Insitec Wet

The industrially robust, technologically proven process particle size analyzer.

Engineered to withstand the rigors of the process environment, Insitec Wet particle size analyzers use laser diffraction technology to measure particles in the size range 0.1 to 2500 µm in emulsions, suspensions and slurries. Insitec Wet can be configured to suit practically every wet particulate process, delivering real-time monitoring and control 24/7.

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Insitec Wet particle size analyzers deliver fully automated real-time - or manual at-line - size measurement of particulates in batch or continuous wet processes. They are used to monitor and control suspensions, emulsions and slurries in a number of industries, from hot sticky highly concentrated mineral streams to dilute lipid pharmaceutical emulsions. To ensure representative sampling, process interfaces are tailored to meet customer needs, whether pilot scale or hundreds of tonnes per hour. Every Insitec Wet 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 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 almost every conceivable wet process application. From integrated sample dilution hardware incorporating multistage cascade diluters, for highly concentrated slurries, to simple static samplers for more dilute suspensions and emulsions. 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 diluted to an appropriate concentration for measurement.
  • Run reliably with minimal maintenance without disrupting the process.
  • Recycle analyzed material to minimize waste wherever feasible.

Sample Measurement
Insitec systems use the technique of laser diffraction to rapidly measure particle size. When applied to wet systems, complete particle size distributions can be 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. Many wet processes have high solids loadings making dilution an essential precursor to laser diffraction measurement. However, the patented multiple scattering algorithms associated with all Insitec systems extend the working concentration range of the technique. These algorithms mathematically correct for the concentration-dependent effect of the source light interacting with not one, but several, particles before reaching the detectors. More samples can be measured without dilution; concentrated solutions require less pre-treatment. And all measurements are 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
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 Wet options meets the specific requirements of different process applications.

Insitec Wet with fully automated concentration control

Reliable, continuous process particle sizing for concentrated wet streams.

A continuous laser diffraction particle sizing solution with integrated, automated concentration control for monitoring concentrated wet process streams. Suitable for measuring particles in the size range 0.1 to 2500µm in solid-liquid or liquid-liquid streams.

Insitec Wet for pharmaceutical processes

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

Engineered to withstand the rigors of the process environment, Insitec Wet for pharmaceutical industry applications provides a robust, proven PAT solution for measuring particles in the size range 0.1 to 2500 µm. Insitec Wet laser diffraction analyzers can be configured to suit practically every wet particulate process, delivering real-time monitoring and control 24/7, with options for:

  • Gas or dust zoned hazardous environments
  • Fully automated concentration control

Insitec Wet for zoned hazardous environments

Reliable, robust wet process particle sizing for zoned hazardous environments.

An ATEX approved, intrinsically safe laser diffraction 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 from 0.1 to 2500µm, it can be configured to suit practically every wet particulate process, delivering real-time measurement, monitoring and control 24/7.

Insitec Wet customized configuration

Fully customized, reliable, robust particle sizing for wet processes.

A variable path length particle sizing sensor that offers maximum flexibility for wet applications, to deliver reliable, continuous monitoring 24/7 under operating conditions that include high temperature or pressure, high or variable solids loadings. Suitable for measuring particles from 0.1 to 2500µm in emulsions, suspensions and slurries.

Insitec Wet - partner solutions (PSI 500)

A fully automated continuous slurry particle size analyzer for mining and minerals applications.

The rugged PSI 500 has integrated, automated concentration control and measures complete particle size distributions at a rate of one per minute. Suitable for measuring particles in the size range 0.1 to 2500µm it was developed with Metso:Outotec, one of the world’s leading suppliers of technology to the minerals and mining sector.


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 Wet can be configured to suit practically every wet particulate process, delivering Gas or dust zoned hazardous environments. 

  • Fully automated concentration control. 
  • Pharmaceutical processes
  • Customized configuration
  • Partnered solutions
Robust wet particulate analysis.

Robust wet particulate analysis.

Continuous particle size analysis for batch or continuous wet processes. Tailored to your unique application. Designed for tough environments.

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