Counter-Current Mixing Technology
The Science Behind Better Mixing.
What is Counter-Current Mixing?
Our proprietary counter-current mixing technology is the most effective mixing technique for consistent uniformity, homogeneity, and rapid mix time. This multi-tool mixing technology consists of a rotating pan, high-speed rotor, and plow that works with a variety of materials, from powders to slurries to high-viscosity mixes.
The counter-current action occurs when the pan rotates in one direction, while the mixing tools rotate in the other. The rotating pan conveys material to the counter-rotating, primary mixing rotor, secondary mixing plows, and side wall scraper. These independently controlled mixing tools allow for custom mix design and/or granulation and pelletization of materials.
Mix-granulate in one machine
Mixing and granulating (pelletizing) in a single machine and operation reduces costs and footprint.
Repeatable
Batches
High repeatability via programmable mix “recipes”.
Shorter Mixing Cycles
Counter-current design enables fast, repeatable mixing.
No Dead
Zones
Mixing tolls are strategically placed to promote maximum material interface and leave no dead zones.
Higher
Yields
Higher Yields compared to traditional mixing and pelletizing equipment.
SOLUTIONS
Multiple Processes in a Single Machine
Lancaster Products mixers rapidly mix and pelletize or granulate in a single machine in a single operation. High-intensive mixing produces tighter spec consistency, faster cycle times, and repeatable results. The mixer becomes a throughput and quality lever — not a commodity.
Homogenization
Our mixers can easily homogenize complex formulas with dissimilar particles sizes or densities that traditional blenders cannot handle.
Granulation & Pelletization
Our high shear mixers reduce the need for multiple pieces of mixing and pelletizing equipment. They can do both in a single operation.
Continuous Batch Processing
The Lancaster Continuous Batch Processing System offers the accuracy and consistency of a batch mixing with the higher yields, and the high production rates of a continuous line.
Material Preparation
Prepare materials for downstream processing with a uniform mix that supports consistent, high-quality results.
Not all Mixing Technologies are Created Equal
|
Feature |
LANCASTER COUNTER CURRENT ALZER(?) |
RIBBON BLENDER |
PADDLE MIXER |
V-CONE MIZER |
PLANETARY MIXER |
|---|---|---|---|---|---|
|
Mixing Intensity |
Low |
Low |
Low |
Medium-High |
|
|
Mix Time |
Slow |
Low-Medium |
Low |
Medium |
|
|
Uniformity |
Fair |
Fair |
Fair |
Good |
|
|
Handles Difficult Materials |
Poor |
Fair |
Fair |
Good |
|
|
Granulation in One Step |
No |
No |
No |
No |
|
|
Energy Efficiency |
Low |
Low |
Low |
Medium |
|
|
Energy Efficiency |
Low |
Low |
Low |
Medium |
APPLICATIONS
Proven Across Challenging Materials
Ceramics >
Fertilizer >
High Performance Concrete >
Refractory Materials >
Batteries >
Building Materials >
Powdered Metals >
Specialty Chemicals >
HOW WE WORK
From Proof of Concept to Production
Proof of Concept Testing
Production Scale Testing
Process System Design
Machine Configuration
Machine & System Build
Start-Up Support
Ongoing Support
TEST CENTER
See Counter-Current Mixing in Action
Validate Your Process with Real Materials
Every material behaves differently. Test your own product using Lancaster’s proprietary counter-current mixing technology to evaluate mix quality, cycle times, and process performance before investing in production equipment.
Why Lancaster Leads in Counter-Current Mixing
The innovators behind industry-leading counter-current mixing technology.
Counter-current mixing is more than a machine – it’s decades of engineering expertise. Lancaster pioneered this technology to solve complex material processing challenges with greater consistency, flexibility, and efficiency across a wide range of applications
INDUSTRIAL MIXING EQUIPMENT
See the Technology in Action
Lancaster’s high-shear counter-current mixers deliver efficient, repeatable processing with higher throughput, homogeneous results, and the flexibility to mix, granulate, and pelletize in a single machine. Built for demanding applications, our equipment supports critical production processes across ceramics, refractories, fertilizers, precision glass, advanced composites, and more