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Malvern Instruments’ consultancy service is designed to demonstrate in situ how continuous real-time particle size analysis can transform plant operation.

Using the Insitec Voyager, the company’s mobile, laser diffraction-based particle size analyzer, Malvern’s specialist team can assess the suitability of laser diffraction technology for specific applications. In addition, an onsite trial provides a practical demonstration of the quality and quantity of data produced by an on-line system.

Plant monitoring over the course of several days provides data that affords new insight into the process and which can be used to:-

  • Improve and/or automate process control
  • Reduce variables costs by minimizing waste, re-work and energy consumption
  • Enhance product quality

A Malvern consultant is present throughout the trial, ensuring that every customer gets maximum benefit from the consultancy program. Any concerns about the operation and effectiveness of the technology can be addressed on site, while the potential for process efficiency gains can be comprehensively explored.

Why does Malvern offer a consultancy service?

While customers tell us that the availability of case studies describing on-line particle size analysis applications is extremely valuable, there is no substitute for hands-on experience.

Understanding exactly how data can be used and establishing the suitability of the technology for individual processes is critical. The consultancy service addresses these issues. It is particularly beneficial for generating information to justify a capital investment in on-line analysis.

How does the consultancy service work?

Following an initial scoping meeting the consultancy runs over five days. A process expert from Malvern is present throughout.
  • Day 1: install Insitec Voyager and optimize set up.
  • Day 2: gather baseline data
  • Days 3 and 4: implement defined test program, assessing the impact of different variables; evaluate potential for process improvement
  • Day 5: complete test program; record all results; generate final report; disconnect Insitec Voyager; remove all associated equipment

What are the objectives of the trial?

Most consultancy projects share two key objectives - to establish the suitability of laser diffraction analysis for the specific application, and to assess the potential benefits of installing a permanent on-line system.

Issues routinely addressed include:

  • the potential for instrument wear (abrasive applications)
  • maintenance requirements
  • operational reliability
  • representative sampling
  • how the measurements compare with historical analytical data

Perhaps more importantly, process teams can gain insight into unique, process-specific issues, investigate the impact of key variables on product and plant performance and evaluate options for improved process control.

Maximum benefit is achieved if the process team can push the plant to the edges of the operating envelope during the two/three day test program.

What connections and services are needed?

The only process interfaces required are one or two process tappings, preferably in a line where material is flowing downwards under gravity. Instrument air (dry and oil free) and electrical supplies are needed to operate the analyzer.

What does Malvern supply?

Malvern supplies an Insitec particle size analyzer for the duration of the trial complete with PC for data recording. A final report is generated covering all aspects of the trial. This includes any problems encountered with installation, specific requirements of the application, trends recorded during testing and conclusions about the benefits of continuous analysis.

For which industries is the consultancy service suitable?

Insitec Voyager can be used in almost any dry process. The consultancy service therefore has widespread application across many industrial sectors.

The consultancy package is offered on a fixed fee basis. Request a quote for our Consultancy service.


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