Camsizer Online 135

The CAMSIZER ONLINE 135 is a real-time particle analyser designed for continuous, dynamic measurement of particles ranging from 160 micrometres to 135 mm. Using patented 3D particle tracking and imaging technology through the Microtrac PartAn software, the system captures multiple images of each particle as it tumbles in free fall through the sensing region, enabling precise determination of particle size, shape, thickness, and overall morphology. This level of particle characterisation provides the detailed and reliable data that industrial process control and quality assurance applications require, going well beyond what conventional 2D imaging or standard microscopy methods can deliver.

The optical measurement system consists of an LED panel light source, strobe-controlled electronics, and a high-speed, high-resolution CMOS camera with advanced lens optics. As particles pass through the illuminated measurement zone, their shadow images are captured by the camera’s digital detector and processed into video streams and measurement files. These files contain detailed information on particle dimensions, perimeter, shape indicators, and other morphological parameters, with the patented 3D imaging capability providing data on particle thickness and true shape characteristics that two-dimensional imaging cannot capture. This comprehensive particle characterisation capability makes the CAMSIZER ONLINE 135 a more informative measurement tool than conventional alternatives for applications where particle shape and morphology are as important as size distribution.

The system is designed for non-intrusive, in-line particle measurement that operates continuously without interrupting production flow. All optical and electronic components are housed within a sealed, cabinet-mounted enclosure that protects sensitive measurement hardware from dust, vibration, and the harsh conditions common in industrial processing environments. The internal electronics are engineered specifically for reliable continuous operation and provide seamless integration with process control systems through standard industrial communication protocols and interfaces, allowing real-time particle data to flow directly into broader process monitoring and control environments.

The CAMSIZER ONLINE 135 can be configured for both laboratory off-line use and fully automated on-line process installations, providing flexibility to suit different operational requirements and integration levels. On-line configurations typically include automated sampling systems controlled through the PartAn software, enabling continuous monitoring, automated data collection, and real-time feedback for process optimisation without requiring manual sample collection or preparation between measurements.

The combination of high-speed imaging, advanced particle tracking algorithms, and 3D measurement capability delivers fast, repeatable, and highly accurate results that minimise sampling errors and improve the overall reliability of the measurement process. Real-time particle size distribution and shape analysis gives operators the information they need to make immediate, informed decisions about process adjustments, supporting better product quality, improved efficiency, and reduced operational downtime across continuous production environments.

The CAMSIZER ONLINE 135 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 beads and industrial granulates. For any facility where consistent particle size and shape are critical to product quality and process performance, the CAMSIZER ONLINE 135 provides a dependable, detailed, and continuously available measurement solution.

• Patented 3D Particle Analysis: Accurately measures particle size and shape from 160 µm to 135 mm using advanced 3D imaging technology.
• Engineered for Harsh Environments: Built for durability and reliability in tough industrial conditions, ensuring uninterrupted online analysis.
• Real-Time Monitoring: Delivers continuous, real-time particle size and shape data for every particle in the sample stream.
• Eliminates Lab Delays: On-site analysis reduces dependency on off-site laboratory testing, speeding up decision-making.
• Custom Sampling Systems: Integrated solutions that return samples to the process, enhancing efficiency and control.
• 100% Sieve Correlation: Ensures precise and consistent particle size measurements aligned with traditional sieve methods.
• 24/7 Operation with Self-Cleaning: Designed for continuous use with minimal maintenance and automatic cleaning features.
• Seamless System Integration: Easily connects with existing plant control systems for streamlined industrial application.
• SOP Automation: Standard Operating Procedure (SOP) feature enables efficient, unattended operation.
• Versatile Industry Applications: Ideal for use in industries such as:
  • Fertilizers
  • Mining (crushed ores, iron sinter)
  • Aggregates and construction materials
  • Industrial minerals (limestone, dolomite)
  • Energy (coke, coal, anthracite, biomass)
  • Polymers and EPS
  • Chemicals and detergents
  • Food and feedstuff
  • Glass beads

The CAMSIZER Online is a high-performance particle analysis system designed for precise size and three-dimensional shape characterisation of dry, free-flowing materials. With a measurement range spanning from 160 micrometres to 135,000 micrometres, it provides comprehensive and reliable particle data across a wide range of material types, supporting quality control, research, and process optimisation in demanding industrial and laboratory environments.

The system uses advanced optical imaging technology to capture up to 100 high-resolution images per second, enabling accurate and statistically meaningful analysis even at high throughput rates. More than 40 morphological parameters are characterised within each measurement, including particle size, shape, form, surface roughness, transparency, density, and true three-dimensional characteristics. This breadth of analytical capability gives users a far more detailed understanding of material properties and behaviour than conventional particle sizing methods provide, supporting more informed decisions in both product development and process control applications.

Measurement is non-contact throughout, preserving sample integrity and ensuring that the material being analysed is not altered or damaged during the measurement process. This is particularly important when working with fragile, friable, or surface-sensitive materials where physical contact during measurement could affect both the sample and the accuracy of the results. The enclosed optical system minimises contamination risk and reduces the maintenance demands associated with dust and material ingress, supporting continuous and reliable operation across extended production periods.

Sample introduction options are customisable to suit different material types and laboratory or production workflows, providing the flexibility to adapt the system to specific operational requirements without significant reconfiguration. A self-cleaning mechanism further reduces the need for manual maintenance intervention, increasing productivity and minimising downtime in environments where continuous measurement is an operational priority.

The CAMSIZER Online is built for durability in demanding conditions, with robust construction that allows effective operation in both controlled laboratory settings and harsh industrial production environments. This versatility makes it a practical long-term investment for facilities that need consistent, detailed particle characterisation across varying conditions and material types.

The system is used across a broad range of industries including aggregates and building materials, fertilisers and agricultural products, food and food ingredients, geology and mining, and glass beads and industrial minerals. For any facility where particle size distribution and shape characteristics directly affect product quality and process performance, the CAMSIZER Online provides a fast, accurate, and highly detailed measurement solution that supports confident, data-driven operational decisions.

The CAMSIZER Online is operated through the Microtrac PartAn software platform, which manages all aspects of measurement, data collection, and process integration from a single interface. The software controls the imaging system, processes incoming particle data in real time, and presents results as detailed particle size distributions and shape analysis reports covering all measured morphological parameters. Measurement results are available immediately as each analysis is completed, giving operators and process engineers access to current particle characterisation data without delay.

Up to 40 morphological parameters can be monitored and reported simultaneously, with users able to configure which parameters are displayed and how results are presented to suit the specific requirements of each application and workflow. Custom measurement programs can be created, saved, and recalled for different material types and process conditions, supporting consistent and repeatable analysis across shifts and operators without requiring reconfiguration between measurement runs.

For on-line process installations, the PartAn software manages automated sampling cycles and provides continuous real-time feedback to connected process control systems, allowing particle size and shape data to be used directly for process adjustment and optimisation without manual intervention. Standard industrial communication protocols and interfaces support integration with SCADA systems, distributed control systems, and other plant-wide control platforms, ensuring that particle measurement data flows seamlessly into the broader process monitoring and management environment.

Data logging is continuous throughout operation, with all measurement results, system events, and process parameters stored automatically for review, reporting, and compliance documentation. Results can be exported in a range of formats compatible with laboratory information management systems and standard data analysis tools, supporting traceability and quality assurance requirements across regulated and high-volume industrial environments in Australia.