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Engineered to withstand the rigors of the process environment, Insitec Dry particle size analyzers use laser diffraction technology to measure particles in the size range 0.1 to 2500 µm. Insitec Dry can be configured to suit practically every dry particulate process, delivering real-time monitoring and control.
Insitec Dry online particle size analyzers deliver fully automated real-time - or manual at-line - size measurement of particulates, in continuous and batch processes having pneumatic or gravity-fed streams. They are used to monitor and control processes ranging from abrasive bulk powders to foods, fine chemicals and pharmaceuticals with strict hygiene standards and subject to stringent regulatory control.
To ensure representative sampling, process interfaces are tailored to meet custom needs, whether at pilot scale or hundreds of tonnes per hour.
Integration with existing control platforms to simplify development of automated control protocols
High reliability of >95% with little downtime, minimal maintenance and maximum ROI
Easy-to-use software and fully automated operation to minimize training requirements and release operator time
Base model hardware manufactured to GAMP5 standards and compatible with CIP/SIP requirements to meet specific manufacturing specifications
All Insitec installations are tailored to the unique requirements of the application. They range from simple at-line, manually-fed systems to fully automated, validated on-line solutions for continuous monitoring and multivariate control.
Malvern Panalytical works in partnership with its customers, providing expertise, hardware and software, where and when it’s needed. This ensures cost-effective, successful project implementation and a positive return on investment.
The success of process analysis depends on detailed consideration of three critical components:
Insitec systems are process equipment and operate within the plant environment. Getting the interface between the instrument and the plant right is essential for long-term, trouble-free operation.
Malvern Panalytical has proven technology for almost every conceivable dry process application. From two-stage auger extraction systems for flow rates of around 100 tph and above, to static samplers, simple eductors and flutes for much lower flow rates. Proven strategies ensure that representative samples are automatically and consistently delivered to the measurement zone, in an appropriately dispersed state and at a suitable concentration for analysis.
Insitec at-line systems run alongside the process and have a manual interface. For automated continuous operation the Insitec is installed in the process line or on an associated sampling loop.
Measurement in an appropriately dispersed state ensures access to relevant data whether it is agglomerates or primary particle size that is of interest.
A dedicated Insitec may be necessary for each measurement point or it may be possible to monitor multiple lines or process steps with a single sensor. This depends on the measurement frequency required.
Well-designed on-line process interfaces:
Insitec systems use laser diffraction to measure particle size rapidly. When applied to dry systems, complete particle size distributions are measured in less than one second, giving instantaneous monitoring. Even processes with fast dynamics can be tracked effectively.
Insitec systems directly measure the process stream. In some processes, particle loading or concentration may vary during routine operation. This presents a challenge for many particle measurement systems and can have a detrimental effect on reported particle size. However, the patented multiple scattering algorithms associated with Insitec ensure reported changes in particle size are always reliable and real. These algorithms mathematically correct for the concentration-dependent effect of the source light interacting with several particles before reaching the detectors. Measurements are robustly independent of sample concentration.
Insitec produces reliable, timely and complete data, reporting full particle size distributions. This provides a secure foundation for better manual or automated process control.
Insitec systems are integrated within the process plant. Typically they are operated from a centralized control room and the measurement results drive routine decision making. Powerful software packages make integration and data interpretation straightforward.
Malvern Link II software provides the functionality required to integrate an Insitec within the existing control system and to automate process control. It allows operation from either a dedicated PC or from existing control mimics. Malvern Link II is not confined only to Insitec integration; it also eases integration with other instrument types, simplifying multivariate control.
RTSizer software presents measurement data in a clear, accessible way. Results reporting can be tailored to industry and customer norms to improve information flow. Insitec data are used to:
Because complete particle size distributions are reported, monitoring and control can be based on whichever size fraction is of interest (e.g. fines, 3-30 µm fraction, amount of material over 200 µm). Insitec data drives optimized manual control strategies and enables automation of process control, delivering substantial economic returns.
Insitec Dry can be configured to suit practically every dry particulate process, delivering real-time monitoring and control 24/7, with options for:
This instrument is used infrequently, but always produces desired results. It is a robust machine that needs little to no attention. Very easy to use. Very valuable instrument that produces great results!
Jason Pike — 3M
| Measurement type | Particle size |
|---|---|
| Measurement range | 0.1 to 2500µm |
| Measurement principle | Laser diffraction |
| Optical models | Mie theory |
| Accuracy | ±2% on Dv(50) reported using the verification reticle |
| Power | 100/240V |
|---|---|
| Enclosure rating | IP65 |
| Operating platforms | 10 bar (g) |
| Software | RTSizer (for instrument control) Malvern Link II (for system automation and data link) |
| Maximum distance from instrument to PC | 500m (up to 2 km using fiber optics) |
| Temperature | 10°C – 70°C |
|---|---|
| Humidity | 35% - 80% (non-condensing) |
An ATEX approved category 3 laser diffraction particle size analyzer for process monitoring in dust zoned hazardous environments rated as zone 22. Suitable for measuring particles in the size range 0.1 to 2500 µm it can be configured to suit practically every dry particulate process, delivering real-time measurement, monitoring and control 24/7.
An ATEX approved intrinsically safe laser diffraction online particle size analyzer for process monitoring in gas or dust zoned hazardous environments rated as zone 0,1 and 2 or 20, 21 and 22. Suitable for measuring particles in the size range 0.1 to 2500µm, it can be configured to suit practically every dry particulate process, delivering real-time measurement, monitoring and control 24/7.
Engineered for use in the process environment, Insitec Voyager is a mobile laser diffraction particle size analyzer that measures particles in the size range 0.1 to 2500µm. Simple to attach to any process line it is especially useful for commissioning, process optimization studies and in multiple line facilities.
Insitec Dry systems for abrasive materials use laser diffraction technology for the continuous measurement of particles in the size range 0.1 to 2500µm. Configurable to suit practically every abrasive process, they deliver real-time monitoring and control 24/7, with options that include:
Engineered to withstand the rigors of the process environment, Insitec Dry for pharmaceutical industry applications provides a robust, proven PAT solution for measuring particles in the size range 0.1 to 2500µm. Insitec Dry laser diffraction analyzers can be configured to suit practically every dry particulate process, delivering real-time monitoring and control 24/7, with options for:
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Version number: MAN0663-01
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Version number: MAN0311-04-DE-01
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Version number: OP-IPP70-nov11
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Insitec 2000 RT Sizer software
Insitec 2000 RT Sizer software
Insitec 2000 RT Sizer software
Malvern Link II Software
Malvern Link II Software
Malvern Link II Software
Malvern Link II Software
Malvern Link II Software
Malvern Link II Software
Malvern Link II Software
Bug fix enabling updates to IMDdata values from WinWrap script in customer data converter
Malvern Link II Software
To ensure that your instrument remains in top condition and performs on the highest level, Malvern Panalytical offers a wide range of services. Our expertise and support services assure an optimal functioning of your instrument.
Service for a lifetime
Adding value to your processes
Continuous particle size analysis. Tailored to your unique application. Designed for tough environments.