Microtrac MRB CAMSIZER ONLINE In-line 3D Particle Size and Shape Analyzer

Overview

The Microtrac MRB CAMSIZER ONLINE is an industrial-grade, in-line 3D particle size and shape analyzer engineered for real-time, non-contact characterization of dry bulk solids within continuous manufacturing processes. Utilizing dual high-speed, high-resolution digital cameras and advanced stereoscopic imaging optics, the system reconstructs true 3D particle models from synchronized orthogonal projections—enabling simultaneous quantification of size distribution, sphericity, convexity, aspect ratio, surface texture, transparency, and bulk density proxies without sample dilution or preparation. Unlike static image-based systems, the CAMSIZER ONLINE operates in dynamic flow mode, analyzing particles as they pass through a precisely controlled measurement zone integrated into process recirculation loops (e.g., pneumatic conveying lines, fluidized beds, or gravity-fed chutes). Its optical architecture is based on calibrated silhouette projection and edge-detection algorithms validated against ISO 13322-2 (Particle size analysis — Image analysis methods — Part 2: Dynamic image analysis) and aligned with USP and FDA guidance for continuous manufacturing process analytical technology (PAT).

Key Features

• True 3D particle reconstruction via synchronized dual-camera stereoscopy, delivering volumetric metrics beyond 2D projection equivalents
• Real-time analysis at up to 100 frames per second, supporting throughput rates compatible with industrial-scale production lines
• Measurement range spanning 22 µm to 35 mm—covering fine pharmaceutical granules, catalyst pellets, agrochemical prills, food powders, and coarse mineral aggregates
• Comprehensive morphological output: 32 standardized parameters including Feret diameters (min/max), circularity, convexity, solidity, roughness index, transparency coefficient, and 3D sphericity
• Robust, compact housing rated for ATEX Zone 21 / IECEx dust environments; designed for wall- or pipe-mounted installation with minimal footprint
• Integrated automatic air-pulse cleaning system minimizing optical window fouling and reducing manual maintenance intervals
• Modular interface architecture supporting OPC UA, Modbus TCP, and analog 4–20 mA outputs for seamless integration with DCS, SCADA, and MES platforms

Sample Compatibility & Compliance

The CAMSIZER ONLINE is optimized for free-flowing, dry particulate materials—including API blends, excipient powders, tablet granules, dairy powders, sugar crystals, fertilizers, sand fractions, and ceramic precursors. It excludes wet slurries, highly cohesive fines (<10 µm), or optically opaque aggregates that impede silhouette definition. The system complies with ISO 13322-2 for dynamic image analysis validation and supports 21 CFR Part 11-compliant data integrity when paired with Microtrac’s optional CAMSIZER Connect software suite. Audit trails, electronic signatures, user role management, and raw image archiving are configurable to meet GMP, GLP, and ICH Q5A/Q5C requirements. Calibration is traceable to NIST-traceable glass microspheres and certified reference materials (CRMs) per ASTM E2917.

Software & Data Management

CAMSIZER Connect serves as the embedded control and analytics platform, providing real-time dashboard visualization, trend monitoring, SPC charting (X-bar/R, Cpk), and automated report generation (PDF/CSV/XML). All raw image sequences, metadata, and processed parameter sets are timestamped and stored in a relational database with configurable retention policies. Batch-level summaries can be exported directly to LIMS or SAP QM modules. The software supports method templates for different material classes (e.g., “Pharma Granule v2.1”, “Mineral Sand v3.0”) and allows operator-defined pass/fail limits with alarm escalation via email or SNMP traps. Data export formats include ASTM E1318-compliant .pdm files for third-party statistical analysis.

Applications

• Pharmaceutical continuous manufacturing: Real-time granule size/shape monitoring during fluid bed drying, roller compaction, and direct compression to ensure content uniformity and tabletability
• Food & beverage quality assurance: Monitoring sugar crystal morphology, milk powder dispersibility, and coffee grind consistency across production shifts
• Agrochemical formulation control: Verifying prill sphericity and surface smoothness to optimize coating adhesion and dissolution kinetics
• Advanced materials R&D: Quantifying 3D morphology evolution during mechanical alloying, spray drying, or additive manufacturing feedstock qualification
• Mining & construction: On-belt particle shape analysis for aggregate grading compliance (ASTM D692, EN 933-4)

FAQ

Can the CAMSIZER ONLINE be installed on existing conveyor systems?
Yes—it integrates via standard flanged or clamp-mounted process adapters compatible with common pneumatic and gravity-fed transfer lines. Custom mounting kits and flow-conditioning inserts are available for turbulent or low-velocity streams.
Is calibration required before each measurement run?
No. System calibration is performed during commissioning using traceable CRMs and remains stable for ≥6 months under normal operating conditions. Daily verification with a reference sample is recommended per ISO/IEC 17025.
Does it support regulatory submissions for FDA or EMA filings?
Yes—when deployed with validated CAMSIZER Connect configurations, full audit trails, and documented IQ/OQ/PQ protocols, the system meets data integrity expectations for Annex 11 and ICH M10.
How is particle transparency quantified?
Transparency is derived from grayscale intensity gradients across particle silhouettes under controlled LED backlighting; values are normalized relative to fully opaque and fully transparent reference standards.
What maintenance is required beyond the auto-cleaning function?
Annual optical alignment verification and camera sensor recalibration are advised. No consumables or reagents are used—only compressed instrument air for cleaning and cooling.