Insitec Spray

The industrially robust, technologically proven process particle size analyzer for sprays and aerosols.

Engineered to withstand the rigors of the process environment, Insitec Spray uses laser diffraction technology to measure droplets and dry particles from 0.1 µm to 2500µm. Capable of measuring even highly concentrated sprays and aerosols, Insitec Spray delivers real-time monitoring and control, 24/7.

Download brochure
Request a quote Request a demo Contact sales


Insitec Spray particle size analyzers deliver fully automated, in situ, real-time particle size measurement for sprays and aerosols. They are used to monitor conditions in wind tunnels and atmospheric chambers, to characterize domestic aerosols and personal care products, and to monitor batch and continuous processes such as spray drying.

Every Insitec Spray 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 operated systems to fully automated, validated in-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.

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 a wide range of spray applications. Insitec Spray at-line systems run alongside the process and have a manual interface. For automated continuous operation the Insitec is installed in the process. The Insitec Spray has flexible configuration options that make the transmitter and detector easy to position around the spray or aerosol with minimal engineering. Both pilot- and commercial-scale applications can be handled. A well-designed in-line interface ensures that the analyzer runs reliably with minimal maintenance without disrupting the process.

Sample Measurement
Insitec systems use the technique of laser diffraction to rapidly measure particle size. Working with spray systems, complete particle size distributions are measured in less than a second, giving instantaneous monitoring. Even fine temporal fluctuations in spray patterns can be tracked effectively.

Insitec Spray directly measures the spray or aerosol, which may have a very high particle concentration. Patented multiple scattering algorithms handle the effect of concentration on measured particle size, mathematically correcting for the effect of source light interacting with several particles before detection, not just one; an effect that is more prevalent at high concentrations. The result is reliable particle size information even for the most concentrated of sprays and aerosols.

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. A time history allows ‘frame-by-frame’ inspection of a spray event enabling the detailed scrutiny of dynamic behavior. 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. Insitec data drives optimal manual control strategies and enables 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
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)

Operating environment

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


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

Insitec Spray customized configuration

Fully customized, reliable, robust particle sizing for sprays and aerosols.

A variable path length particle sizing sensor that offers maximum flexibility for spray and aerosol applications, delivering reliable, continuous monitoring 24/7. Suitable for droplets or particles from 0.1 to 2500µm with an intrinsically safe option for zoned hazardous environments.

Insitec Spray for powder streams

Reliable, robust particle sizing for unconfined powders.

A variable path length particle sizing sensor that offers maximum flexibility for the continuous monitoring of powders which flow freely, unconfined by vessels or pipework. Suitable for measuring particles from 0.1 to 2500µm.

Insitec Spray for pharmaceutical processes

PAT solution for real-time particle size analysis of pharmaceutical sprays.

Engineered to withstand the rigors of the process environment, Insitec Spray for pharmaceutical industry applications provides a robust, proven PAT solution for measuring particles from 0.1 to 2500 µm. Insitec Spray laser diffraction analyzers can be configured to measure sprays and aerosols in most processes, delivering real-time monitoring and control 24/7, with options for gas or dust zoned hazardous environments.


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


  • User training events

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 Spray is capable of measuring even highly concentrated sprays and aerosols, Insitec Spray delivers real-time monitoring and control, 24/7. Flexible configuration simplifies installation on the process with options for: 

  • Fully customized configuration
  • Powder streams
  • Pharmaceutical processes
Robust spray particulate analysis.

Robust spray particulate analysis.

Spray and aerosol particle analysis. Fully automated, in situ, real-time measurement. Tailored to your unique application.

Request a quote Request a demo Contact sales