top of page

Insitec Spray


Malvern Panalytical

Malvern Panalytical

Insitec Spray The industrially robust, technologically proven process particle size analyzer for sprays and aerosols. Engineered to withstand the rigors of the process environment, Insitec Spray uses laser diffraction technology to measure droplets and dry particles from 0.1 µm to 2500µm. Capable of measuring even highly concentrated sprays and aerosols, Insitec Spray delivers real-time monitoring and control, 24/7.

Key Differences

< click here

Insitec Spray particle size analyzers deliver fully automated, in situ, real-time particle size measurement for sprays and aerosols. They are used to monitor conditions in wind tunnels and atmospheric chambers, to characterize domestic aerosols and personal care products, and to monitor batch and continuous processes such as spray drying.

Every Insitec Spray system offers:

  • Base model hardware manufactured to GAMP5 standards and compatible with CIP/SIP requirements to meet specific manufacturing specifications.

  • Easy-to-use software and fully automated operation to minimize training requirements and release operator time.

  • Integration with existing control platforms to simplify development of automated control protocols.

  • High reliability of >95% with little downtime, minimal maintenance and maximum ROI.

All Insitec installations are tailored to the unique requirements of the application. They range from simple at-line manually operated systems to fully automated, validated in-line solutions for continuous monitoring and multivariate control. Malvern Panalytical works in partnership with its customers, providing expertise, hardware and software, where and when it’s needed. This ensures cost-effective, successful project implementation and a positive return on investment.

Factors for success
The success of process analysis depends on detailed consideration of three critical components:

  • The process interface.

  • Sample measurement.

  • Data presentation and use.


The process interface
Insitec systems are items of process equipment and operate within the plant environment. Getting the interface between the instrument and the plant right is essential for long-term, trouble-free operation.

Malvern Panalytical has proven technology for a wide range of spray applications. Insitec Spray at-line systems run alongside the process and have a manual interface. For automated continuous operation the Insitec is installed in the process. The Insitec Spray has flexible configuration options that make the transmitter and detector easy to position around the spray or aerosol with minimal engineering. Both pilot- and commercial-scale applications can be handled. A well-designed in-line interface ensures that the analyzer runs reliably with minimal maintenance without disrupting the process.


Sample Measurement
Insitec systems use the technique of laser diffraction to rapidly measure particle size. Working with spray systems, complete particle size distributions are measured in less than a second, giving instantaneous monitoring. Even fine temporal fluctuations in spray patterns can be tracked effectively.

Insitec Spray directly measures the spray or aerosol, which may have a very high particle concentration. Patented multiple scattering algorithms handle the effect of concentration on measured particle size, mathematically correcting for the effect of source light interacting with several particles before detection, not just one; an effect that is more prevalent at high concentrations. The result is reliable particle size information even for the most concentrated of sprays and aerosols.

Insitec produces reliable, timely and complete data, reporting full particle size distributions. These data provide a secure foundation for better process control whether that control is manual or automated.


Data presentation and use
Insitec systems are integrated within the process plant. Typically they are operated from a centralized control room and the measurement results drive routine decision making. Powerful software packages make integration and data interpretation straightforward.

Malvern Link II software provides the functionality required to integrate an Insitec within the existing control system and to automate process control. It allows operation of the analyzer from either a dedicated PC or from existing control mimics. Importantly Malvern Link II is not confined only to Insitec integration. This software also eases integration with other instrument types, simplifying multivariate control.

RTSizer software presents the measurement data in a clear and accessible way. A time history allows ‘frame-by-frame’ inspection of a spray event enabling the detailed scrutiny of dynamic behavior. Results reporting can be tailored to industry and customer norms to improve information flow. Insitec data are used to:

  • Improve process understanding.

  • Deliver instant upset detection.

  • Support comprehensive process optimization.

  • Automate process control.

Because complete particle size distributions are reported, monitoring and control can be based on whichever size fraction is of interest. Insitec data drives optimal manual control strategies and enables the full automation of process control, delivering substantial economic returns.

Technical Specification

< click here


Measurement type: Particle size

Measurement range: 0.1 to 2500µm

Measurement principle: Laser diffraction

Optical models: Mie theory

Accuracy: ±2% on Dv(50) reported using the verification reticle


Power: 100/240V

Enclosure rating: IP65

Operating platforms: 10 bar (g)


RTSizer (for instrument control) Malvern Link II (for system automation and data link)

Maximum distance from instrument to PC:

500m (up to 2 km using fiber optics)

Operating environment

Temperature: 10°C – 70°C

Humidity: 35% - 80% (non-condensing)

Insitec Spray


Related Products

Insitec Dry
Insitec Wet
bottom of page