Automated wet laser diffraction particle size analysis combines a laser diffraction particle size analyzer with automated sample handling, liquid dispersion, circulation, measurement control, and cleaning functions. Instead of relying on operators to perform every step manually, an integrated system can coordinate sample feeding, dispersant management, ultrasonic dispersion, measurement, result processing, and equipment cleaning through a defined workflow. The appropriate configuration depends on sample properties, particle size distribution, measurement requirements, throughput, and the level of automation needed.
Automate the complete measurement workflow: Automation can cover sample loading, liquid supply, dispersion, circulation, measurement, data processing, and cleaning.
Wet dispersion is a critical step: Particle wetting, deagglomeration, concentration, and suspension stability can influence the measurement result.
Automation goes beyond one-click testing: A complete solution may connect sample handling, the analyzer, control software, and laboratory data systems.
Choose the system based on the sample: Powders, suspensions, slurries, emulsions, and other materials may require different dispersants and preparation procedures.
Distinguish laboratory automation from online process measurement: Automated batch testing and continuous process monitoring have different sampling and integration requirements.
Verify the complete workflow: Repeatability, carryover, cleaning effectiveness, sample identification, and data transfer should all be evaluated.
Automated wet laser diffraction particle size analysis is a measurement workflow that uses liquid dispersion and laser diffraction technology to determine the particle size distribution of a sample with reduced manual intervention.
In a conventional wet measurement process, an operator may need to prepare the dispersant, add the sample, adjust the dispersion conditions, start the measurement, clean the system, and record the results.
An automated configuration coordinates some or all of these operations through mechanical components, sensors, instrument software, and workflow control.
A typical system may include:
A wet laser diffraction particle size analyzer
A sample loading or feeding mechanism
A liquid supply and drainage unit
A dispersion tank or wet dispersion module
A circulation pump and measurement cell
An ultrasonic dispersion unit, where required
Automated cleaning and rinsing functions
Instrument control and analysis software
A computer or laboratory data interface
The degree of automation can vary. A basic system may automate liquid supply, dispersion, measurement, and cleaning, while a more advanced configuration may also automate sample loading, sample identification, sequential testing, and data transfer.
The objective is to establish a repeatable measurement process that reduces unnecessary manual operations while maintaining appropriate control over sample preparation and analytical conditions.
Laser diffraction determines particle size distribution by measuring the angular distribution and intensity of light scattered by particles passing through a laser beam.
In general, larger particles tend to scatter light at smaller angles, while smaller particles produce relatively wider-angle scattering patterns. The instrument collects the scattered-light signals using detectors and calculates a particle size distribution using an appropriate optical model, such as Mie theory or Fraunhofer approximation.
For wet measurement, the sample is dispersed in a suitable liquid before entering the measurement zone.
A typical measurement sequence involves:
Sample preparation: A representative sample is prepared for measurement.
Liquid dispersion: The sample is introduced into a suitable dispersant to wet and separate particles.
Circulation: A pump moves the suspension through the measurement path.
Laser measurement: The instrument records the scattering pattern produced by the dispersed particles.
Particle size calculation: Software processes the scattering data and calculates the particle size distribution.
Result review: The operator or system reviews the measurement data and saves the results.
The quality of the result depends on more than the optical measurement itself. Sample representativeness, dispersion conditions, concentration, particle stability, and measurement method selection are also important.
For this reason, wet laser diffraction automation should be designed around the complete sample preparation and measurement process.
An automated wet laser diffraction system combines measurement hardware with sample preparation and workflow control components.
The analyzer is the core measurement component. It includes the optical system, laser source, detector arrangement, measurement cell, and associated analysis software.
When selecting the analyzer, laboratories should consider:
Measurement range required by the application
Optical configuration and detection capability
Suitable measurement models
Sample and dispersant compatibility
Required measurement repeatability
Software functions and data export
Maintenance and verification requirements
The instrument should be selected according to the expected particle size distribution and material characteristics rather than measurement range alone.
The wet dispersion unit prepares the sample in a liquid medium and delivers it to the measurement area.
Depending on the configuration, it may include:
A sample tank or dispersion vessel
A circulation pump
A liquid supply system
A dispersant level or flow monitoring function
A mixing or agitation mechanism
An ultrasonic dispersion component
A drainage and cleaning circuit
The purpose is to maintain a suitable and sufficiently stable particle suspension during measurement.
Manual sample addition can create differences between operators, especially when testing a large number of samples.
An automated sample feeding module may use sample racks, containers, positioning mechanisms, or robotic handling to introduce samples in a defined sequence.
The design should account for:
Sample container dimensions
Sample quantity and physical properties
Feeding and positioning accuracy
Sample identification
Cross-contamination risks
Compatibility with the analyzer's inlet and preparation process
Not every application requires robotic sample loading. For some laboratories, automating the dispersion and measurement stages provides sufficient operational improvement.
Wet laser diffraction requires a suitable dispersant to suspend particles and transport them through the measurement cell.
An automated liquid management module may control liquid filling, circulation, drainage, and rinsing.
Important design considerations include:
Dispersant type and compatibility
Liquid volume requirements
Flow stability
Tank capacity
Drainage arrangement
Waste collection
Cleaning procedures
The dispersant should be selected based on the sample's wetting behavior, chemical compatibility, and measurement method. Water is not suitable for every material.
Some samples contain agglomerates that may need additional dispersion before measurement.
An ultrasonic unit can introduce acoustic energy into the suspension to help separate agglomerated particles. However, ultrasonic treatment should be controlled carefully.
Excessive energy or treatment time may break fragile particles and change the measured distribution. Insufficient dispersion may leave agglomerates that are interpreted as larger particles.
The appropriate ultrasonic settings should therefore be established through method development and verified using representative samples.
Software coordinates the instrument and automated components according to the configured measurement method.
Depending on the system, functions may include:
Measurement method selection
Pump and dispersion control
Ultrasonic parameter settings
Measurement sequence execution
Automatic data calculation
Result storage and export
Sample identification and batch records
Cleaning cycle control
Equipment status and error notifications
For laboratories that need broader automation, the system may also exchange data with laboratory information systems or other workflow platforms, subject to interface availability.
A well-designed system should define each stage from sample input to final data output.
A typical automated workflow can be divided into seven stages.
The system receives a sample and associates it with the correct test record.
Depending on the configuration, identification may be performed through barcode scanning, sample rack positions, or operator confirmation.
For multi-sample testing, sample identification should remain linked to the correct measurement sequence and result.
The wet dispersion module supplies the required liquid medium to the sample tank or measurement circuit.
The system may control liquid filling and circulation according to predefined operating parameters.
Dispersant selection and preparation should be established by the analytical method, not left to an arbitrary default.
The sample is introduced into the dispersant.
The objective is to achieve suitable wetting and distribution without introducing unnecessary bubbles, contamination, or sample loss.
For materials that are difficult to wet or disperse, additional preparation steps may be required.
The suspension is mixed and circulated through the measurement path.
Depending on the sample, the system may use agitation, pumping, and controlled ultrasonic treatment to maintain a suitable dispersion state.
The circulation process should minimize sedimentation and avoid introducing excessive air bubbles.
The dispersed sample passes through the optical measurement zone.
The analyzer collects scattering signals and calculates the particle size distribution.
Depending on the method and instrument, the software may report parameters such as:
Dv10
Dv50
Dv90
Mean particle size
Particle size distribution curves
Cumulative and differential distributions
These parameters should be interpreted according to the measurement method and reporting requirements.
After measurement, the software processes the data and associates the result with the relevant sample record.
For laboratories conducting batch testing, electronic result storage and structured reporting can reduce manual data entry and simplify comparison between samples.
After a measurement is completed, the system may execute a cleaning or rinsing procedure.
This helps remove residual particles and dispersant from the tank, circulation path, and measurement cell.
The cleaning sequence should be appropriate for the sample and liquid used. For materials that are sticky, oily, highly concentrated, or difficult to remove, additional cleaning procedures may be necessary.
The next measurement should begin only when the system has met the defined readiness conditions.
The difference between manual and automated particle size testing is not simply whether the instrument has an automatic measurement button.
A more meaningful comparison considers how much of the complete testing workflow is controlled by the system.
| Evaluation factor | Manual wet testing | Automated wet testing |
|---|---|---|
| Sample addition | Operator adds each sample | May use automated feeding or defined loading procedures |
| Dispersant supply | Manual preparation or adjustment | Can be controlled by the system |
| Dispersion | Operator adjusts mixing or ultrasound | Defined parameters can be executed automatically |
| Circulation | Instrument-dependent operation | Can be coordinated within the automated sequence |
| Measurement | Operator starts and manages tests | Software can execute programmed measurements |
| Cleaning | Manual rinsing or instrument cleaning functions | Automated cleaning cycles may be configured |
| Sample identification | Often depends on manual records | Can be linked to barcodes or electronic records |
| Data management | May require manual export and entry | Can support automatic result storage and transfer |
| Operator involvement | Required throughout more stages | Reduced for automated steps, with oversight still needed |
Automation may improve workflow consistency and reduce repetitive manual tasks. However, it does not automatically guarantee more accurate particle size results.
Analytical performance still depends on sample representativeness, dispersion method, concentration, instrument condition, measurement settings, and verification.
Manual differences in sample addition, liquid preparation, dispersion, and cleaning can influence the testing process.
A programmed workflow can standardize defined operating steps and reduce unnecessary variation between operators.
Automating liquid supply, circulation, measurement, and cleaning can reduce the number of routine actions performed by laboratory personnel.
This is particularly useful when many samples need to be tested using similar procedures.
When sample feeding and sequential measurement are integrated, the system can process multiple samples according to a defined sequence.
Actual throughput depends on sample preparation, measurement duration, cleaning requirements, and instrument availability.
When sample identification and measurement records are connected, laboratories can more easily associate results with the corresponding sample and test method.
This can support batch comparison, quality control records, and subsequent data review.
Automation can standardize parameters such as liquid supply, circulation, and programmed dispersion conditions.
However, method development and periodic performance verification remain necessary.
Automated result storage and export can reduce manual transcription and help organize particle size data for comparison, reporting, and further analysis.
Choosing an automation system requires evaluating the sample, measurement method, equipment, and laboratory workflow together.
Different materials may behave differently in liquid dispersion.
Consider:
Particle size and distribution range
Particle density
Hydrophilic or hydrophobic properties
Solubility in the proposed dispersant
Agglomeration tendency
Sedimentation behavior
Particle fragility
Viscosity and sample concentration
A system designed for one type of suspension may not be suitable for every powder or slurry.
The dispersion method should be appropriate for the material.
Evaluate whether the sample requires mechanical mixing, circulation, ultrasonic treatment, a specific dispersant, or a combination of methods.
The objective is to disperse the sample adequately without altering the particles being measured.
The expected number of samples influences the required level of automation.
A laboratory testing a small number of samples may need only automated dispersion and measurement. A high-throughput laboratory may benefit from sequential sample loading, automatic identification, and integrated result management.
Residual particles from a previous sample may affect subsequent measurements.
Evaluate the cleaning path, rinsing volume, cleaning time, drainage design, and compatibility with the sample material.
Where carryover could affect results, define an appropriate verification procedure using representative samples.
If the analyzer is being integrated into a wider automation platform, confirm its available control and communication interfaces.
Check whether the software supports method selection, remote operation, result export, status feedback, and the required data format.
Do not assume that a network connection automatically provides full instrument control.
The design should allow convenient access to pumps, tubing, tanks, valves, sensors, and other components that require cleaning or replacement.
A system that is difficult to maintain may create operational interruptions even if its automated workflow performs well under ideal conditions.
Automated laboratory testing and online process measurement are related but different applications.
An automated laboratory system usually processes discrete samples in a controlled measurement environment. Samples are loaded, dispersed, measured, cleaned, and recorded in a batch or sequential workflow.
An online particle size measurement system is designed to monitor material directly from a production process or a representative process sampling point.
| Factor | Automated laboratory measurement | Online process measurement |
|---|---|---|
| Sample source | Collected laboratory samples | Process stream or automated process sampling point |
| Measurement mode | Batch or sequential testing | Continuous or near-real-time monitoring, depending on configuration |
| Main purpose | Laboratory analysis and quality testing | Process monitoring and control support |
| Sample handling | Laboratory loading and preparation | Process interface and sampling system |
| Dispersion | Controlled in a laboratory wet dispersion unit | Designed for process conditions and sample characteristics |
| Data use | Test records, batch comparison, quality control | Process trends, monitoring, and potential control inputs |
| Integration | Analyzer software and laboratory data systems | Process control platforms such as PLC or DCS, where supported |
A laboratory automation system may support quality control and process development without being an online process analyzer.
For online applications, representative sampling, process compatibility, continuous operation, cleaning, and integration with plant control systems become additional design considerations.
The two approaches can complement each other: laboratory testing can support method development and independent verification, while online measurement can provide process information at the production level.
Battery material laboratories may use wet laser diffraction to evaluate particle size distributions in selected powders, suspensions, or slurry-related samples.
Automated preparation and measurement can help standardize repetitive testing procedures.
The specific dispersant, sample concentration, and dispersion settings must be selected according to the material and test method.
Chemical and mineral laboratories may need to measure particle size distributions in suspensions and other liquid-dispersed materials.
Automated wet measurement can support repeatable sample preparation and sequential testing when the material is compatible with the dispersion system.
Particle size can be an important quality attribute for certain pharmaceutical ingredients, intermediates, and fine chemical materials.
Automated measurement may support routine laboratory workflows, provided the method is suitable for the material and the system meets the laboratory's applicable quality requirements.
Ceramic powders, pigments, and other advanced materials may require particle size characterization to support formulation development and quality control.
Wet dispersion can be appropriate when the selected liquid medium and preparation method are compatible with the material.
Some food ingredients, coating materials, and emulsions are measured as liquid-dispersed systems.
The measurement procedure should consider viscosity, stability, droplet or particle behavior, and the potential influence of the dispersant.
A successful project should begin with the testing requirements rather than a predetermined equipment configuration.
A practical implementation process includes:
Assess the current testing workflow. Document sample preparation, manual operations, measurement steps, cleaning, and data recording.
Define the automation scope. Decide whether the project requires automated dispersion, automatic sample feeding, sequential testing, cleaning, or broader system integration.
Evaluate representative samples. Confirm the dispersant, sample concentration, dispersion method, and measurement conditions.
Select compatible equipment. Check the analyzer, wet dispersion module, pumps, sensors, sample containers, and software interfaces.
Develop the workflow logic. Define operating sequences, sample identification, measurement methods, cleaning conditions, and exception handling.
Integrate the hardware and software. Connect the required components and verify communication between them.
Test and verify performance. Evaluate repeatability, carryover, sample handling, cleaning effectiveness, and data integrity.
Train operators and establish maintenance procedures. Define routine checks, cleaning schedules, troubleshooting, and system recovery.
Acceptance criteria should be established before commissioning. They should reflect the intended samples, measurement methods, and operational requirements.
Exceed Testing (ECD), Zhejiang Qibiao Intelligent Laboratory Technology Co., Ltd., provides laboratory automation products, customized automation systems, and laboratory system integration services.
For particle size analyzer automation, the engineering objective is to coordinate the analyzer with the required sample handling, wet dispersion, measurement, and data workflow.
Depending on the project requirements, an automated wet laser diffraction configuration may be designed around:
A wet laser diffraction particle size analyzer
Automated sample handling and positioning
Liquid supply and drainage functions
Dispersion and circulation control
Ultrasonic treatment where required
Automated measurement sequences
Cleaning and rinsing procedures
Computer-based control and result management
The final configuration should be determined by the specific analyzer model, sample characteristics, testing procedure, and required automation level.
For laboratories working with repeated particle size testing, the integration approach can help reduce manual handoffs and establish a more structured measurement workflow.
Learn more about Exceed Testing laboratory automation solutions and its particle size analyzer automated analysis system.
It is a particle size measurement workflow that combines wet sample dispersion and laser diffraction with automated operations such as liquid supply, circulation, measurement control, cleaning, and data processing.
The sample is dispersed in a suitable liquid and circulated through a measurement cell. A laser beam passes through the dispersed particles, and the instrument measures the scattered light. Software processes the scattering pattern to calculate the particle size distribution using an appropriate optical model.
Wet laser diffraction disperses particles in a liquid medium before measurement. Dry laser diffraction disperses particles in a gas, usually air. The suitable method depends on material properties, sample requirements, dispersion behavior, and the intended application.
A wet dispersion unit prepares and circulates a sample suspension for laser diffraction measurement. Depending on its configuration, it may include a tank, pump, mixing mechanism, ultrasonic unit, liquid supply, and drainage or cleaning functions.
It can. Ultrasonic treatment may separate agglomerates, but excessive energy or treatment time may break fragile particles. The appropriate conditions should be determined through method development and verification.
Yes, if the system includes suitable sample loading, identification, and sequential testing functions. The supported sample quantity and throughput depend on the equipment configuration and measurement workflow.
Automation can coordinate repetitive operations such as liquid supply, sample dispersion, measurement, cleaning, and data recording. Operators still need to prepare representative samples, establish methods, monitor system status, and review results.
Applications may include battery materials, chemicals, minerals, pharmaceuticals, ceramics, coatings, food ingredients, and other industries that need particle size characterization in liquid-dispersed samples.
No. Automated laboratory testing generally processes discrete samples in a laboratory workflow. Online monitoring measures material from a process stream or automated sampling point and may provide continuous or near-real-time process information.
Automated wet laser diffraction particle size analysis integrates sample handling, liquid dispersion, circulation, optical measurement, cleaning, and data management into a coordinated laboratory workflow.
The main design challenge is not simply automating the measurement button. It is ensuring that each stage—from sample loading to final result storage—operates under suitable and repeatable conditions.
For laboratories conducting frequent particle size testing, a well-configured automation system can reduce repetitive manual operations, improve workflow consistency, and support more structured sample and result management.
The most suitable solution depends on sample characteristics, dispersion requirements, throughput, cleaning needs, analyzer compatibility, and the desired level of integration. A workflow-based design provides a practical foundation for reliable and scalable particle size analysis.
About ECD (Exceed Testing)
ECD (Exceed Testing), Zhejiang Qibiao Intelligent Laboratory Technology Co., Ltd., specializes in laboratory automation system integration and smart laboratory solutions. The company combines in-house research and development, manufacturing, sales, and implementation services to support applications in environmental testing, food and pharmaceutical analysis, life sciences, new energy, and advanced materials.
According to the company's published website information, ECD reports more than 60 laboratory deployments and over 20 collaborating academic and corporate organizations. Its offerings include standard laboratory automation products, customized non-standard automation systems, and intelligent laboratory management software. Depending on project requirements, solutions can integrate sample handling, laboratory instruments, automation hardware, and digital workflow management.
ECD's approach focuses on improving laboratory workflow consistency, operational efficiency, and data traceability. System configurations should be evaluated against the customer's analytical methods, sample throughput, instrument compatibility, and operational requirements.
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