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Morphologi 4 0
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Morphologi 4 4

Morphologi 4

Rapid, automated particle size and particle shape analysis

  • Measures particle size and shape 
  • Ideal for powders, suspensions and particulates
  • Static image analysis technology

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Overview

Morphologi 4 provides detailed morphological descriptions of particulate samples through static image analysis, enabling a greater understanding of both sample and process.

It can equally be used as an R&D tool to investigate challenging applications and in automated QC analysis where generation of robust, user-independent results and validation are required.

Features

  • Broad particle size range, from 0.5 μm to over >1300 μm, enables size measurements of a wide range of samples

  • 20+ morphological parameters deliver a highly-detailed description for deeper understanding of your particulate material

  • Advanced manual microscope mode and ability to return to particles of interest enables an even closer examination of unexpected particles

  • High-resolution microscope ensures quality particle images for optimum image analysis data

  • Integrated dry powder dispersion unit delivers reproducible sample dispersion, critical to achieving meaningful results

  • SOP control, from sample dispersion to data analysis, provides simple and automated operation for robust, repeatable measurements

  • Dedicated sample presentation accessories enable measurement of a wide variety of sample types, including suspensions and filters

Compliance and reporting

  • 21 CFR Part 11 software option ensures regulatory compliance
  • Conforms to standards: ISO 9276-6 and ISO 13322-1
  • Automated ‘Sharp Edge’ analysis enables the detection of even low-contrast particles
  • Advanced data exploration tools generate maximum sample knowledge

The only instrument that can measure the particle size range from low to high for polymer particles dispersed in water.

Ron Peters — DSM

Specification

General

Technology Static automated imaging
Particle size 0.5 μm – 1300 μm (upper limit may be extended for some applications*)
* Sample and substrate dependent
Particle properties measured Size, shape, transparency, count, location
Particle size parameters Circle equivalent (CE) diameter, length, width, perimeter, area, maximum distance, sphere equivalent (SE) volume, fiber total length, fiber width
Particle shape parameters Aspect ratio, circularity, convexity, elongation, high sensitivity (HS) circularity, solidity, fiber elongation, fiber straightness
Particle transparency parameters Intensity mean, intensity standard deviation
Integrated Sample Dispersion Unit
For fully automated dispersion and measurement of dry powders. Manual or SOP control of dispersion pressure, injection time and settling time
Illumination White light LED: brightfield, diascopic and episcopic; darkfield, episcopic
Detector 18 MP; 4912 x 3684 pixel color CMOS array; pixel size 1.25 μm x 1.25 μm
Optical system Nikon CFI 60 brightfield / darkfield system
Lens (and particle size range)
2.5x: 8.5 µm – 1300 µm (nominal)
5x: 4.5 µm – 520 µm (nominal)
10x: 2.5 µm – 260 µm (nominal)
20x: 1.5 µm – 130 µm (nominal)
50x: 0.5 µm – 50 µm (nominal)

Weight and dimensions

Dimensions
810 mm (W) x 520 mm (D) x 685 mm (H)
with carry handles: 1100mm (W) x 520mm (D) x 685mm (H)
Weight 76 kg (84kg including carry handles)
Power 100-240 V ac 50/60 Hz (<100W load)

Accessories

Appropriate dispersion of the individual particles and agglomerates within a sample leads to robust and reliable results. Good spatial separation and representative sampling of the particles is required.  To achieve this, a number of dispersion options are available with the Morphologi 4.


Easy, reproducible, automated sample dispersion  

Morphologi 4 comes with an integrated dry powder dispersion unit.  It enables simple, reproducible preparation of dry powder samples. A precise amount of sample is dispersed automatically using a unique compressed air dispersion mechanism controlled from within the software, for reproducible dispersions every time. 


Optional accessories – for analysis of particles in suspension   

A range of instrument accessories supports preparation of samples on microscope slides, in wet suspensions or on filters, extending the capability of the Morphologi 4 beyond the characterization of dry sample dispersions. Each accessory fits directly into the automated stage area and is easily selectable in the Morphologi software.

Analyzing particles in suspension

Thin-path wet cell

The thin-path wet cell is designed for both morphological and chemical characterization of up to 100 μL of sample. It is ideal for applications such as the identification of subvisible particles in therapeutics (described by guidance in USP <787> and USP <788>), especially when a traditional membrane filtering approach may risk changing particles of interest, such as protein aggregates.

Thin-path wet cell

Wet dispersion cell

The wet dispersion cell allows between 2 ml and 6 ml of sample to be analyzed. This is particularly useful for characterizing larger particles or where volumetric particle count is important.

Wet dispersion cell

2-slide and 4-slide holders

‘Sandwiching’ a few μL of a suspension of smaller particles between a microscope slide and a cover slip is a traditional method of sample preparation for microscopy. Samples are presented in this form to the Morphologi G3-ID using either the 2-slide or 4-slide holder. Slides suitable for chemical identification applications are available.

2-slide and 4-slide holders

Twin 35 mm petri dish holder

The twin 35 mm petri dish holder provides an alternative means of measuring suspended particles that may be at risk of being deformed when dispersed into a cell.

Twin 35 mm petri dish holder

Analyzing particles captured on a membrane filter

25 mm and 47 mm diameter filter holders

Methods used to detect and characterize particles in suspension often rely on filtering the sample in order to capture particles on a membrane filter. Dedicated filter holders (25 mm or 47 mm diameter) and also the 2-slide holder allow samples on filter membranes to be presented directly to the Morphologi for analysis.

25 mm and 47 mm diameter filter holders

Fused silica filters and holder

Fused silica filters are designed to enable the analysis of filtered samples containing low-contrast particles, such as protein aggregates or contaminant particles.  The fused silica filters are housed in a support for ease of handling, and are presented to the Morphologi in the fused silica holder, which can hold up to 2 filters.

How it works

The Morphologi 4 measurement procedure can be split into four sections: 

  • Sample preparation   
  • Image capture 
  • Image processing 
  • Results generation 

Sample preparation

Spatial separation of individual particles and agglomerates is critical to representative results.  The integrated dry powder disperser makes preparing dry powder samples easy and reproducible. The applied dispersion energy can be precisely controlled, enabling the measurement process to be optimized for a range of material types. Dispersion is achieved without explosively shocking the particles, avoiding the damage of fragile particles whilst ensuring strongly-agglomerated materials are dispersed.  Accessories that fit directly in to the Morphologi 4’s automated stage are available for preparing suspended or filtered samples.

Image capture

The instrument captures images of individual particles by scanning the sample underneath the microscope optics. The Morphologi 4 can illuminate the sample from below or above, whilst accurately controlling the light levels. 

Image processing

Use of either the automated ‘Sharp Edge’ segmentation analysis or the manually-controlled thresholding enables the detection of particles and the calculation of a range of morphological properties for each.

Results generation

Statistically representative distributions are constructed for each parameter from the thousands of particles that have been analyzed.  Advanced graphing and data classification options in the software ensure that extracting the relevant data from the measurement is straightforward, via an intuitive visual interface. Individually-stored grayscale images for each particle provide qualitative verification of the quantitative results.

The only instrument that can measure the particle size range from low to high for polymer particles dispersed in water.

Ron Peters — DSM

Key applications

Morphologi 4 provides value in a wide range of applications, some of which are described below:

Pharmaceutical development

Active Pharmaceutical Ingredient (API) and excipient particle size and shape are critical material attributes which must be understood and controlled during formulation development and process scale-up for both innovator and generic products.  Morphologi 4 delivers the statistically-relevant particle size and shape information to enable this.

Spray drying

Spray drying techniques are employed across a range of manufacturing industries because of the high fluidity of the granules that they produce.  This fluidity comes from the tight particle size distributions and specific particle shapes that are produced by the process.  These morphological attributes can be monitored by Morphologi 4, which provides statistically-relevant data to support the optimization of the process and to enable manufacturers to confidently specify their product.

Energy storage/Batteries

Controlling the application of the electrode material in the battery manufacturing process, and the resulting film density and uniformity, is essential in optimizing battery power and energy storage .  Morphologi 4 enables particle size and shape descriptions of the electrode material powder to be correlated with battery performance, to support product development and to ensure final product quality. 

Powder metallurgy

Metal powder properties, such as particle size and shape, are critical for powder metallurgy processes as they impact final component quality and performance.  Morphologi is used by metal powder producers and component manufacturers to ensure an optimum, consistent and traceable powder supply with the desired packing and flow characteristics, to mitigate the risk of costly part failure.

Mining and minerals

The morphology of geological deposits helps trace the extent of natural disasters and predict the impact of future environmental events. Particle properties also determine the effectiveness of abrasive minerals for use in cutting and polishing tools. Morphologi 4 automatically generates the statistically-relevant particle data required to meet these challenges. 

The only instrument that can measure the particle size range from low to high for polymer particles dispersed in water.

Ron Peters — DSM

User manuals

Software downloads

09 January 2026

11.02

  • Fixed an issue where the aperture could occasionally remain open. During initialization of the instrument the top light aperture will open by default. During operation, the aperture, if required, should be manually controlled.
11.02

28 April 2025

11.00

  • Software Re-branding to Malvern Panalytical
  • Windows 11 Support
  • Core Isolation Compatibility
  • Fixed 3 critical bugs on manual focusing, 1-click ID measurement, and plate tilt resurfacing
  • Improvements on focus coincidence test script
  • Fixed some ui bugs
  • Updated the environmental libraries and 3rd party tools
11.00

08 November 2023

10.34

Reverting to a previous driver version and improving the robustness of the image capture code and ability to restart an unresponsive camera to maintain ESD compliance.

10.34

11 August 2021

10.32

Version 10.32 fixes 2 critical bugs, the audit trail files are now protected from accidental modification and manual light

setting measurements which were prevented by v10.31 can be run again.

10.32

02 December 2020

10.31

This release improves the Installation Qualification (IQ) process with new Performance Verification (PV) and system

check reports for Morphological and ID components. Stability and security have also been

improved with new camera drivers and restrictions on custom calculation functionality.

10.31

23 June 2020

10.30

Improved spectral performance

  • Addition of option to collect a background spectrum at start of measurement. This feature improves the user’s workflow as it ensures a background spectrum is collected from the actual sample being analyzed at the start of the measurement process, preventing the possibility of an incorrect background being used.
  • Improvements to the Raman Spectra signal to noise when acquisition time is 2 minutes or longer.
10.30

12 February 2020

10.21

  • Enable full software functionality with non-English PC language settings (tested on English & French and verified on German and Japanese locales).
10.21

18 March 2019

10.20

  • 21 CFR Part 11 support
10.20

06 July 2018

10.10

  • Morphologi 4-ID instrument support
10.10

22 March 2018

10.00

  • Morphologi 4 instrument support
  • Windows 10
10.00

Support

Solutions to maximize the return on your investment

To assure that your instrument remains in top condition and performs on the highest level, Malvern Panalytical offers a wide range of services. Our expertise and support services assure an optimal functioning of your instrument.

Support

Service for a lifetime

  • Phone and remote support
  • Preventive maintenance and checkups
  • Flexible Customer Care Agreements
  • Performance certificates
  • Hardware and software upgrades
  • Local and global support

Expertise

Adding value to your processes 

  • Sample preparation development/optimization
  • Analytical methodologies 
  • Turnkey solutions for XRD 
  • Operations via IQ/OQ/PQ, quality assurance (GLP, ISO17025) or round robins/inter laboratory studies
  • Consultancy services

Training and education

  • Training on-site or at our competence centers
  • Broad range of basic and advanced courses on products, applications and software
Rapid, automated particle size and particle shape analysis.

Rapid, automated particle size and particle shape analysis.

Static image analysis ideal for R&D and QC. Automate your manual microscopy with advanced software and particle analysis with accessories for every sample.

Contact sales Request a quote Request a demo