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.

Request a quote Request a demo Contact sales


The Insitec Wet particle size analyzer for gas or dust zoned hazardous environments delivers fully automated real-time - or manual at-line - size measurement of particulates in continuous or batch processes requiring ATEX zoned equipment. It is 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.

  • CE marked and ATEX certified (Ex ia IIC T4 Ga, Ex op is IIC T4 Ga, Ex ta IIIC T100°C Da.  Ta = -20°C to +70°C) for use in zones use in a zone 0, zone 1, zone 2 gas environments and zone 20, zone 21, zone 22 dust environments. FM badged, Class I, Division 1, Groups A, B, C and D. Class II, Division 1, Groups E, F and G.
  • 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.

How it works

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)