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Malvern Consultancy Service for particulate processors

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Malvern Instruments’ consultancy service for in-process particle size analysis is proving highly successful, with more than 85% of clients subsequently switching to on-line measurement. The service is aimed at helping manufacturers to better understand and optimize particulate processing operations. During the 5-day consultancy period a Malvern specialist uses the Insitec Voyager, a mobile particle size analyzer, to conduct a plant trial at the client’s site.

The resulting real-time data stream allows the client to properly quantify the benefits of on-line measurement, for their specific process.

Malvern’s Insitec Voyager is a fully automated, laser diffraction-based, mobile particle size analyzer. Capable of measuring at- or on-line it is suitable for use in dry processes with particles in the size range 1 to 1000 microns. The system is normally installed on the process line in just a few hours, requiring only the provision of the necessary tappings, instrument air and a suitable electrical supply. Real-time particle size data are generated for the bulk of the trial, allowing the client to thoroughly explore the potential for improved control. Quantifying this potential provides a sound basis for investment decisions.

A typical consultancy programme involves: installation and optimization of sampling; measurement of the current status of the process; running defined test programs; and the generation of comprehensive reports. The aims include finding the best parameters for process control, and testing sensitivity to process change. There is an option to rent or buy the Insitec Voyager system after completion of the study.

Optimum benefit is derived from the trial if the process team is prepared to push the plant to the edges of its operating envelope, but even monitoring a grade change can be illuminating. The study is an ideal opportunity to investigate complex aspects of the process, problems that have occurred in the past and key areas where most economic gain is expected from real-time analysis.

As part of the consultancy process, clients also have the opportunity to assess the need for permanent installation of on-line particle size analysis and to determine the optimal set-up required. Where a permanent on-line analysis solution is selected as a result of the study, then a pre-trial enhances confidence in the technology. Any issues that arise during the consultancy can be addressed ahead of the decision to invest. Streamlining design, installation and commissioning, and identifying at an early stage where cost benefits will accrue, ensures maximum return on investment.

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