Lancaster Products high-intensity K-series mixers can mix and granulate in a single machine in a single operation.
Our proprietary mixing knowledge and technology, our counter-current mixers are a high-value, high-throughput granulation solution for many applications.
ideal tool to granulate powdered materials
Because our mixers can mix and granulate in the same process, there are no segregation problems during handling and it ensures a homogeneous granule. Powders granulated in a Lancaster K-Series mixer provide uniform mixtures and flow. The granulation process in a Lancaster Mixer optimizes the overall mix quality and reduces the use of binders, water and minor ingredients due to the efficient dispersion of ingredients throughout the mix. The granulation process also allows for a dust free product for handling, bagging and transportation. In addition to working with powders, for certain applications, the mixer can act as a rough milling device, using the high speed rotor to break down non-uniform or lumpy materials into a powder in order to build the material back up into a granule.
ONE MACHINE ONE PROCESS
The Lancaster Difference: Counter-Current Mixing Technology
Using our proprietary mixing knowledge and technology, Lancaster Products high-intensity K-series mixers can mix and granulate in a single machine. Within each mixer, the pan rotates clockwise and the tooling rotates counterclockwise, imparting a tremendous amount of energy into each batch.
Each piece of tooling in the mixer is independently controlled and the counter-current shearing action creates a rolling motion at the proper settings – allowing granules to form. Like a snowball rolling down a hill, granules and pellets can grow larger with additional time in the mixer – all completely at your control.
- Recovery of waste streams and dust from a steel mill.
These waste streams can include floor sweeping, dust collected from the cupola and other general bag house dust collected throughout the process. These materials can then be combined and blended with a binding agent to allow reintroduction into the melting furnace.
- Blend and granulation for production of iron ore pellets.
Blending the iron ore with the bentonite prior to entering the standard balling drum ensures a more homogeneous mixture, thus resulting in a reduction in the amount of bentonite required to create the iron ore pellets. A reduction in bentonite usage resulted in a significant cost saving in the production of green iron ore pellets.
- Creation of Granulated Fertilizer
Lancaster Products works with many fertilizer companies, mixing and granulating both mineral and organic fertilizers to create a range of products for residential, farming and golf course usage. Our fertilizer customers enjoy the ability to alter the size ranges to create different product granule sizes for different markets and the ability to create a homogenous all in one granule.
- Granulation of Carbon Black for De-dusting and Material handling
Carbon black in its milled process form is extremely flighty and difficult to handle. Granulating in a Lancaster Mixer is optimized by allowing for a minimal amount of binder. The granulated product is much easier to handle and because it is densified, dust from handling is nearly eliminated.
Synergies Between Lancaster Products, Bradley Pulverizer, and Kercher Industries Lead to Improved Efficiencies and Market Growth
In January of 2020, Lancaster Products/Kercher Enterprises acquired the assets of Bradley Pulverizer and we are thrilled to add over 130 more years of industry experience to our 70+ years. While each will continue to operate as 3 separate businesses, we are already leveraging the benefits of the new acquisition. When Curt Snyder (owner) first explored this opportunity he immediately identified 5 primary synergies between the businesses that would benefit from cross-company collaboration and improve efficiencies to benefit our organizations as well as our combined pool of clients.
In just a short amount of time a strategic plan has been instituted to align the best of all 3 companies with a focus on the following:
High Shear mixers are used in a wide variety of applications in many different industries. Finding the right blend and being able to produce the same mix consistently is the key to success at Highwater Clays, a clay and glaze supplier to the arts & crafts industry. The company has two locations with the main production center located in Ashville, North Carolina. Highwater Clays produces a wide range of clay bodies using fireclays, ball clays, kaolin, and stoneware clays. All the clay bodies consist of complex compositions and must be mixed into one reliable consistency.