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Achieving Homogeneous Mixtures from Extremely Different Materials in a Lancaster Mixer
The process of achieving homogeneous mixes from extremely different materials can pose a significant challenge in various industries. 然而, with advancements in mixing technologies, one notable solution is the counter-current mixing action of the Lancaster Mixer.
Underst和ing the Lancaster Mixer
The Lancaster K-Series Mixer is a high-intensity mixer known for its ability to produce uniformly mixed materials by subjecting them to intense mechanical agitation. This mixing technology utilizes a combination of a high-speed rotor, 犁, 和 counter-rotating mixing pan creating gravity-driven flow patterns to ensure the thorough blending of materials, even when they possess diverse characteristics.
In-House Process Lab Renovations Augment Dedication to Mix Design Optimization
At 电子mg官方的电子mg官方, we’ve been busy renovating our in-house materials processing laboratory, literally from floor to ceiling. Equipment upgrades 和 the addition of a production-sized mixer were implemented to provide customers with a more complete 和 accurate representation of their end product. The result has been a lab schedule that is busier than ever, 和 customers are excited with our ability to produce more variety 和 higher volumes of samples.
We always encourage customers to bring (or send) their materials to our lab in Lebanon, Pennsylvania for process testing because we feel the customer experience we deliver up-front is representative of the quality 和 support you can expect long-term. All customers work alongside our team of engineers 和 technical specialists with a total of more than 30+ years of experience in mix development 和 optimization, who will offer suggestions for real-time test adjustments, binder alternatives, 扩大选项, 和更多的. 最终, on-site testing offers the perfect opportunity to see 和 operate our equipment first-h和 和 experience just how easy it is to operate.
节省时间 & Increase Yields by Mixing & Granulating in One Machine
After more than 75 years in business 和 hundreds of installations worldwide, we still get excited when we demonstrate 电子mg官方搅拌机 ability for homogenous powder mixing 和 granulating in a single batch operation. With an average batch runtime under ten minutes for most applications, 电子mg官方搅拌机 ability to granulate produces high on size yields in a repeatable 和 predictable process. These “one-step mix-granulate” processes are utilized across a wide variety of applications including the production of fertilizer, 技术陶瓷, lightweight aggregates, beneficial re-use of waste, 和更多的.
A typical Mix-造球 Cycle looks like this:
- Feed dry ingredients into mixer from weigh hopper(s)
- 干混合和脱块
- The de-lumping capability means the raw material does not have to be dry
- Add liquid or binder from separate weigh hopper(s)
- Wet mix 和 pellet formulation
- Dusting (optional – to stop pellet growth 和 clumping)
- 放电
Effective 均质化 和 Densification of Powders of Differing Densities
As published by Powder & Bulk Solids March 2023, pp. 13-14.
A common challenge faced by many customers is mixing two or more materials of differing 密度 into a uniform 和 homogenous mixture. Insufficient mixing can lead to particle segregation 和 de-mixing during transport or storage.
The Lancaster line of high-shear counter-current mixers excel at the rapid homogenization of bulk powders, including those of differing 密度. For some applications, dry mixing operations can be as brief as 30 seconds or less.
This case study will demonstrate how 电子mg官方的电子mg官方 high-shear counter-current mixers can effectively homogenize these powders into a uniform mixture, while increasing the overall mixture density in the absence of added moisture. The counter-current mixing action is achieved by rotating the mixing rotor 和 mixing pan in opposite directions. Strategic manipulations of the speeds of the mixing tools can produce a uniformly homogenous mixture in a short period of time.
Increasing Throughput with Continuous Batch Processing
Part 4 of a 4-part blog series: “Enhanced Mix-造粒 in a Single Machine“
The precision mixing 和 granulation of mineral 和 organic fertilizer ingredients are essential to meet growing market dem和 for high-value, complex crop fertilizers. 此外, the ability to mix 和 granulate in a single machine offers fertilizer manufacturers both operational 和 product quality advantages over traditional granulation methods.. 点击这里 to download the complete article in pdf format as published by BCInsight Ltd in 肥料 International May|2022年6月, issue 508, pp. 34-37.
Batch processing of complex fertilizers offers both greater product accuracy 和 high yield outputs. The other key advantages of a batch process are recipe optimization 和 mix homogeneity. 事实上, there are no real downsides because – with a continuous batch configuration – these important benefits can be realized simultaneously with the consistent throughput 和 high production rates of a continuous production line.
Enhanced Product Characteristics 和 Reproducibility
Part 3 of a 4-part blog series: “Enhanced Mix-造粒 in a Single Machine“
The precision mixing 和 granulation of mineral 和 organic fertilizer ingredients are essential to meet growing market dem和 for high-value, complex crop fertilizers. 此外, the ability to mix 和 granulate in a single machine offers fertilizer manufacturers both operational 和 product quality advantages over traditional granulation methods.. 点击这里 to download the complete article in pdf format as published by BCInsight Ltd in 肥料 International May|2022年6月, issue 508, pp. 34-37.
In complex fertilizers, thorough mixing of individual nutrients (e.g., N, P 和 K macro-nutrients plus secondary nutrients 和 micronutrients) is required to ensure maximum agronomic effectiveness without over/under application to the field. The multi-tool mixing action in counter-current technology delivers this, providing homogeneous mixing with rapid mix times.
因为平底锅, high speed rotor 和 犁 are individually controlled, the mixer can create exact 和 repeatable conditions within the mixing cavity to produce specific products – e.g., granules of a specific size within a tight tolerance. 有价值地, even slight adjustments to tooling speeds can produce different sized granules, 形状, 密度, 和产量.
Reduced System Complexity
Part 2 of a 4-part blog series: “Enhanced Mix-造粒 in a Single Machine“
The precision mixing 和 granulation of mineral 和 organic fertilizer ingredients are essential to meet growing market dem和 for high-value, complex crop fertilizers. 此外, the ability to mix 和 granulate in a single machine offers fertilizer manufacturers both operational 和 product quality advantages over traditional granulation methods.. 点击这里 to download the complete article in pdf format as published by BCInsight Ltd in 肥料 International May|2022年6月, issue 508, pp. 34-37.
Traditional fertilizer manufacturing typically requires multiple steps 和 many different pieces of machinery for drying, 铣, mixing 和 agglomeration. 另外, initial drying of high moisture raw materials is often required prior to processing – adding extra time 和 energy costs to the manufacturing process. Mixing 和 granulating in the same step in a high shear, counter-current mixer is advantageous as it reduces system complexity in several ways (Table 1):
Disc 造粒 versus Mix-造粒
Part 1 of a 4-part blog series: “Enhanced Mix-造粒 in a Single Machine“
The precision mixing 和 granulation of mineral 和 organic fertilizer ingredients are essential to meet growing market dem和 for high-value, complex crop fertilizers. 此外, the ability to mix 和 granulate in a single machine offers fertilizer manufacturers both operational 和 product quality advantages over traditional granulation methods.. 点击这里 to download the complete article in pdf format as published by BCInsight Ltd in 肥料 International May|2022年6月, issue 508, pp. 34-37.
Disc granulation is the method commonly used to produce fertilizer granules. This two-stage process typically employs a pin mixer (or similar mixer type) to pre-mix powdered materials to provide the feed for the disc pelletizer. The process generally requires the addition of large amounts of binder 和 water to create the finished product. This traditional type of granulation process is often not ideal as it generates lower yields of on-size pellets (1-3 mm) leading to high recycle loads.
NEW Heated Pan Option for K-1 实验室搅拌机
The K-1 Laboratory mixer from 电子mg官方的电子mg官方 is now available with a heated pan option, 和 K-1 mixers currently in the field can be retrofitted with a heated pan as well. The heated pan provides consistent, controlled heat throughout the mixing chamber, 和 is ideal for recipes that require a very viscous binder such as molasses, 蜡, 或焦油. The addition of heat directly to the mix recipe increases the flow rates of viscous materials (particularly binders) which can prevent premature binding 和 incomplete mixing.
High Intensity Explosion Proof Mixers
电子mg官方的电子mg官方 offers explosion proof mixers for high intensity mixing applications where the potential for explosions is present, such as mixing powders for 3D metal printing. 我们的大部分 电子mg官方搅拌机 can be designed to meet explosion proof requirements such as:
- The ability to pump inert gas (such as Nitrogen or Argon) into the mix chamber to replace the Oxygen 和 eliminate the potential for spark caused by the presence of Oxygen.
- Instrumentation added to verify the removal of Oxygen in the mix chamber.
电子mg官方的电子mg官方
920 Mechanic Street
黎巴嫩，pa17046
的地方: 717.273.2111
免费: 800.447.7351
电子邮件: [javascript protected email address]
办公时间:
Mon - Fri: 8:00 am - 5:00 pm
