Microtrac MRB CAMSIZER ONLINE 3D Dynamic Image-Based Particle Size and Shape Analyzer
| Brand | Microtrac MRB |
|---|---|
| Origin | Germany |
| Manufacturer Type | Authorized Distributor |
| Product Origin | Imported |
| Model | CAMSIZER ONLINE |
| Instrument Type | In-Line / Dynamic |
| Measurement Parameters | Particle size (minimum size, length, equivalent spherical diameter, D10/D50/D90), shape descriptors (aspect ratio, symmetry, sphericity, convexity, roughness, transparency, density-related morphology), compliant with ISO 9276-6 |
| Measurement Range | 22 µm – 35 mm |
| Imaging Speed | Up to 100 high-resolution images per second |
| Output | 32 morphological parameters per analysis cycle |
| Design | Explosion-proof (optional ATEX/IECEx certification), compact footprint, integrated auto-cleaning mechanism, compatible with third-party sample transfer systems (e.g., pneumatic conveyors, screw feeders, belt samplers) |
Overview
The Microtrac MRB CAMSIZER ONLINE is an in-line, real-time 3D dynamic image analysis system engineered for continuous, non-contact characterization of dry particulate solids in industrial process streams. Unlike static or batch-based imaging analyzers, the CAMSIZER ONLINE operates within a closed-loop recirculation path—integrated directly into production lines for fertilizer granulation, mineral processing, food powder blending, pharmaceutical granule drying, and construction aggregate classification. Its core measurement principle relies on high-speed, dual-angle silhouette imaging combined with advanced stereoscopic reconstruction algorithms to generate true 3D particle models from orthogonal projections. This enables simultaneous quantification of dimensional metrics (e.g., maximum length, Feret diameters, projected area diameter) and intrinsic shape descriptors—including sphericity, convexity, aspect ratio, symmetry index, and surface texture proxies—without reliance on statistical assumptions or calibration beads. The system’s optical architecture is optimized for robust performance under variable ambient lighting, vibration, and dust exposure typical of factory-floor environments.
Key Features
- Real-time in-line operation: Fully integrated into process loops via standardized flanged connections; supports continuous monitoring at up to 100 particles per second.
- True 3D particle reconstruction: Dual-camera stereoscopic imaging captures orthogonal silhouettes, enabling accurate volume estimation and orientation-independent size reporting (e.g., equivalent spherical diameter, minimum bounding rectangle dimensions).
- Comprehensive morphological output: Delivers 32 standardized parameters per particle—including ISO 9276-6–compliant shape indices (sphericity, convexity, roundness), surface irregularity metrics, and transparency-sensitive segmentation for semi-transparent materials (e.g., crystalline sugars, coated APIs).
- Ruggedized industrial design: IP65-rated enclosure with optional ATEX/IECEx Zone 21 certification; compact footprint (< 0.8 m² floor space); passive cooling and sealed optics for long-term stability in dusty or humid settings.
- Automated maintenance functions: Integrated air-pulse cleaning system for lens and illumination windows; self-diagnostic routines for optical alignment verification and LED intensity drift compensation.
- Seamless process integration: Analog (4–20 mA) and digital (Modbus TCP, OPC UA) I/O interfaces for direct connection to DCS, SCADA, or MES platforms; configurable alarm thresholds for SPC-based deviation detection.
Sample Compatibility & Compliance
The CAMSIZER ONLINE is validated for free-flowing, dry particulates ranging from fine powders (22 µm) to coarse granules (35 mm), including but not limited to: nitrogen-phosphorus-potassium (NPK) fertilizer granules, silica sand, crystalline sucrose, roasted coffee grounds, limestone chips, and polymer pellets. It excludes cohesive, moist, or fibrous materials requiring dispersion aids or vacuum aspiration. All shape parameters conform to ISO 9276-6:2015 (“Representation of results of particle size analysis — Part 6: Descriptive and quantitative representation of particle shape and morphology”). Data integrity complies with ALCOA+ principles; audit trails, electronic signatures, and user-access controls are configurable to support FDA 21 CFR Part 11 and EU Annex 11 requirements when deployed in GMP-regulated environments.
Software & Data Management
The CAMSIZER ONLINE runs on Microtrac’s proprietary S3 (Smart Sample System) software platform, which provides real-time dashboard visualization, historical trend analysis, and automated report generation (PDF/CSV). Raw image archives and parameter databases are stored locally on an industrial-grade SSD with optional network backup. S3 supports role-based access control (RBAC), version-controlled method templates, and configurable data export protocols aligned with ISA-88/ISA-95 standards. Batch export functionality enables correlation with upstream process variables (e.g., mill speed, classifier rotor frequency, dryer inlet temperature) for root-cause analysis. Software validation documentation (IQ/OQ/PQ protocols) and cybersecurity hardening (TLS 1.2+, disabled legacy protocols) are available upon request for regulated industries.
Applications
- Fertilizer manufacturing: Real-time monitoring of granule size distribution and sphericity to optimize binder dosage and drum residence time.
- Food processing: In-line verification of sugar crystal uniformity, cocoa powder flowability, and snack pellet integrity pre-packaging.
- Mineral aggregates: Automated classification feedback for crusher and screen control loops based on flakiness index and elongation ratio.
- Pharmaceutical solid dosage: Support for granule release testing (USP ) and blend uniformity assessment via shape-driven segregation risk modeling.
- Recycled concrete: Quantification of angularity and surface texture to assess suitability for high-strength structural applications.
FAQ
What particle size range does the CAMSIZER ONLINE cover?
It measures dry particles from 22 micrometers to 35 millimeters in maximum dimension.
Can it analyze wet or suspended samples?
No—the system is designed exclusively for dry, free-flowing particulates in pneumatic or gravity-fed recirculation loops.
Is compliance with ISO 9276-6 fully implemented in the shape parameter calculation?
Yes—all shape descriptors—including sphericity, convexity, and aspect ratio—are computed according to the mathematical definitions and normalization procedures specified in ISO 9276-6:2015.
How is data traceability ensured for quality audits?
S3 software includes full electronic audit trail logging (user actions, parameter changes, calibration events), time-stamped raw image archiving, and optional 21 CFR Part 11 compliance modules with digital signature enforcement.
Does the system require periodic recalibration with reference standards?
No routine recalibration is needed; however, annual verification using NIST-traceable glass microsphere standards is recommended for metrological assurance in regulated environments.
