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.

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The Insitec Spray customized configuration particle size analyzer delivers fully automated real-time - or manual at-line - size measurement of particulates in any continuous or batch spray process. Easily integrated within existing plant, its applications include: condition monitoring in wind tunnels and atmospheric chambers; characterizing domestic aerosols and personal care products; monitoring and control of processes such as spray drying and granulation.

  • 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.
  • Variable path length cell that offers the flexibility to customize to specific application requirements and streamlines integration within an existing unit.

How it works

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 and avoids process disruption.

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 one second, giving instantaneous monitoring. Even fine temporal fluctuations in spray patterns can be tracked effectively.

Insitec Spray directly measures the spray or aerosol. Such materials may have very high particle concentrations and can present a challenge for many particle measurement systems. However the patented multiple scattering algorithms associated with all Insitec systems 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. 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)