Trueway Sizer Online Laser Diffraction Particle Size Analyzer

Overview

The Trueway Sizer Online Laser Diffraction Particle Size Analyzer is an industrial-grade in-line particle sizing system engineered for continuous, real-time monitoring of dry or slurry-based particulate processes. Built upon the proven optical architecture and fluidic design principles of XOPTIX—formerly a UK-based leader in online laser diffraction instrumentation—the Trueway Sizer delivers metrologically traceable size distribution data under dynamic process conditions. It operates on the Mie scattering theory, utilizing a stabilized He-Ne or diode-based laser source, precision-aligned optical train, and high-sensitivity multi-element photodetector array to resolve particle size distributions from approximately 0.1 µm to 2000 µm (D10, D50, D90, span, and full PSD). Designed for integration into existing PLC/DCS environments, the instrument supports 4–20 mA analog output, Modbus TCP/RTU, and OPC UA protocols, enabling seamless data ingestion into MES and LIMS platforms. Its robust mechanical housing (IP65-rated) and temperature-compensated optics ensure stable operation in ambient conditions ranging from 5 °C to 45 °C, with optional heated purge air or vibration-dampened mounting kits available for harsh industrial settings.

Key Features

• Real-time, non-invasive measurement via in-situ flow cell or bypass loop configuration
• Optical path optimized for minimal window fouling and automatic self-cleaning capability via integrated air purge or ultrasonic transducers
• Calibration traceability aligned with ISO 13320:2020 for laser diffraction particle size analysis
• Dual-mode operation: wet dispersion (for slurries) and dry dispersion (for pneumatically conveyed powders)
• Onboard signal processing unit with embedded Linux OS, supporting local data logging (≥30 days at 1 Hz sampling)
• Modular hardware design allowing field-replaceable optical modules, flow cells, and detector assemblies without factory recalibration
• Compliance-ready firmware architecture supporting audit trails, user role management, and electronic signature functionality per FDA 21 CFR Part 11 requirements

Sample Compatibility & Compliance

The Trueway Sizer accommodates a broad range of industrial particulates—including cement clinker, ground limestone, metal oxides (e.g., NiCoMn hydroxides), graphite anode materials, catalyst supports, and API suspensions—across varying concentrations (0.1–20 wt% solids in liquid; 0.5–50 g/m³ in gas streams). Its sample introduction systems conform to ASTM D7924–18 (Standard Guide for On-Line Particle Size Analysis) and are validated for use in GMP-compliant pharmaceutical manufacturing environments. The analyzer meets CE marking requirements (EMC Directive 2014/30/EU, Low Voltage Directive 2014/35/EU) and carries RoHS 3 compliance certification. All software updates and calibration records are stored with time-stamped metadata, satisfying GLP documentation standards for QC laboratories and process validation dossiers.

Software & Data Management

The Trueway Sizer is operated via TrueView™ Process Analytics Suite—a Windows-based engineering workstation software supporting remote configuration, spectral diagnostics, and trend analysis. It provides configurable alarm thresholds (e.g., D50 drift > ±2.5%), automated report generation (PDF/CSV), and direct export to SQL databases or cloud-hosted historian systems (e.g., OSIsoft PI, Ignition). Data integrity safeguards include SHA-256 hashing of raw scatter patterns, encrypted local storage, and dual-user authentication (operator + supervisor). Batch history files retain full scatter matrix data alongside environmental metadata (temperature, pressure, flow rate), enabling retrospective root-cause analysis during deviation investigations. The system supports IQ/OQ documentation packages compliant with Annex 11 and ISPE GAMP 5 guidelines.

Applications

The Trueway Sizer serves as a critical control node across multiple continuous manufacturing workflows: real-time feedback control of jet mill classifiers in lithium cathode material production; endpoint detection during wet grinding of pigment dispersions; consistency monitoring of spray-dried ceramic precursors; and granulation uniformity verification in high-shear mixer granulators. In mining and mineral processing, it enables closed-loop optimization of hydrocyclone overflow fineness. In cement manufacturing, it replaces offline sieve analysis for clinker grinding circuit control, reducing lab turnaround time from hours to seconds. Its adaptability to both aqueous and organic solvent-based slurries makes it suitable for fine chemical synthesis and polymer latex production where particle nucleation kinetics directly impact product performance.

FAQ

Does the Trueway Sizer require periodic factory recalibration?
No—field calibration is performed using NIST-traceable PSL or silica reference standards; only annual verification against certified reference materials is recommended per ISO/IEC 17025 internal quality procedures.
Can it be integrated with Siemens PCS7 or Honeywell Experion DCS?
Yes—native Modbus TCP and OPC UA drivers are preloaded; custom DCS interface logic blocks are available upon request.
Is the instrument suitable for explosive atmospheres (ATEX Zone 21)?
Not by default—but explosion-proof enclosures (II 2D Ex tb IIIC T135°C) and intrinsically safe purge systems can be configured as optional accessories.
What is the minimum detectable concentration for dry powder applications?
For pneumatic transport lines, reliable measurement begins at ~1 g/m³ with optimal optical path length and carrier gas velocity control.
How does Trueway support method transfer from offline Malvern Mastersizer data?
TrueView™ includes a correlation module that applies empirically derived correction factors based on comparative testing against laboratory-grade instruments under identical sample preparation protocols.