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 pilot scale or hundreds of tonnes per hour. Every Insitec Dry system offers:

  • Base model hardware manufactured to GAMP5 standards and compatible with CIP/SIP requirements to meet specific manufacturing specifications
  • Easy to use software and fully automated operation to minimize training requirements and release operator time
  • Integration with existing control platforms to simplify development of automated control protocols
  • High reliability of >95% with little downtime, minimal maintenance and maximum ROI.

Features and benefits

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 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.

Factors for success
The success of process analysis depends on detailed consideration of three critical components:

  • The process interface.
  • Sample measurement.
  • Data presentation and use.

The process interface
Insitec systems are items of 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:

  • Deliver sample that is representative of the bulk.
  • Run reliably with minimal maintenance without disrupting the process.
  • Recycle analyzed material to minimize waste.

Sample Measurement
Insitec systems use the technique of laser diffraction to rapidly measure particle size. 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 all Insitec systems ensure that 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 not one, but several, particles before reaching the detectors. Measurements are therefore robustly independent of sample concentration.

Insitec produces reliable, timely and complete data, reporting full particle size distributions. These data provide a secure foundation for better process control whether that control is manual or automated.

Data presentation and use
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 of the analyzer from either a dedicated PC or from existing control mimics. Importantly Malvern Link II is not confined only to Insitec integration. This software also eases integration with other instrument types, simplifying multivariate control.

RTSizer software presents the measurement data in a clear and accessible way. Results reporting can be tailored to industry and customer norms to improve information flow. Insitec data are used to:

  • Improve process understanding.
  • Deliver instant upset detection.
  • Support comprehensive process optimization.
  • Automate process control.

Because complete particle size distributions are reported, monitoring and control can be based on whichever size fraction is of interest: the fines, the 3 to 30 micron fraction, the amount of material over 200 microns, for example. Insitec data drive optimized manual control strategies and enable the full automation of process control, delivering substantial economic returns.



Measurement type:
Particle size
Measurement range:
0.1 to 2500µm
Measurement principle:
Laser diffraction
Optical models:
Mie theory
±2% on Dv(50) reported using the verification reticle


Enclosure rating:
Operating platforms:
10 bar (g)
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)

Operating environment

10°C – 70°C
35% - 80% (non-condensing)


A range of Insitec Dry options meets the specific requirements of different process applications.

Insitec Dry

Insitec Dry for dust zoned hazardous environments


Reliable robust process particle sizing for dust zoned hazardous environments.

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.

More information Request a quote

Insitec Dry for gas or dust zoned hazardous environments


The world’s first ATEX/FM intrinsically safe online process particle size analyzer.

An ATEX/FM 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.

More information Request a quote

Insitec Dry mobile measurement


Reliable, robust process particle size measurement – wherever it is needed.

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.

More information Request a quote

Insitec Dry for abrasive materials


Reliable, robust particle size analysis for abrasive materials.

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:

  • A ruggedized lab system for use at-line or as part of an automated laboratory.
  • On- and in-line solutions for real-time measurement.
More information Request a quote

Insitec Dry for pharmaceutical processes


PAT solution for real-time particle size analysis of pharmaceuticals.

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:

  • Dust zoned hazardous environments.
  • Gas or dust zoned hazardous environments.
  • Mobile application.
More information Request a quote


Protect your investment and ensure optimized performance at all times with Malvern Panalytical's service plans.

When you purchase a Malvern Panalytical product we understand that this is just the first stage of a working relationship that will last for the lifetime of the instrument. Depending on your needs, Malvern Panalytical will provide the support for your business.

Help Desk


Software downloads

Malvern Panalytical's service options- choose the right plan for you:

Malvern Panalytical Platinum Plan

For laboratories where maximizing instrument up-time is critical to its daily performance. Our highest level of response and the 'all inclusive' price plan takes care of those unexpected repair bills should the unfortunate occur.

Malvern Panalytical Gold Plan

Enhance your laboratory productivity by maintaining instrument efficiency. Still receive that priority response, combined with specialist technical and software support, we'll keep your instrument performance on track to deliver.

Malvern Panalytical Bronze Visit

For laboratories looking to optimize instrument performance, regular preventative maintenance is essential.

Platinum PlanGold PlanBronze Visit
Annual PM/PV Test
Telephone / Email Support
Priority Response
Emergency Breakdown visits*
Parts Included
Technical & Software Support
IQ/OQ (Pharma)***

*including labour & travel costs***available at an additional cost

Key applications

The Malvern Insitec Dry can be configured to suit practically every dry particulate process, delivering real-time monitoring and control 24/7, with options for: 

  • Dust zoned hazardous environments
  • Gas or dust zoned hazardous environments
  • Mobile application
  • Abrasive materials
  • Pharmaceutical processes