: We’ll produce a mix design that achieves your goals or testing will be free of charge*.
*Within an acceptable range of size, yield, homogeneity or hardness from predefined criteria set prior to testing.
Lancaster Products engineers work with our customers to create an optimized mix design by identifying their product & process goals as well as discussing possibilities for improvements with a Lancaster Mixer over other mixing or agglomerating equipment.
Proof of Concept Testing
Once we’ve evaluated the customer’s process and conducted research regarding the material we’ll be working with, we develop the initial mix design for proof of concept testing. This is accomplished through review of our extensive mixing database and utilizing our skilled knowledge of mixing to determine a starting mixing recipe — including mixing time, rotor and pan speeds and ingredient amounts and order.
Once the small scale test is completed, customers have the option to test in a production environment using one of our K4, K5 or K6 mixers. This allows customers to verify that our proof of concept is scalable and achieves the exact same end result when produced in a larger batch. Lancaster Products engineers calculate any necessary adjustments to the mixing recipe to ensure the specified end result is obtained.
We also offer equipment rentals for testing or production. Customers can try equipment in their own facilities over a period of time so other factors related to the equipment itself such as footprint, size, location, electric and air, etc. can be evaluated as well. It is during these test runs that unanticipated issues are often identified and addressed, thus helping in both the proof of concept of the process itself, as well as any equipment modifications that may be required to fit the needs of the application.
Lancaster Products offers a variety of equipment rental possibilities. We have a fleet of K-Series high shear mixers in a variety of sizes from the K1-LAB (0.5 ft. 3 capacity) to the K5 (24 ft. 3 capacity)* that is ready for use by companies looking to run sample processing on-site in their own facility. We offer rental terms of various durations.
*Availability of Equipment may vary.
920 Mechanic Street
Lebanon, PA 17046
Toll Free: 800.447.7351
Mon - Fri: 8:00 am - 5:00 pm
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.
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.