Lancaster Products Mixing technology transforms waste streams into valuable products.


Lancaster Products High Shear Mixers are used in a wide variety of industries to repurpose waste materials into viable products. Waste materials can be mixed, densified and agglomerated in the same operation – allowing waste materials to be reintroduced into production streams or to be used as a stand-alone or additive in separate products.

Repurposing WASTE material application

Lancaster Products High-Shear Mixers have been used successfully to re-purpose previously discarded materials for use in the development of new products or reintroduction to production streams.  This results in a more environmentally friendly handling of material as well as reducing hazardous waste that is landfilled, stored in ponds etc.

Some applications include:

  • Pelletizing waste by-product sulfur for fertilizer
  • Pelletizing carbon black for flowability and better handling
  • Pelletizing synthetic gypsum for fertilizer
  • Agglomerating of fly ash for building and road aggregate
  • Granulating fly ash into cold set ceramic
  • Repurposing dry scrubber material into  lightweight cat litter
  • Pelletizing iron oxide dust for re-introduction into production furnaces
  • Pelletizing raw chicken manure for use in fertilizers.

ONE MACHINE ONE PROCESS

The high intensive action of the Lancaster High Intensive Mixers provides the opportunity to use relatively small amounts of additive materials needed to transform a waste material. The smaller amounts of additives mean lower production costs when using a more expensive material that may provide added product benefits.

Lancaster Products
920 Mechanic Street
Lebanon, PA 17046

Local: 717.273.2111
Toll Free: 800.447.7351

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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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