Granulation Process

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

Lancaster Products High Shear Mixer
Lancaster Products

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.

GRANULATION APPLICATIONS:

  • 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.

Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

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Infographic: Optimize Your Fertilizer Pelletizing Process

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.

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Lancaster Products Multi Tool Mixing Advantage

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.

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