An automated particle size analysis system combines a particle size analyzer with automated sample handling, preparation, dispersion, measurement control, and data management equipment. Depending on the application, it can support laboratory batch testing, at-line analysis, or online process monitoring. By coordinating these operations, laboratories and manufacturers can reduce repetitive manual handling, standardize testing workflows, and obtain particle size data more efficiently.
An automated particle size analysis system connects sample preparation, measurement, and data management into a coordinated workflow.
Laser diffraction is a widely used measurement technology for automated particle size analysis.
Wet and dry measurement systems require different sample feeding and dispersion configurations.
Automation can include sample loading, liquid handling, ultrasonic dispersion, circulation, measurement, and cleaning.
Online particle size measurement requires a suitable process sampling interface and industrial system integration.
System configuration should be based on material characteristics, testing frequency, measurement methods, and production requirements.
A documented Exceed Testing engineering scheme for lithium iron phosphate (LFP) slurry demonstrates how multiple sampling points can be connected to automated wet laser diffraction analysis.
An automated particle size analysis system is a combination of analytical instruments, sample preparation equipment, automation hardware, and control software designed to perform particle size testing with reduced manual intervention.
Traditional particle size testing often requires laboratory personnel to:
Collect and identify samples.
Prepare the sample for measurement.
Add dispersing liquid or load dry powder.
Operate the particle size analyzer.
Clean the sample-contact components.
Record and review measurement results.
When testing volumes increase, these repeated operations can become a bottleneck.
An automated system coordinates suitable steps through mechanical handling, liquid processing, instrument control, and software communication.
Depending on the application, a system may include:
Automatic sample collection or loading
Sample identification and tracking
Automatic powder feeding
Wet or dry dispersion
Liquid supply and circulation
Ultrasonic dispersion
Automated measurement sequences
Automatic drainage and cleaning
Particle size distribution data collection
Communication with laboratory or production software
The system can be configured for different operating environments:
| System Type | Main Purpose | Typical Application |
|---|---|---|
| Automated laboratory particle size analysis | Automates repeated laboratory testing | Quality control and R&D laboratories |
| At-line particle size analysis | Measures samples near the production line | Manufacturing quality inspection |
| Online particle size analysis | Measures samples collected from a production process | Continuous process monitoring |
| Integrated particle size testing system | Connects multiple instruments and process operations | High-throughput or multi-line production |
The appropriate configuration depends on the measurement method, sample properties, testing frequency, and required level of automation.
A typical automated system follows a coordinated workflow:
Sample Collection → Sample Identification → Sample Preparation → Dispersion → Particle Size Measurement → Data Processing → Cleaning
The exact sequence varies according to whether the system uses wet dispersion, dry dispersion, or an online process sampling arrangement.
The system first obtains or receives a sample.
For laboratory applications, samples may be loaded into designated containers or racks. For online applications, a sampling device may collect material from a production pipeline or process vessel.
Sample identification can be managed through barcode scanning, rack positions, or software-based task assignment.
The objective is to maintain the relationship between the physical sample, measurement task, and resulting data.
Sample preparation is essential because the measured particle size distribution can be affected by sample concentration, agglomeration, moisture, and dispersion conditions.
Depending on the application, preparation may involve:
Sample weighing
Liquid addition
Dilution
Mixing
Pre-dispersion
Sample transfer
For industrial slurry applications, the system may require automatic sampling and dilution before measurement.
The dispersion method depends on the material and measurement technique.
Wet dispersion commonly uses a suitable liquid medium, circulation, stirring, and sometimes ultrasonic energy.
Dry dispersion generally uses controlled powder feeding and an air-based or mechanical dispersion mechanism.
The dispersion conditions must be selected carefully. Excessive energy may alter fragile particles, while insufficient dispersion may leave agglomerates that affect the reported particle size distribution.
Once the sample reaches suitable measurement conditions, the particle size analyzer performs the measurement.
For laser diffraction systems, particles scatter laser light at angles related to their size. The instrument analyzes the scattering pattern and calculates a particle size distribution using an appropriate optical model.
Commonly reported parameters include:
D10: Particle size below which 10% of the measured distribution falls.
D50: Median particle size; 50% of the distribution falls below this value.
D90: Particle size below which 90% of the measured distribution falls.
The exact calculation and reporting basis depend on the instrument, measurement method, and selected analysis settings.
After measurement, the system can collect the result and associate it with the relevant sample or process point.
For wet systems, the next step may involve draining and rinsing the sample-contact path.
For dry systems, cleaning may involve removing residual powder and checking the feeding and dispersion components.
Cleaning procedures should be validated for the actual material. Automation does not automatically eliminate carryover or contamination risks.
A complete system may contain several equipment modules.
| Equipment Module | Main Function | Typical Application |
|---|---|---|
| Particle size analyzer | Measures particle size distribution | Wet or dry particle analysis |
| Automatic sampling unit | Collects samples from designated points | Online or multi-point testing |
| Sample handling module | Transfers sample containers | Laboratory batch testing |
| Automatic feeder | Supplies powder or liquid samples | Dry or wet analysis |
| Wet dispersion unit | Disperses samples in liquid | Suspensions and slurries |
| Dry dispersion unit | Separates and feeds dry powder particles | Powder testing |
| Ultrasonic module | Supports dispersion when suitable | Wet sample preparation |
| Liquid supply system | Provides dispersing medium | Wet laser diffraction |
| Circulation pump | Moves the dispersed sample through the measurement path | Wet measurement |
| Drainage and cleaning unit | Removes residual sample and dispersing liquid | Multi-sample workflows |
| PLC control system | Coordinates equipment actions | Integrated automation |
| Control software | Manages tasks and instrument operations | Laboratory and industrial applications |
| Data communication interface | Transfers measurement information | LIMS, PLC, DCS, or MES integration |
Not all systems require every module.
A laboratory batch testing system may use a robotic sample handler and an existing laser diffraction analyzer. An online slurry measurement system may require process sampling, dilution, ultrasonic pre-dispersion, valve control, and industrial communication.
The equipment list should follow the actual workflow rather than a standard package.
Wet and dry particle size analysis use different sample preparation and dispersion methods.
Choosing the correct configuration is one of the most important decisions in system design.
| Comparison | Wet Particle Size Analysis | Dry Particle Size Analysis |
|---|---|---|
| Sample condition | Particles dispersed in liquid | Dry powders or granules |
| Sample feeding | Liquid transfer or sample addition | Powder feeder or controlled feeding |
| Dispersion method | Stirring, circulation, ultrasound where appropriate | Airflow or mechanical dispersion |
| Main equipment | Liquid tank, pump, tubing, flow cell | Feeder, air supply, dispersion unit |
| Cleaning | Rinsing, drainage, liquid replacement | Powder removal and dust management |
| Typical materials | Slurries, suspensions, emulsions, suitable powders | Dry powders and granules |
| Main design concern | Liquid compatibility and dispersion stability | Feeding consistency and dust control |
Wet particle size analysis is commonly used for suspensions, emulsions, and powders that can be dispersed in a suitable liquid.
A wet automated system may include:
Sample collection
Liquid addition
Sample dilution
Ultrasonic pre-dispersion
Stirring and circulation
Laser diffraction measurement
Automatic drainage
Pipeline cleaning
For slurry applications, the system must be designed around sample viscosity, concentration, sedimentation, and the required dispersion conditions.
Dry particle size analysis is suitable for materials that can be measured without liquid dispersion.
A dry automation system may include:
Automatic powder feeding
Controlled sample dosing
Air pressure regulation
Dry dispersion
Measurement sequence control
Powder residue removal
The feeding and dispersion conditions should be evaluated for cohesive, fragile, or easily agglomerated materials.
Automated laboratory analysis and online particle size measurement are related but different applications.
| Factor | Laboratory Automation | Online Process Measurement |
|---|---|---|
| Sample source | Laboratory sample containers | Production pipeline or process stream |
| Sample handling | Racks, containers, robotic transfer | Sampling probes, valves, process loops |
| Testing mode | Batch or scheduled testing | Continuous or frequent measurement |
| Dispersion | Laboratory wet or dry dispersion | Process-specific sample conditioning |
| Main objective | Standardize laboratory testing | Monitor particle size during production |
| Data destination | Laboratory software or database | PLC, DCS, MES, or process software |
| Main design challenge | Sample handling and repeatability | Representative sampling and process compatibility |
Laboratory automation is appropriate when samples are collected and sent to a laboratory for scheduled testing.
The main design priorities are sample identification, preparation consistency, measurement sequence management, and cleaning.
Online measurement is relevant when manufacturers need particle size information directly from a production process.
A suitable process interface must deliver a representative sample to the analyzer under appropriate measurement conditions.
The system may also need to communicate with industrial control platforms.
Online measurement should not be confused with simply installing a laboratory analyzer near a production line. Sampling, conditioning, equipment protection, and data integration must all be considered.
Automated particle size analysis is used in industries where particle size distribution is an important quality or process parameter.
Particle size distribution is an important material characterization parameter in battery manufacturing and research.
Potential applications include:
Lithium iron phosphate (LFP)
Graphite
Cathode and anode materials
Conductive materials
Battery-related slurries
For laboratory testing, automated systems may focus on sample preparation, dispersion, measurement, and cleaning.
For production monitoring, the system may require multiple sampling points, automated sample conditioning, and communication with production control systems.
Chemical manufacturers may use particle size analysis to evaluate powders, suspensions, and other particulate products.
Automation can support scheduled testing, sample preparation, and consistent measurement sequences.
Mineral processing operations may require particle size information at different stages of crushing, grinding, classification, or slurry processing.
Online particle size monitoring can help provide information about process changes, subject to suitable sampling and measurement design.
Particle size distribution can influence powder processing, dispersion, and final material properties.
Automated laboratory testing can help organize repeated measurements and reduce manual sample handling.
Particle size characterization is relevant to pharmaceutical powders and suspensions.
Automation may support sample handling and standardized measurement procedures. Where regulated quality systems apply, data integrity, documentation, validation, and software access control should also be evaluated.
Particle size measurement is used to characterize pigments, coatings, and liquid dispersions.
Wet automated systems may be suitable for samples that can be prepared and measured using a validated liquid dispersion method.
One practical example of particle size analysis automation is the wet laser diffraction testing scheme published by Exceed Testing for lithium iron phosphate (LFP) slurry production.
The technical scheme addresses multi-point sampling and particle size analysis associated with fine grinding equipment across multiple production lines.
Application: LFP slurry particle size monitoring
Measurement approach: Wet laser diffraction
System objective: Automate sample collection, pretreatment, particle size measurement, and production data communication.
The published technical scheme describes the following planned production configuration:
| Project Parameter | Design Information |
|---|---|
| Material | Lithium iron phosphate slurry |
| Application | Slurry particle size testing associated with the grinding process |
| Production lines | 8 |
| Fine grinding equipment | 4 units per production line |
| Planned sampling coverage | Multiple fine-grinding equipment sampling points |
| Particle size analyzers | 2 sets |
| Sample pretreatment | Automatic water addition and ultrasonic pre-dispersion |
| Control system | PLC, valves, and upper-level control software |
| Data integration | DCS/MES communication according to project requirements |
The technical scheme also identifies the FRITSCH A22 NeXT Nano laser particle size analyzer as part of the proposed equipment configuration.
These details describe the published project design. They should not be interpreted as universal system specifications or guaranteed operating results for other production lines.
The proposed system connects several functional modules.
1. Automatic Sampling
Sampling devices and controlled valves obtain slurry samples from designated production points.
2. Liquid Addition and Pretreatment
The system adds water according to the configured process and uses external ultrasonic equipment for pre-dispersion.
3. Sample Transfer
The prepared sample is transferred through the designed pipeline and valve arrangement to the wet laser particle size analyzer.
4. Particle Size Measurement
The analyzer performs the measurement according to the configured testing procedure.
5. PLC and Software Control
The PLC, control cabinet, and upper-level software coordinate sampling, equipment operation, and measurement tasks.
6. Data Communication
Measurement information can be transmitted to the relevant DCS or MES platform according to the agreed project interface.
The published scheme describes a design in which multiple sampling points can be measured sequentially.
The control logic can be configured around:
Sampling point sequence
Measurement frequency
Testing intervals
Repeated measurements
Priority settings
Test requests from the central DCS system
The proposed technical scheme lists an approximate measurement time of 3–4 minutes per sampling point.
This figure refers to the stated point-level testing time in the design material. It should not be treated as the total cycle time for all sampling points. Overall cycle time also depends on sample transfer, valve switching, cleaning, repeat testing, and equipment scheduling.
The project illustrates several important principles for industrial particle size automation.
Representative sampling: Sampling positions should reflect the intended production process and material condition.
Dispersion control: Water addition and ultrasonic pretreatment should be evaluated against the slurry's physical properties and analytical method.
Multi-point scheduling: Testing order and frequency should reflect production priorities and the number of measurement resources.
Cleaning management: Pipeline flushing and residual sample control are important when samples are transferred through shared flow paths.
Data integration: The data fields, communication protocol, and task-triggering logic should be agreed before implementation.
The main lesson is that an automated particle size analysis system is not simply a particle size analyzer with an automatic sample feeder.
For multi-line production, the system must coordinate sampling, sample conditioning, instrument measurement, equipment control, cleaning, and data communication.
The appropriate architecture depends on the number of sampling points, material characteristics, measurement frequency, and production environment.
For a similar application, a preliminary engineering assessment should establish the required measurement coverage, expected cycle time, sample handling method, and system interfaces before equipment configuration is finalized.
Selecting a system requires a review of both the analytical method and the surrounding automation workflow.
Start by defining the sample type.
Consider:
Particle size range
Particle density
Sample concentration
Viscosity
Moisture content
Flowability
Agglomeration behavior
Sensitivity to shear or ultrasonic energy
These characteristics influence the feeding and dispersion design.
Determine whether the application requires laser diffraction, dynamic image analysis, or another particle characterization technique.
For laser diffraction, define the wet or dry measurement method and the optical model and analysis settings appropriate to the material.
Estimate the number of samples or sampling points to be processed.
Include:
Sample collection time
Preparation time
Measurement time
Cleaning time
Repeat testing
Instrument availability
Required reporting frequency
A system's actual capacity should be evaluated using the complete workflow rather than the analyzer's measurement time alone.
Determine which operations should be automated.
A basic system may only automate sample feeding and measurement sequences.
A more comprehensive system may coordinate sample collection, dispersion, measurement, cleaning, and data communication.
For existing analyzers, confirm:
Manufacturer and model
Sample introduction configuration
External control capability
Data export functions
Communication interfaces
Mechanical access
Software limitations
Not every analyzer supports full external automation. Compatibility should be confirmed before finalizing the system design.
For wet systems, consider liquid residues, pipeline cleaning, drainage, and sample carryover.
For dry systems, consider powder residue, dust collection, feeder cleaning, and safe access to internal components.
The maintenance plan should be practical for the intended operating environment.
Identify which systems need to exchange data.
Potential interfaces include:
PLC
SCADA
DCS
MES
LIMS
Laboratory instrument software
Define sample IDs, measurement values, timestamps, status information, alarms, and data ownership before implementation.
| Evaluation Factor | Manual Particle Size Testing | Automated Particle Size Analysis |
|---|---|---|
| Sample handling | Mainly performed by operators | Can be handled by automated modules |
| Sample preparation | Manual or semi-automatic | Programmed preparation where configured |
| Measurement sequence | Operator controlled | Software coordinated |
| Sample throughput | Depends heavily on staffing and workflow | Depends on equipment capacity and cycle time |
| Cleaning | Manual or instrument-assisted | Can include automated cleaning functions |
| Data management | Manual entry or instrument software | Can include sample and process data integration |
| Initial investment | Generally lower | Requires automation and integration investment |
| Flexibility | Direct operator adjustment | Depends on hardware and software configuration |
Automation is not always necessary.
For laboratories processing only a small number of samples, manual testing may remain practical.
For laboratories with repeated sample batches, multiple testing points, or production monitoring requirements, automation may provide greater workflow consistency and operational flexibility.
Exceed Testing, operated by Zhejiang Qibiao Intelligent Laboratory Technology Co., Ltd., focuses on laboratory automation equipment, customized automation systems, and laboratory system integration.
Its product portfolio includes particle size analyzer automation products and related laboratory automation equipment.
Depending on the application, a customized solution may involve:
Particle size analyzer integration
Automated sample handling
Wet dispersion and circulation
Automatic sampling and sample transfer
Ultrasonic pretreatment where appropriate
Measurement workflow coordination
Pipeline cleaning
PLC and software control
DCS or MES communication where required
The company's published LFP slurry technical scheme provides a specific reference for multi-point wet laser diffraction automation.
The actual configuration should be determined by the customer's material, production process, analyzer model, sampling requirements, and expected measurement cycle.
Explore related Exceed Testing resources:
An automated particle size analysis system combines a particle size analyzer with automated sample preparation, feeding, dispersion, measurement control, cleaning, and data management equipment. It can be configured for laboratory batch testing, at-line analysis, or online process monitoring.
The system obtains or receives a sample, prepares and disperses it using a suitable method, and delivers it to the particle size analyzer. The analyzer measures the particle size distribution, while the automation system coordinates the workflow and records relevant information.
Yes. Laser diffraction analysis can be integrated with automatic sample feeding, wet or dry dispersion, liquid handling, sample transfer, measurement sequence control, and data collection. The available functions depend on the analyzer model and system configuration.
Wet automation uses a liquid dispersing medium and may include pumps, circulation, stirring, and ultrasonic dispersion. Dry automation uses powder feeding and dry dispersion mechanisms, often involving controlled airflow or mechanical feeding.
Yes. An online system can obtain representative samples from a production process and deliver them to a particle size analyzer through a suitable sampling and conditioning interface. It may also connect to PLC, DCS, or MES platforms.
Common applications include battery materials, chemicals, minerals, ceramics, pharmaceuticals, coatings, pigments, and advanced materials. The appropriate measurement and automation configuration depends on the material and process.
Yes, a system can be designed to handle multiple sampling points or production lines. The number of points and achievable measurement frequency depend on the analyzer quantity, sampling architecture, transfer time, cleaning cycle, and scheduling logic.
It can when the analyzer, PLC, and software support compatible communication interfaces. The project should define data fields, measurement triggers, result transfer, alarm handling, and communication requirements.
Measurement time varies with the instrument, material, dispersion method, and testing procedure. The complete automated cycle also includes sampling, preparation, transfer, cleaning, and data processing. These stages should be considered when calculating system throughput.
Evaluate the supplier's understanding of particle measurement methods, sample preparation, wet and dry dispersion, mechanical automation, control software, instrument integration, commissioning, and technical support. Ask for a system configuration based on your actual sample and workflow requirements.
An automated particle size analysis system connects sample preparation, particle dispersion, measurement, cleaning, and data management into a coordinated testing workflow.
For laboratory applications, automation can help standardize repeated sample handling and measurement procedures. For industrial production, a more integrated system can connect multiple sampling points with particle size measurement and process data communication.
The most suitable system depends on the material, measurement method, sampling requirements, testing frequency, and existing equipment.
For manufacturers seeking to automate particle size testing, the first step is to define the complete sampling and measurement workflow. A detailed engineering assessment can then determine the required analyzer configuration, automation modules, control logic, and data interfaces.
Exceed Testing provides laboratory automation equipment and customized system integration services for particle size analysis and related testing applications.
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