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.

GETTING STARTED

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.

TESTING PROCESS

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.

Scale Up

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.

EQUIPMENT RENTALS

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 duration.

*Availability of Equipment may vary.

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

Full Scale Mix Recipe Optimization in Lancaster K4 Mixers

This is the third video in our lab and testing series. The Lancaster Products Lab is equipped with a production-sized K4 mixer to test and optimize mix recipes at full scale. In this video, we are testing a clay type of material for pelletization.

The K4 mixer introduces a third tool, the low-speed plow, which, along with the rotating pan, transports material to the high-speed rotor. You can see how the high shear counter-current movement creates a rolling action which agglomerates the materials into pellets. The K4 mixer has a bottom discharge; the plow allows for the rapid and complete evacuation of the mixing cavity. After the mixer is fully evacuated, the bottom discharge closes, and reseals ready for the next batch.

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Prototype Mix Recipe Optimization in Lancaster K3 Mixers

This is the second video in our lab and testing series. The Lancaster Products lab is equipped with a small production-sized K3 mixer to test and optimize mix recipes at a prototyping scale. In this video, we are testing a clay type of material for pelletization.

Looking inside of the mixing cavity, you see the counter-current mixing action. The pan rotates clockwise, and the high shear mixing tool spins counterclockwise. The mixing pan actively transports material to the primary mixing tool. Slowing the action down gives us a good view of how the Lancaster mixing action creates a tumbling that promotes agglomeration by rolling the particles much the same way as a snowball growing larger by rolling down a hill.

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