Microtrac MRB CAMSIZER ONLINE XL Image-Based Particle Size and Shape Analyzer

Overview

The Microtrac MRB CAMSIZER ONLINE XL is a high-performance, fully automated inline image analysis system engineered for real-time particle size and shape characterization in continuous industrial processes. Operating on the principle of dynamic silhouette imaging—where particles pass individually through a precisely illuminated measurement zone at controlled velocity—the instrument captures high-resolution monochrome images at up to 100 frames per second. Unlike static or batch-based microscopy systems, the CAMSIZER ONLINE XL employs a true dynamic acquisition mode compliant with ISO 13322-2 (Particle Size Analysis — Image Analysis Methods — Part 2: Dynamic Image Analysis). Its optical architecture features a sealed, maintenance-optimized light path with integrated LED illumination and telecentric lensing, ensuring long-term photometric stability and minimal calibration drift under demanding plant-floor conditions.

Key Features

• True inline operation with seamless integration into existing material handling infrastructure—including vibratory feeders, pneumatic conveyors, and rotary valves—via standardized mechanical and electrical interfaces (e.g., PROFIBUS, PROFINET, EtherNet/IP)
• Extended dynamic measurement range from 160 µm to 135 mm, enabling simultaneous analysis of coarse granules, agglomerates, and irregular fragments common in pharmaceutical tabletting, catalyst production, and mineral processing
• Comprehensive morphological quantification: extraction of 32 standardized shape descriptors (e.g., elongation, convexity, solidity, roundness) plus surface texture metrics derived from edge gradient analysis
• Integrated 3D reconstruction capability via multi-angle shadow projection and depth-from-focus algorithms—providing volumetric estimates and orientation-aware statistics without physical particle rotation
• ATEX-certified explosion-proof enclosure options (Zone 21/22) for safe deployment in classified environments handling combustible powders
• Self-diagnostic optics monitoring, automatic focus validation, and real-time image quality scoring to ensure data integrity across shifts

Sample Compatibility & Compliance

The CAMSIZER ONLINE XL is designed for dry, free-flowing particulates with minimal cohesion or electrostatic adhesion. It accommodates heterogeneous mixtures including crystalline APIs, excipient blends, metal powders, ceramic granules, and polymer flakes. Sample conditioning is achieved via optional integrated modules: adjustable air-assisted dispersion nozzles, vibratory de-agglomeration stages, and humidity-controlled sample chambers. The system complies with key regulatory frameworks for process analytical technology (PAT): it supports audit-trail-enabled operation per FDA 21 CFR Part 11, facilitates GMP-aligned validation protocols (IQ/OQ/PQ), and generates raw image archives and metadata logs traceable to individual measurement events. All shape parameters conform to ISO 9276-6 (Representation of Results of Particle Size Analysis — Part 6: Descriptions of Shape and Shape-Related Properties).

Software & Data Management

The proprietary CAMSIZER Control Software v8.x provides full remote configuration, real-time dashboard visualization, and SPC-based trend monitoring. Process data streams—including mean Feret diameter, aspect ratio distribution, and surface roughness index—are exportable in CSV, XML, and OPC UA formats for integration with MES (e.g., Siemens Opcenter, Rockwell FactoryTalk) and LIMS platforms. Advanced reporting tools enable automated generation of compliance-ready PDF summaries with embedded timestamps, operator IDs, and instrument calibration status. All user actions, parameter changes, and alarm events are recorded in an immutable audit trail supporting GLP/GMP documentation requirements.

Applications

• Pharmaceutical manufacturing: Real-time monitoring of wet granulation endpoints, roller compaction ribbon breakage, and final blend uniformity prior to tableting
• Catalyst quality control: Quantifying pellet fragmentation, attrition resistance, and pore structure proxies via convexity and surface fractality indices
• Food & feed processing: Detection of oversized lumps in dairy powder drying lines or inconsistent flake morphology in extruded pet food
• Advanced materials: In-line verification of additive manufacturing metal powders for spherical fraction, satellite count, and surface oxidation indicators
• Mining & minerals: Rapid classification of crushed ore fragments to optimize downstream comminution energy use

FAQ

Can the CAMSIZER ONLINE XL measure transparent or semi-transparent particles?
Yes—its dual-illumination mode (backlight + diffuse top-light) enables reliable silhouette capture and transparency classification based on pixel intensity gradients.
Is calibration traceable to national standards?
Yes—system calibration uses NIST-traceable glass scale targets and certified reference particle sets (e.g., Microtrac PS-Standard Series), with documented uncertainty budgets per ISO/IEC 17025.
What level of IT security does the software support?
The software supports TLS 1.2+ encrypted communications, Windows Active Directory integration, role-based access control (RBAC), and configurable password policies aligned with IEC 62443-3-3.
Does it require periodic recalibration during continuous operation?
No—its self-monitoring optical subsystem performs automatic focus and exposure validation every 15 minutes; manual intervention is only required after mechanical shock or major environmental shifts.
Can it interface with PLCs from different vendors?
Yes—through native drivers for Siemens S7, Allen-Bradley Logix, and Mitsubishi MELSEC, as well as generic Modbus TCP and OPC UA server functionality.