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.
For customers who aren’t ready to make the capital investment in a production mixer or need product immediately, Lancaster Products offers toll processing services. We can produce significant amounts of blended, homogenized, granulated or pelletized materials in our facility to satisfy our customers’ needs.
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.