Advanced Process Analysis PDF

Zetasizer ® Sysmex ®
nano zs FPIA
Particle size
SyNIRgi ® Insitec ®
LPS
ISys ® Rheology®
Chemical imaging
anaysis software
Bohlin® Rosand ®
RH2000
Bohlin® Rosand ®
RH7&10
Bohlin® Insitec ®
Visco 88 Process
The eye in your process

Real-time particle sizing,
whatever your application
detailed specification sheets from www.malvern.com

RH7&10
Insitec ® Advanced process analysis in real-time

Process
A watchful eye to help optimize your process

Malvern Insitec analyzers can measure particle size distributions from 0.1 to 1000µm, wet or dry, at-line,
in-line or on-line, including mobile or static solutions for most industrial applications.
Using advanced laser diffraction technology pioneered and developed by Malvern, our comprehensive
range of instruments are now standard in most particulate processing industries including toners,
pharmaceuticals, cement, minerals, powder coatings, pigments and metal powders.
Their rugged construction and robust technology reflect the exacting demands placed on analytical
instrumentation that is in continuous use in such process environments as milling, classification, spray
drying, atomization, filtration and granulation.
Capable of taking scattering patterns every second and delivering the particle size distribution in real-
time, an Insitec analyzer can make more than a million measurements every year – effectively becoming
your ever watchful ‘eye in the process’. The result of which is to increase the manufacturing ROI by
helping to:
Process optimization & ROI
— produce batches of raw materials

that are ‘right first time’, reducing
waste and the amount of material
to be recycled Process
Process control
— reduce batch-to-batch variation, Plant
Process
Operations
thereby improving quality
Optimized
— control and maintain quality process
continually Improved
Automatic product
— ‘close the loop’ and ensure sampling
the mill operates closer to Communication
target limits
Real time particle size
Continuous measurement Insitec ®
data transfer
The range of Malvern Insitec analyzers, the process interface, analysis software, automation and data reporting can
all be customized to your individual needs.
Furthermore, Malvern offers a 5-day trial period to demonstrate the potential of a dedicated on-line Insitec system
for your process. Please see page 15 for further details.
2 Insitec ALISS For further information please visit www.malvern.com/process

RH7&10

Process
On-line
At-line
In-line
Insitec T
Spray
Zone
We t
Dry
The Insitec T is the base model of

the Insitec range. Widely used within
industries as diverse as cement
— Size range 0.1 to 1000µm production and metal powder
— Model independent analysis atomization it is an on-line laser
— Patented high concentration sizing diffraction particle size analyzer
method using a correction for manufactured to GAMP4 standards.
multiple scattering
Delivering accurate, continuous
— 4 measurements per second measurement for dry powder
of the complete particle size streams, the Insitec T provides an
distribution based on thousands
excellent, fully automated solution
to millions of particles per minute
for a broad range of applications.
— First principles measurement Easy-to-use software and fully
using rigorous Mie theory and
automated operation minimize
needing no calibration
training requirements and deliver
— Rigorous measurement integration with existing control
technique has been validated for
platforms. Maintenance requirements
pharmaceutical use
are minimal and reliability is
— Changeable lenses in the sensor extremely high. Most Installations
allow configuration of instrument
of the Insitec T generally provide a
resolution to individual process
payback time of 6-12 months.
needs
— CE badged
— Watertight and dustproof to http://www.malvern.com/insitecT
industrial protection rating IP65
(optical head to IP66)
— Optical head and sample path
certified to Pressure Shock
Resistance of 11bar(g)
— Compliant with industrial-grade
electromagnetic compatibility
(EMC) requirements for safe,
reliable operation
Our 5-day trial offer is based on the

Insitec T mounted on our mobile
Voyager (see page 9) to explore the
potential of a dedicated on-line system,
demonstrated on your process.
For further information please visit www.malvern.com/process Insitec LPS 3

RH7&10

Process
On-line
At-line
In-line
Insitec D
Spray
Zone
We t
Dry
ATEX approved for use in Zone

22 rated areas, the Insitec D is an
ATEX on-line laser diffraction particle size
22
— Size range 0.1 to 1000µm analyzer designed in accordance
— Model independent analysis with the latest international standard
— Patented high concentration sizing for electrical equipment in dusty
method using a correction for areas – IEC 61241.
multiple scattering A category 3 rated instrument,
— 4 measurements per second it offers accurate continuous
of the complete particle size measurement for dry particulate
distribution based on thousands streams. Easy-to-use software
to millions of particles per minute and fully automated operation
— First principles measurement minimize training requirements,
using rigorous Mie theory. No deliver integration with existing
calibration required control platforms and allow data
presentation to be customized to
— Rigorous measurement
technique has been validated for meet the requirements of the user.
pharmaceutical use Maintenance requirements are
minimal and reliability extremely high,
— Changeable lenses in the sensor making the instrument ideal for the
process environment.
needs
— ATEX badged (Ex II 3 D EEx tD http://www.malvern.com/insitecD

A22 IP65 T120°C)
— CE badged
— Watertight and dustproof to

4 Insitec LPS For further information please visit www.malvern.com/process

RH7&10

Process
On-line
At-line
In-line
Insitec X
Spray
Zone
Wet
Dry
Approved for use in zones 0, 1

and 2, 20, 21 and 22 the Insitec X
ATEX is the world’s first intrinsically safe
0,1
— Size range 0.1 to 1000µm on-line laser diffraction particle size
2,20 — Model independent analysis analyzer. Manufactured to GAMP4
21,22 — Patented high concentration sizing standards and designed to fully
method using a correction for
meet requirements for CIP and SIP
multiple scattering
it is particularly suitable for hygienic
— 4 measurements per second applications.
of the complete particle size
distribution based on thousands The Insitec X delivers accurate
to millions of particles per minute continuous measurement for dry
— First principles measurement particulate streams. Easy-to-use
using rigorous Mie theory and software and fully automated operation
needing no calibration minimize training requirements,
— Rigorous measurement deliver integration with existing control
technique has been validated for platforms and allow data presentation
pharmaceutical use to be customized to meet the
— Changeable lenses in the sensor requirements of the user. Maintenance
allow configuration of instrument requirements are minimal and reliability
resolution to individual process extremely high making the instrument
needs ideal for the process environment.
— ATEX badged (EEx ia IIC T4)
CE badged
— Watertight and dustproof to http://www.malvern.com/insitecX
reliable operation
— FM badged
Class I, Division 1, Groups A, B, C & D
Class II, Division 1, Groups E, F & G
For zone information, please contact

Malvern Instruments.

RH7&10

Process
On-line
At-line
In-line
Insitec S & SX
Spray
Zone
Wet
Dry
The Insitec S is a rugged laser

diffraction particle size analyzer for
the continuous measurements of
— Droplet range 0.1 to 1000µm sprays. Configuration flexibility allows
— High speed data acquisition. Real the instrument to be customized
time spray measurement at up to 4 to meet the requirements of an
measurements per second, reveals
individual application while a
fine temporal fluctuations in spray
patented algorithm ensures that
patterns
even high concentration sprays
— High concentration measurement can be accurately measured. An air
capability. Patented ‘multiple purge prevents build–up of spray
scattering’ analysis routine allows
droplets on the optics, delivering high
measurements of sprays with
reliability; maintenance requirements
light obscurations up to 95%
are minimal. Easy-to-use software
(5% transmission)
allows data presentation to be
— User-friendly software. Time history tailored to meet customer needs.
display allows ‘frame by frame’
The Insitec S can be used to
inspection of a spray event. Flexible
monitor conditions in wind tunnels,
data filtering options. Compliance
atmospheric chambers, atomizer
with 21 CFR Part 11
performance and unit operations
— Instrument configuration flexibility such as spray drying.
and customizable specification
enables aerosol and spray
researchers to configure an
instrument to meet their http://www.malvern.com/insitecS
precise need
— CE badged
— Purgeable optics to counter spray
contamination. Separate control and
electronics unit gives robustness of
operation in machinery area
— IQ/OQ available as per GAMP
guidelines
ATEX Insitec SX can be configured to

0,1 operate successfully in a wide range
2,20
of hazardous or hostile locations
21,22

RH7&10

Process
On-line
At-line
In-line
Insitec L & SX
Spray
Zone (with wet flow cell)

Wet
Dry
Designed for real-time measurement

— Size range 0.1 to 1000µm of solid particulates and emulsions in
— Automatic on-line continuous, or dilute and concentrated liquid streams

at-line manual e.g. pharmaceuticals and minerals.
The Insitec L is manufactured to
— Mobile installation
GAMP4 standards. The hardware is
— Model independent analysis designed to be compatible with CIP
— Patented high concentration sizing and SIP requirements.
multiple scattering
— 4 measurements per second of the http://www.malvern.com/insitecL
complete particle size distribution
based on thousands to millions of Insitec L
particles per minute
— First principles measurement using
rigorous Mie theory and needing no
calibration
— Rigorous measurement
technique has been validated for
pharmaceutical use
— Changeable lenses in the sensor
needs
— CE badged
— Compliant with industrial-grade Insitec SX (with wet flow cell)
reliable operation
ATEX For liquid application in hazardous

0,1 or hostile locations, the Insitec SX is
2,20 configurable with a wet flow cell
21,22

RH7&10

Process
On-line
At-line
In-line
Insitec LPS
Spray
Zone
We t
Dry
The Insitec LPS brings the

reliability and accuracy of laser
ATEX diffraction particle size analysis to
1,21
— Size range 0.1 to 1000µm wet processes. Incorporating a
— Model independent analysis sampler, pre-diluter, cascade diluter
— Patented high concentration sizing and measurement cell it is a fully
using automatic correction for automated, integrated solution for
multiple scattering almost any wet stream - from hot,
— 4 measurements per second sticky, concentrated slurries to lipid
of the complete particle size emulsions. Each component of the
distribution based on thousands system is customized for a given
to millions of particles per minute operability. Designed for off-, at- or
— First principles measurement on-line use the Insitec LPS is suitable
using rigorous Mie theory and for solid-liquid or liquid-liquid streams.
needing no calibration It has easy to-use software and can
— Changeable lenses in the sensor be easily integrated with existing

allow configuration of instrument control platforms. Maintenance
resolution to individual process requirements are minimal and
needs reliability extremely high making the
instrument ideal for continuous use in
— CE badged
the process environment.
http://www.malvern.com/insitecLPS
— Zones 1, 21 version available
on request

RH7&10

Process
On-line
At-line
In-line
Insitec Voyager
Spray
TM
Zone
We t
Dry
The award-winning Insitec Voyager is

a neatly packaged mobile laser
diffraction particle size analyzer for
— Size range 0.1 to 1000µm at- or on-line use. A fully integrated
— Model independent analysis system for dry streams, it is ideal for
— Patented high concentration sizing commissioning, process optimization
method using a correction for studies and multiple unit facilities.
multiple scattering Simple to attach to any process line
— 4 measurements per second with the required tappings, the Insitec
of the complete particle size Voyager delivers continuous real-time
distribution based on thousands data that gives an insight into the
to millions of particles per minute process and allows the potential of
— First principles measurement a dedicated on-line system to be
using rigorous Mie theory and demonstrated. Analytical procedures
needing no calibration are fully automated and results
— Rigorous measurement presentation is easily customized.

technique has been validated for Maintenance requirements for the
pharmaceutical use instrument are low and reliability is
extremely high.
needs
http://www.malvern.com/insitecVoyager
— CE badged
reliable operation
Our 5-day trial offer is based on the

Insitec T mounted on this mobile
platform to allow the potential of
a dedicated on-line system to be
demonstrated (see page 15).

RH7&10

Process
On-line
At-line
In-line
Zone* Insitec Voyager Pharma
Spray
TM
Wet
Dry
The Insitec Voyager Pharma is a

— Size range 0.1 to 1000µm specialized version that has been
— Model independent analysis modified to industry specifications

including polished connections and
— Patented high concentration sizing an easy-to-clean build to meet both
CIP and SIP requirements. It can
multiple scattering
incorporate all Insitec dry powder
— 4 measurements per second analyzer systems (X, D or T).
of the complete particle size
All necessary measurement
distribution based on thousands
electronics, cabling and pneumatics
to millions of particles per minute
are in a compact mobile system with
— First principles measurement a human machine interface (HMI).
using rigorous Mie theory and
The Pharma Voyager is ideal for pilot
needing no calibration
plant operation or Process Analytical
— Rigorous measurement Technology (PAT) research where
technique has been validated for mobility, cleanability, and ease of
pharmaceutical use
operation are required. The Voyager
— Changeable lenses in the sensor can be easily moved between
allow configuration of instrument production suites at any point as it is
resolution to individual process designed for the plant environment.
needs
— CE badged
— Watertight and dustproof to http://www.malvern.com/insitecPharmaVoyager

reliable operation.
The version depicted above is FM

approved and is available on request.
*For zone information, please contact

Malvern Instruments.

RH7&10

Process
On-line
At-line
In-line
Parsum In-line Particle Probe IPP70
Spray
Zone
We t
Dry
The Parsum IPP70 offers an

ATEX
0,1
— Size range 50 to 6000µm alternative solution for in-line particle
2,20 — Small optics optimized for high size analysis using advanced spatial
21,22 particle loadings filter velocimetry for processes
involving larger particulate sizes of
— Lower sensitivity to loading
up to 6000µm.
fluctuations delivers more reliable
measurements Robust and easy to use, the rugged
— Measurement rate up to 15000 IPP70 probe can be inserted
particles per second for greater directly into a process line or vessel.
performance Measuring at rates of up to 15000
particles per second, the instrument
— Optional casing LEDs clearly
indicate status of instrument for continuously tracks Dv(10), Dv(50)
ease of use and Dv(90) making it ideal for
endpoint detection, process control
— Robust laser holder to help
and process optimization for a range
prevent mis-alignment during use
of applications including wet and dry
— Integrated air pipe for the In-line granulation, coating and spray drying,
Disperser D22/23
from pharmaceuticals to detergents.
— ATEX badged (E Exib IIBT4)
The small fiber optics at the heart
— CE badged of the IPP70 deliver consistent,
— Optional user interface – highly accurate measurement with
Standard output (Dv10, 50 and 90) low sensitivity to fluctuations at high
for general process control particle loadings, making this an
— Operating temperature at extremely robust and reliable solution.
measuring point –20˚C to 85˚C
— Operating temperature on probe
housing –10˚C to 60˚C
http://www.malvern.com/parsum

RH7&10

Process
On-line
At-line
In-line
Insitec ALISS
Spray
TM
Zone
Wet
Dry
The award-winning Insitec ALISS is a

robust at-line laser diffraction particle
— Size range 0.1 to 1000µm size analyzer designed specifically for
the process environment. It has a large
— Model independent analysis
sample volume handling capability, fully
— Patented high concentration sizing automated analytical protocols and
requires no sample preparation making
multiple scattering
it the ideal choice for automated labs
— Measurement of the complete and multiple unit processing facilities.
particle size distribution (based on
Suitable for measuring dry particulate
thousands to millions of particles)
in less than a minute streams, the Insitec ALISS is used
in the manufacture of a range of
— First principle measurement using
products including cement, coffee,
rigorous Mie theory and needing
no calibration and powder coatings. Easy-to-use
software delivers customized results
presentation, an essentially de-skilled
resolution to individual process analytical process and integration
needs with existing control platforms.
The simplicity of an upgrade to
— CE badged
continuous on-line analysis provides
capital protection.
Manual version
The manual package is primarily
No complex sample preparation or
designed for use by plant operators
disposal procedures are required
in the production environment. Plant
operators can make measurements
of a full grab sample (typically up to
Automated version
100g) without subdivision, avoiding the
The automated package is primarily introduction of errors associated with
designed for integration into an sub-sampling procedures.
automated laboratory. Samples can
be loaded by the feeding system
(typically up to 100g) without As would be expected from an industrial instrument,
subdivision, avoiding the introduction maintenance requirements are minimal. Ceramic
of errors associated with sub- linings protect critical, high-velocity areas of the
sampling procedures. sample pathway and purging ensures that windows
are kept free from dust.
http://www.malvern.com/insitecALISS

RH7&10

Process
Malvern Link – the complete solution

Our process analyzers are capable of working every minute of every day to keep a constant eye on
your process. Malvern Link, our software interface, can enable full integration with your plant control
system and is the key to fully unlocking the potential of in-process particle characterization alongside
system automation.
Through Malvern Link we can deliver results in real-time to your control room and allow automation of
routine tasks such as cleaning, maintenance and background checks.
Our Malvern Link software package:

Malvern Insitec analyzers, the Malvern Link
— Simplifies plant operation through automatic process control interface, analysis software, automation and data
and by streaming data in real-time to the control room reporting can all be customized to the unique
— Increases system reliability and up-time needs of individual clients.
— Minimizes training requirements Our comprehensive package not only provides for
specialists to install and set up the system but also
— Reduces time and manpower required to maintain
includes training key personnel in maintenance
and operate the instrument
operations, for your complete peace of mind.
OPC Server
RT Sizer
PROCESS
AIR
Process Process Control Industrial
Line Protocol
Insitec ®
Malvern
Analyzer Link
Automation
Cabinet
Customer PLC
http://www.malvern.com/malvernlink

RH7&10

Process
An Insitec solution, whatever the application
On-line
At-line
In-line
Spray
Insitec instrument
Zone
We t
Dry
T (page 3)
ATEX
22 D (page 4)
ATEX
ATEX/
FM*
0,1
2,20 X (page 5)
21,22
S (page 6)
ATEX
0,1
2,20 SX (page 6)
21,22
L (page 7)
ATEX
0,1
2,20 SX (with wet flow cell) (page 7)
21,22
ATEX
1,21 LPS (page 8)
Voyager TM
(page 9)
ATEX
0,1
2,20 Parsum IPP70 (page 11)
21,22
ALISS TM
(page 12)
*FM badged
Class I, Division 1, Groups A, B, C & D
Class II, Division 1, Groups E, F & G
The rugged construction and robust technology of our Insitec systems lends itself to continuous monitoring and
control of operations such as milling, classification, spray drying, atomization, filtration and granulation in a wide
variety of industries.
In fact, whatever the application, there’s a Malvern Insitec solution waiting to enhance your process and improve
your return on investment.

RH7&10

Process
Evaluation and consultancy

An opportunity to assess the value of on-line particle
size analysis and to optimize your process set-up
without any commitment to purchase.
5 days to find the answers for one small fixed fee
Call Malvern to schedule a pre-trial meeting to discuss and agree

your particular needs and to identify the goals you wish to achieve.
After that, arrangements will be made for an Insitec VoyagerTM to
be delivered accompanied by a Specialist consultant from Malvern.
Day 1 Installation of the Voyager and optimising set-up
On-site
support from
Day 2 Preliminary results from initial process configuration
a Malvern
Specialist Evaluate potential improvement and subsequent ROI
Day 3 & 4 by running defined test program
throughout
Day 5 Final data output, recording and report generated. Voyager removed
Malvern provides: You provide:

The Insitec Voyager Venturi and purge air
On-site Specialist (compressed air or nitrogen
Consultant support at 6-10 bar, dust and oil free)
Weld stubs, consumables 16A, 110-230V power supply
Data communication cables
http://www.malvern.com/consultancy

RH7&10

Process
To check availability and to

arrange your evaluation and
consultancy, please contact your
Malvern Specialist Representative
Malvern Instruments Limited

Grovewood Road • Malvern • Worcestershire • UK • WR14 1XZ
Telephone: +44 (0)1684 892456 • Facsimile: +44 (0)1684 892789
Malvern Instruments Worldwide

Sales and service centres in over 50 countries. For details visit www.malvern.com/contact
Process
Advanced technology made simple

distributor details
Insitec
ALISS
Malvern Instruments is part of Spectris plc, the Precision Instrumentation and Controls Company.
All information supplied within is correct at time of publication

Insitec, Malvern and the ‘green hills’ logo are international Trade Marks owned by Malvern Instruments Ltd.
detailed specifications at www.malvern.com
© 2007 MRK967-03

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Zetasizer ® Sysmex ®

The eye in your process

detailed specification sheets from www.malvern.com

Insitec ® Advanced process analysis in real-time

A watchful eye to help optimize your process

Process optimization & ROI

— produce batches of raw materials

2 Insitec ALISS For further information please visit www.malvern.com/process

Insitec ® Advanced process analysis in real-time

The Insitec T is the base model of

Our 5-day trial offer is based on the

For further information please visit www.malvern.com/process Insitec LPS 3

Insitec ® Advanced process analysis in real-time

ATEX approved for use in Zone

— ATEX badged (Ex II 3 D EEx tD http://www.malvern.com/insitecD

— Optical head and sample path

4 Insitec LPS For further information please visit www.malvern.com/process

Insitec ® Advanced process analysis in real-time

Approved for use in zones 0, 1

For zone information, please contact

For further information please visit www.malvern.com/process Insitec LPS 5

Insitec ® Advanced process analysis in real-time

The Insitec S is a rugged laser

ATEX Insitec SX can be configured to

6 Insitec LPS For further information please visit www.malvern.com/process

Insitec ® Advanced process analysis in real-time

Zone (with wet flow cell)

Designed for real-time measurement

— Automatic on-line continuous, or dilute and concentrated liquid streams

ATEX For liquid application in hazardous

For further information please visit www.malvern.com/process Insitec LPS 7

Insitec ® Advanced process analysis in real-time

The Insitec LPS brings the

— Changeable lenses in the sensor be easily integrated with existing

8 Insitec LPS For further information please visit www.malvern.com/process

Insitec ® Advanced process analysis in real-time

The award-winning Insitec Voyager is

— Rigorous measurement presentation is easily customized.

Our 5-day trial offer is based on the

For further information please visit www.malvern.com/process Insitec LPS 9

Insitec ® Advanced process analysis in real-time

The Insitec Voyager Pharma is a

— Model independent analysis modified to industry specifications

industrial protection rating IP65

The version depicted above is FM

*For zone information, please contact

10 Insitec LPS For further information please visit www.malvern.com/process

Insitec ® Advanced process analysis in real-time

The Parsum IPP70 offers an

For further information please visit www.malvern.com/process Insitec LPS 11

Insitec ® Advanced process analysis in real-time

The award-winning Insitec ALISS is a

12 Insitec LPS For further information please visit www.malvern.com/process

Insitec ® Advanced process analysis in real-time

Malvern Link – the complete solution

Our Malvern Link software package:

For further information please visit www.malvern.com/process Insitec LPS 13

Insitec ® Advanced process analysis in real-time

An Insitec solution, whatever the application

14 Insitec LPS For further information please visit www.malvern.com/process

Insitec ® Advanced process analysis in real-time

Evaluation and consultancy

5 days to find the answers for one small fixed fee

*For zone information, please contact