Insitec Voyager is a mobile system that delivers fully automated real-time - or manual at-line - size measurement for dry process streams. It is used to gather particle size information for both continuous and batch processes, to support commissioning and process optimization, and to assess the potential benefits of installing a dedicated on-line analyzer. It can be especially valuable in multi-line facilities. Insitec Voyager is easily attached to any suitable process line with the necessary couplings, to monitor and control processes ranging from abrasive bulk powders to foods, fine chemicals and pharmaceuticals.

  • A mobile unit for real-time particle size analysis anywhere in a facility.
  • 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.
  • High reliability of >95% with little downtime and minimal maintenance.

How it works

Insitec Voyager is a fully integrated mobile particle size analyzer that is either used at-line, or installed in- or on-line for continuous monitoring. Suitable installation points include on an existing sampling loop or sampling point, or a free-flowing process line.

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

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

The process interface
Malvern Panalytical has robust technology and relevant experience for sampling almost every conceivable dry process application. Appropriate sampling hardware is supplied with the Insitec Voyager. 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. This ensures the production of relevant data whether it is agglomerates or primary particle size that is of interest.

Sample Measurement
Insitec Voyager uses the technique of laser diffraction to rapidly measure particle size. When applied on-line 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 Voyager is typically used to 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 Voyager 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 Voyager can operate on a stand-alone basis or be integrated within the process plant. 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 where this is required.

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.

Voyager data are used to:

  • Improve process understanding.
  • Deliver instant upset detection.
  • Support comprehensive process optimization.
  • Support effective commissioning.
  • Assess the potential benefit of a dedicated on-line analyzer.



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)

Weight and dimensions

Dimensions (W, D, H):
Height range 0.5m to 1.5m x W 1.2m to 1.6m x D 0.97m
Insitec 25kg, Trolley 30kg, Automation 20kg.

Operating environment

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