Issues and Solutions of Data Migration When Replacing Laser Diffraction Particle Size Analyzers

Hello everyone!
This time, I will talk about data migration when replacing laser diffraction particle size analyzers.

Specifically, I will explain why data differs across devices even when they use the same principle of laser diffraction, depending on the manufacturer or model.

Even with the same manufacturer, data can differ when the model is changed.

There is no complete compatibility in laser diffraction particle size distribution analyzers.

First, let’s look at the reasons why data differs depending on the model of the device.

Reference Articles

Differences in Sampling Mechanism

First, the differences in sampling methods before laser irradiation within the device contribute to data differences. For example, differences in ultrasonic dispersion force in wet conditions, segregation in circulation systems, and differences in dispersion force in dry conditions.

Differences in Optical Systems

Also, optical system factors contribute to data differences. Optical system factors include the type and wavelength of the light source, the position of detectors, and differences in stray light.

Differences in Calculation Algorithms

Furthermore, differences in calculation algorithms also affect the data. Elements related to calculation algorithms include calculation theory, parameters, inverse calculation algorithms, and data correction methods.

As such, due to numerous reasons, there is no complete compatibility in laser diffraction particle size distribution analyzers.

There is a “legacy product compatibility mode” used during data migration to maintain data compatibility of old devices in new devices, but even if software elements are the same, differences related to hardware elements may prevent complete compatibility, so caution is needed.

Therefore, when setting quality control standard values using a new device, it is optimal to verify the correlation of measurements with new devices and final quality parameters and create new standards.

Let’s also consider the operation post-data migration.

・Methods to obtain results equivalent to the old device with the new device

Even so, there are cases where it is not possible to change the standard values set using the legacy product. In such cases, methods to obtain data similar to the old device can be considered for the new device.

For instance, by adjusting circulation speed, ultrasonic application, and refractive index parameters, it may be possible to obtain data similar to that of the old device.

In adjusting the calculation parameters, the refractive index and absorption rate of the sample are important factors. To find the optimal values, multiple parameters must be experimented with and adjusted.

An “optical property optimization tool” is useful when performing this work.

Furthermore, as a last resort, using an emulation function can be considered.

The emulation function converts measurement results to mimic those of another device.

By applying a coefficient to convert characteristics like the 10%, 50%, 90% diameters of the data, it can be brought closer to the distribution’s central value and shape of the previous model’s data.

Data before conversion ↓

Data after conversion ↓

With the emulation function, it is possible to achieve results comparable to those of another device. However, coefficients must generally be set for each sample type.

Nevertheless, by embedding these correction coefficients in SOP files created for each sample, comparable measurement results to another device can be obtained effortlessly.

While it is possible to align data with the old device using such methods, if quality control is performed based on the resulting data, thorough validation by measuring a sufficient number of samples is required to ensure that the achieved data and standard values can accurately distinguish between good and defective products, ensuring product quality.

That is to say, it must be operated under the customer’s own responsibility.

・Formalizing operation procedures

Once the final measurement procedures are decided, it is important to formalize procedures before operating the device, such as setting standard values, creating SOP files, and creating measurement procedure documents to maintain consistency.

The above covers the causes of data differences, data migration, and operation of laser diffraction and scattering type particle size distribution analyzers. While adjusting data between old and new devices requires caution, useful data acquisition and operation are feasible with appropriate procedures and ingenuity.

The “Mastersizer 3000+” minimizes data differences!

The Mastersizer 3000+ software allows examination of refractive index and analysis settings while balancing compatibility and reliability through the “Optical Properties Optimization Program”.

Also, we offer various technical support seminars to assist customers with method transfers, supporting everyone. 

If you are considering replacement, check here for details on the Mastersizer.

Solutions for four common measurement concerns are also listed, so please check them out.

Concern 1: Setting and optimizing methods (test methods) is difficult
Concern 2: Differences between devices of different models or manufacturers
Concern 3: Differences in experience reflecting in measurement results
Concern 4: Wanting assurance in measurement results

A free demonstration measurement is also available!