Camsizer Online 30

The CAMSIZER ONLINE 30 is a real-time online particle size analyser engineered for continuous measurement of particles ranging from 30 micrometres to 30 mm. Powered by Microtrac’s PartAn software and built around patented 3D particle tracking and analysis technology, the system delivers accurate, repeatable, and comprehensive data on both particle size and shape, enabling precise characterisation of dry, free-flowing bulk materials directly within the industrial production environment.

Material is automatically sampled from the production stream and guided through a funnel onto a controlled vibrating tray, where particles are evenly dispersed and allowed to tumble naturally before entering the measurement zone. This tumbling motion ensures that each particle is captured in multiple orientations as it passes through the sensing region, allowing the system to measure true three-dimensional characteristics including length, width, thickness, perimeter, and shape factors. Capturing particles across multiple orientations is a fundamental advantage of the system over conventional two-dimensional measurement methods, which can only measure particles in a single plane and therefore miss shape and thickness information that directly affects how materials perform in downstream processes.

High-speed, high-resolution CMOS cameras combined with stroboscopic LED illumination capture up to 300 images per second as particles pass through the sensing zone, producing sharp, high-contrast silhouettes for precise optical analysis. Particle shadows are projected by a calibrated LED light source onto a digital detector with pixels of known dimensions, allowing the system to calculate accurate particle size distributions and morphological parameters in real time without physical contact with the sample. This non-contact measurement principle preserves sample integrity throughout the analysis process and ensures contamination-free operation, which is important in industries where sample purity and measurement traceability are critical quality requirements.

The system is housed in a rugged, sealed enclosure that protects all optical and electronic components from dust, vibration, and harsh industrial conditions, supporting reliable continuous operation around the clock with minimal maintenance requirements. Automated sampling and measurement processes reduce the need for operator intervention throughout the measurement cycle, minimising human error and ensuring consistent, repeatable monitoring of product characteristics across extended production runs.

Integration with plant control systems is supported through standard industrial communication interfaces, enabling continuous process monitoring, automated data logging, and real-time feedback for process optimisation and quality assurance. Operators can detect process deviations as they occur, respond to changes in particle size distribution before they affect product quality, and maintain consistent product specifications across high-volume production environments without relying on delayed offline sampling and analysis.

The CAMSIZER ONLINE 30 is used across a broad range of industries handling dry, free-flowing bulk materials, including mining and mineral processing, aggregates and construction materials, food and agricultural products, fertilisers and chemicals, and glass, plastics, and industrial granulates. For any facility where particle size and shape directly influence product quality and process performance, the CAMSIZER ONLINE 30 provides a dependable, detailed, and continuously available measurement solution that supports smarter process control and more consistent operational outcomes.

The CAMSIZER ONLINE empowers operators with real-time particle size and shape data, enabling precise control over the production process. This advanced system enhances operational efficiency, product quality, and workplace safety across a wide range of industrial applications.

Key Benefits:

• Instant Access to Data – Receive immediate online measurements, reducing reliance on delayed laboratory results. This helps prevent out-of-spec production, minimises downtime, and supports continuous process optimisation.
• Improved Safety Compliance – By eliminating the need for manual sampling, the CAMSIZER ONLINE significantly reduces the risk of workplace injuries and supports adherence to health and safety regulations.
• Built for Harsh Environments – Housed in a robust IP66-rated industrial enclosure, the system is engineered to perform reliably in demanding conditions.
• Automated SOP Functionality – Includes a Standard Operating Procedure (SOP) feature for fully unattended operation, ensuring consistent performance with minimal human intervention.
• Low Maintenance and High Reliability – Equipped with self-cleaning mechanisms, the CAMSIZER ONLINE requires minimal maintenance, making it ideal for continuous, long-term use.

The CAMSIZER ONLINE 30 delivers advanced real-time particle size and shape analysis through high-resolution imaging technology and automated sampling directly from the production process. Material is continuously extracted from the process line and transferred via a funnel onto a vibrating tray within the analyser, where it is evenly dispersed to ensure accurate and representative measurement of free-flowing particles without requiring manual sample collection or preparation between measurements.

High-performance cameras and precision optical components capture detailed particle images as they pass through the sensing zone. These images are processed by the PartAn software to calculate particle size distribution and shape characteristics, delivering reliable and repeatable data for process monitoring and quality assurance across continuous production cycles. The automated sampling system can be configured for integration with conveyor belts or process pipes, allowing the CAMSIZER ONLINE 30 to be incorporated into a wide range of industrial production environments without requiring significant modifications to existing infrastructure.

The system is engineered for continuous operation with minimal maintenance under normal operating conditions. Its robust industrial design ensures dependable performance in demanding environments where dust, vibration, and extended operating hours are routine. Real-time data output gives operators immediate visibility over particle characteristics as they change throughout the production process, enabling rapid identification of process variations and informed adjustments before product quality is affected. This combination of continuous automated measurement, detailed particle characterisation, and real-time process feedback enhances process control, improves product consistency, and supports greater operational efficiency across industrial bulk material handling and processing environments in Australia.

The CAMSIZER ONLINE 30 is operated through the Microtrac PartAn software platform, which manages automated sampling, real-time image processing, and data output from a single interface. The software controls the full measurement cycle from sample extraction through to results output, processing images captured by the high-speed camera system and calculating particle size distributions and shape parameters in real time as each measurement is completed.

Measurement programs can be configured, saved, and recalled for different material types and process conditions, allowing consistent and repeatable analysis to be maintained across shifts and operators without reconfiguring the system between runs. All measured morphological parameters are available for display and reporting, with users able to customise which parameters are shown and how results are presented to suit the specific requirements of each application.

For continuous on-line process installations, the PartAn software manages automated sampling cycles and delivers real-time particle data to connected process control systems through standard industrial communication interfaces, including integration with SCADA platforms and distributed control systems. This allows particle size and shape information to be used directly within the broader process control environment for automated adjustments and quality assurance monitoring without requiring manual data transfer between systems.

Process trend monitoring and alarm functions allow operators to define acceptable ranges for key particle parameters and receive immediate notification when measurements fall outside these limits, supporting rapid response to process deviations before they affect product quality or downstream operations. All measurement results, system events, and operational data are logged continuously and can be exported in formats compatible with laboratory information management systems and standard reporting tools, supporting full traceability and compliance documentation for quality management requirements across industrial and regulated environments in Australia.