High Shear Mixers

Lancaster High Shear Mixers are being used in an ever-widening array of industries seeking improved mixing processes of blending, pelletizing or granulating with reduced additives and short, economical mixing times. Almost weekly, Lancaster Products is being contacted by existing and new customers that previously had a limited outlook on their mixing processes. They are now realizing increasingly new dimensions in processes and are even discovering processes they did not know existed— all by using a single Lancaster high shear mixer.


Why do Lancaster High Shear Mixers work so well? Primarily, it is about how much energy you put into a mix.

The Lancaster counter-current mixing action is widely accepted as the most effective mixing technique for rapid and consistent uniformity. The rotating pan is used to convey material to the counter-rotating primary mixing rotor, secondary mixing plows and side wall scraper. These mixing tools are strategically placed to promote maximum material mixing. This design allows for increased relative particle velocities and provides countless material exchanges throughout the batch cycle. Using the rotating pan to move the material allows for the mixing tools to be designed for optimal mixing energy input without regard for any need of material movement. This separation of functions also allows for individual speed adjustment of Lancaster high shear Mixer components. This ability to individually change component speeds adds tremendous versatility in meeting the customer’s ultimate product needs.


The amazing thing about high intensive mixing is the ability to take a small amount of material and water and disperse it within a large amount of material resulting in a homogeneous mix. The Lancaster high shear mixer does it best.


  • All in ONE Machine – For Blending, Pelletizing, Granulating, Slurrying, Dissolving, De-Dusting and Reacting.
  • Faster Mixing – Processing times can be greatly reduced while providing a more homogeneous batch using a Lancaster high shear mixer. Free-flowing powders and granular materials can reach desired homogeneity within one minute. More complex applications such as mix-granulation are generally completed within a cycle of 6 minutes or less.
  • Less Additives – The thorough Lancaster Mixing action usually allows for the addition of less additional binder materials or water.
  • No Dead Zones – There are effectively no dead corners or un-swept surfaces inside the high shear mixer where ingredients can lodge. The combination of a rotating pan, side scraper, and the counter-rotating plow eliminates all dead zones in the mixer.
  • Continual Material Removal – The plow and side scraper also provide for continual material removal from the pan bottom and sidewall surfaces.
  • Works with a Variety of Materials – Lancaster High Intensive or High Shear Mixers can handle the full gamut of materials from powders, to slips and slurries, to taffy-like materials with viscosities exceeding 1,000,000 CP.
  • Custom Designed – Specific process criteria are custom designed into each Lancaster High Shear Mixer tooling set to address the customer’s specific needs. Lancaster Application Engineers design toward many goals, including: mixing cycle times, moisture and air entrapment, particle size distributions, surface draw-down, pumping action and tip speed requirements.
  • Variable Speeds – The intensity and type of mixing action can be controlled through the use of various style mixing rotors and speeds. A very popular application of the Lancaster K-Mixer is to first homogenize a mix and then pelletize or agglomerate the material to form micro-pellets or larger agglomerations – all in one machine. The K-Mixer can also coat pellets, de-fiber, de-lump, fluff and slurry. In certain applications, the high speed rotor is removed in favor of a slower speed plow system with or without muller wheels.

The Lancaster Mixer Testing Process

STEP 1 – We recommend beginning by testing in the LANCASTER K1-LAB Mixer. The K1-LAB serves as a “proof of concept” by experimenting with 2000-3000 grams of material and seeing what new processes or products may be developed. This testing can take place in the Lancaster testing facility in Lebanon, PA or a Lancaster K1-Lab Mixer may be rented or bought for your own testing. The Lancaster K1-LAB is a minimal investment for potentially maximum dividends.

STEP 2– Once the mix is perfected in the K1-LAB, your materials can be tested in a Lancaster K4 production style high shear mixer at our testing facility. Testing in the K4 Model provides more precise data for actual production scale-up design.

Whether it is a ½ cu. Ft. capacity K1-LAB or a 210 cu. Ft. K10, Lancaster Products is proud to be able to “Take a tiny amount of this , add it to a lot of that, and turn it into something really great!”

Please contact us to see how Lancaster Products may improve or provide for your various mixing needs!

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