Quick Answer

A custom particle size analyzer system is designed to meet specific laboratory or industrial testing requirements that standard particle size analyzers cannot fully address. Customization may include automatic sampling, sample preparation, wet or dry dispersion, instrument integration, automated cleaning, data management, and communication with laboratory or production control systems.

Rather than modifying the core measurement technology unnecessarily, a customized solution typically integrates a suitable particle size analyzer with application-specific automation, control software, and sample-handling equipment.

Key Takeaways

• Custom particle size analyzer systems can be designed for laboratory testing, production-line sampling, or automated process monitoring.

• Customization may involve wet dispersion, dry powder feeding, automatic sampling, sample dilution, cleaning, and data integration.

• Laser diffraction is commonly used when particle size distribution measurement across a broad size range is required.

• Existing particle size analyzers can often be integrated into an automated workflow without replacing the entire instrument.

• The right design depends on sample properties, measurement standards, throughput, cleaning requirements, and the level of automation required.

• A successful custom solution should be validated against the application's measurement requirements before routine operation.

1. What Is a Custom Particle Size Analyzer System?

A custom particle size analyzer system is an application-specific measurement and automation solution developed around particular sample characteristics, testing procedures, and operational requirements.

A standard particle size analyzer generally provides the core measurement function. However, many laboratories and manufacturing facilities require additional operations before, during, and after measurement.

For example, a laboratory may need to automatically prepare multiple powder samples, while a battery materials manufacturer may need to collect slurry samples from several production lines and measure their particle size distributions.

These requirements can involve several integrated components:

The objective is not simply to automate an instrument. It is to create a complete and repeatable particle size testing workflow.

2. When Do You Need a Customized Particle Size Analyzer?

A custom particle size analysis system may be appropriate when standard equipment cannot meet the required sample-handling, testing, or integration conditions.

2.1 Non-Standard Sample Characteristics

Some materials require special handling before particle size measurement.

Examples include:

• High-viscosity slurries

• Agglomerated powders

• Fine chemical powders

• Battery electrode materials

• Materials that are sensitive to moisture

• Samples that require controlled dispersion

• Materials with strict contamination-control requirements

For these applications, the sampling and pretreatment process may be just as important as the analyzer itself.

2.2 High-Volume Sample Testing

Laboratories that process large numbers of samples may benefit from automated sample loading, sample identification, measurement sequencing, and cleaning.

A customized system can reduce repetitive manual operations and help standardize the testing workflow.

However, the achievable throughput depends on the measurement method, sample preparation time, cleaning cycle, and number of analyzers.

2.3 Multiple Sampling Points

Manufacturing processes may require particle size testing at different locations or production stages.

A customized sampling system can be designed to collect samples from multiple points and transfer them to a centralized measurement station.

This is particularly relevant to battery materials, chemical production, mineral processing, and other processes where particle size distribution is an important quality parameter.

2.4 Integration With Existing Laboratory Equipment

Replacing an existing particle size analyzer may not always be necessary.

If the analyzer remains suitable for the required measurement method, an automation retrofit can add functions such as:

• Automatic sample feeding

• Automated sample transfer

• Automatic liquid addition

• Ultrasonic dispersion

• Automatic cleaning

• Instrument status monitoring

• Centralized data collection

The feasibility of integration depends on the analyzer's communication interfaces, mechanical configuration, software access, and manufacturer specifications.

3. What Can Be Customized in a Particle Size Analyzer System?

Customization should be based on the complete testing process rather than a single equipment specification.

3.1 Custom Sampling System

The sampling system determines how material is collected and delivered for measurement.

Common options include:

Representative sampling is essential. A highly automated system cannot compensate for a sampling method that fails to collect material representative of the process.

3.2 Custom Wet Dispersion System

Wet particle size analysis is commonly used for powders and materials that can be dispersed in a suitable liquid medium.

A customized wet dispersion system may include:

• Liquid storage and supply

• Automatic water or dispersant addition

• Sample mixing

• Ultrasonic dispersion

• Circulation pumps

• Flow control

• Temperature monitoring

• Automatic drainage and cleaning

The dispersion method must be selected according to the material's physical and chemical properties.

Excessive ultrasonic energy, for example, may break fragile particles and change the measured particle size distribution. Insufficient dispersion may leave agglomerates in the sample and produce misleading results.

3.3 Custom Dry Powder Feeding System

For materials that are unsuitable for wet dispersion, dry dispersion may be considered.

A customized dry powder feeding unit may include:

• Automatic powder dosing

• Vibrating feeders

• Hopper systems

• Powder transfer mechanisms

• Air pressure and flow regulation

• Dust collection

• Enclosed sample handling

The system should control feeding stability and dispersion conditions to improve measurement repeatability.

For cohesive, electrostatic, or moisture-sensitive powders, the feeding mechanism and environmental conditions require particular attention.

3.4 Custom Automatic Cleaning System

Residual material can affect subsequent measurements, especially when testing different materials or samples with significantly different particle size distributions.

A cleaning system may be designed around:

• Water or solvent selection

• Automatic flushing

• Pipeline cleaning

• Measurement-cell cleaning

• Drainage

• Drying, where necessary

• Cleaning-cycle verification

Cleaning requirements should be established through contamination testing rather than assumed from the appearance of the equipment.

3.5 Custom Control Software and Data Integration

A custom particle size analyzer automation system may use a PLC, industrial computer, or a combination of control devices.

Typical software functions include:

• Automatic testing sequence management

• Sample ID and barcode management

• Sampling-point selection

• Instrument status monitoring

• Alarm and fault records

• Measurement data collection

• Historical data queries

• Report generation

• Communication with DCS, MES, or laboratory information systems

The available functions depend on the analyzer's software interfaces and the integration requirements of the project.

4. Wet vs. Dry Custom Particle Size Analysis Systems

The selection of wet or dry particle size analysis depends on the sample's physical properties and the measurement method.

Neither method is universally better.

The selection should consider whether the measurement conditions can represent the material's actual application state. For example, a powder that dissolves or reacts in water may not be suitable for wet analysis.

5. How Is a Custom Particle Size Analyzer System Designed?

A reliable customization project should begin with the testing requirements and process workflow.

Step 1: Define the Measurement Requirements

Before equipment selection, establish:

• Material name and composition

• Sample physical state

• Expected particle size range

• Required measurement parameters

• Applicable testing standards

• Sample volume

• Number of samples per day

• Required measurement frequency

• Repeatability and accuracy requirements

For laser diffraction applications, the required particle size distribution may include D10, D50, and D90.

These values represent the particle sizes below which 10%, 50%, and 90% of the measured distribution fall, respectively, based on the selected distribution basis.

Step 2: Evaluate the Sample Preparation Process

Determine whether the material requires:

• Drying or moisture control

• Dilution

• Mixing

• Wetting

• Ultrasonic dispersion

• Deagglomeration

• Temperature control

• Special cleaning procedures

The preparation method should be validated to ensure that it does not unintentionally change the particle size distribution.

Step 3: Select the Measurement Instrument

The measurement instrument should match the sample and application.

Potential technologies include:

The choice should be based on measurement range, sample properties, required output, testing standards, and method validation.

Step 4: Design the Automation Workflow

After selecting the measurement method, define how samples move through the system.

A typical automated wet particle size analysis workflow is:

1. Sample collection

2. Sample identification

3. Sample transfer

4. Liquid addition

5. Mixing and dispersion

6. Measurement

7. Data collection

8. Sample discharge

9. Cleaning

10. Preparation for the next sample

For production applications, the workflow may also include sampling-point switching, process communication, and abnormal-condition handling.

Step 5: Integrate Hardware and Software

The integration design may include:

• Analyzer communication

• PLC control

• Sensors and actuators

• Pumps and valves

• Industrial computer

• Human-machine interface

• Database

• DCS or MES communication

Before implementation, define communication protocols, signal ownership, alarm logic, data formats, and system responsibilities.

Step 6: Test and Validate the Complete System

A custom system should be evaluated using actual application materials.

Important validation items include:

Acceptance criteria should be agreed upon before commissioning.

6. Applications of Custom Particle Size Analyzer Systems

Custom particle size analysis and automation are relevant to several industries.

6.1 Lithium Battery Materials

Particle size distribution is an important characterization parameter for battery materials and electrode slurries.

Depending on the material and process stage, customized systems may support:

• Cathode material testing

• Anode material testing

• LFP slurry particle size analysis

• Slurry sampling from multiple production points

• Wet dispersion and laser diffraction measurement

• Measurement data transfer to production systems

For slurry applications, sampling location, sample homogeneity, dilution, dispersion energy, and cleaning procedures must be carefully controlled.

6.2 Chemical and Fine Chemical Manufacturing

Chemical manufacturers may require particle size monitoring for pigments, fillers, catalysts, and other particulate materials.

Customized automation can support sample preparation, measurement sequencing, and centralized data management.

6.3 Pharmaceutical and Food Ingredients

Particle size can influence powder flowability, dissolution behavior, blending, and product consistency.

The testing system should be designed according to the material's properties and the relevant analytical procedures.

For regulated applications, equipment qualification, cleaning documentation, data integrity, and method validation may also be required.

6.4 Minerals and Building Materials

Minerals, cement, and other construction materials may require dry or wet particle size analysis.

A customized system can automate powder feeding, sample transfer, dispersion, and measurement-data collection according to the production or laboratory workflow.

7. Engineering Example: Custom Particle Size Analysis for LFP Slurry

The following example is an engineering design illustration based on a published Exceed Testing technical solution. It describes the proposed system configuration, not independently verified production performance.

Application Background

In lithium iron phosphate (LFP) battery material production, particle size analysis may be required during the fine grinding stage.

A multi-line production process creates a challenge: samples need to be collected from different locations, prepared under consistent conditions, measured, and associated with the correct production point.

Manual sampling and testing can involve repeated operator handling and data recording.

Proposed System Configuration

The published Exceed technical scheme describes the following design conditions:

The technical scheme indicates approximately 3–4 minutes of measurement time per sampling point. This is not the complete system cycle time. Actual cycle time must also account for sample transfer, line switching, cleaning, repeat measurements, and other process operations.

Proposed Workflow

1. Select a production sampling point.

2. Collect the LFP slurry sample automatically.

3. Transfer the sample to the preparation unit.

4. Add water according to the configured procedure.

5. Apply ultrasonic pre-dispersion.

6. Transfer the prepared sample to the laser diffraction analyzer.

7. Collect particle size measurement data.

8. Associate the result with the relevant sampling point.

9. Clean the sample-contact components before the next measurement.

Engineering Considerations

Several factors should be evaluated during detailed design:

• Whether the sample collection method provides representative slurry samples

• Whether dilution changes the measurement conditions

• Whether ultrasonic treatment causes particle breakage

• Whether the pipeline and valves are compatible with the slurry

• Whether cleaning can prevent cross-contamination

• Whether the analyzer supports the required communication interface

• Whether two analyzers can meet the required sampling frequency

This type of project demonstrates why a custom particle size analysis system needs coordinated design across sampling, preparation, measurement, control, and data integration.

8. Can an Existing Particle Size Analyzer Be Customized?

In many cases, an existing analyzer can be integrated into a customized automation system.

This approach may be suitable when the current instrument still meets the required measurement range, accuracy, and testing method.

Possible retrofit functions include:

• Automatic sample loading

• Automatic liquid addition

• Automated dispersion

• Automatic measurement triggering

• Sample transfer and positioning

• Automatic cleaning

• Data collection

• Centralized control

However, not every analyzer can support every automation function.

Before selecting a retrofit solution, engineers should evaluate:

1. Analyzer model and manufacturer.

2. Available communication protocols.

3. Whether external control is supported.

4. Available mechanical access and connection points.

5. Software permissions and integration limitations.

6. Warranty and maintenance implications.

7. Required measurement and safety validation.

A retrofit feasibility assessment should be completed before finalizing the system design.

9. Custom Particle Size Analyzer vs. Standard Equipment

A customized system is not automatically the best option for every laboratory.

For low sample volumes and straightforward testing procedures, a standard analyzer may be more economical. Customization becomes more valuable when the sample-handling process, testing frequency, or integration requirements are complex.

10. How to Choose a Custom Particle Size Analyzer Supplier

Choosing a supplier requires evaluating both measurement expertise and system integration capabilities.

Consider the following factors:

10.1 Understanding of Particle Size Measurement

The supplier should understand the measurement principles, sample preparation requirements, and limitations of the selected analyzer.

10.2 Sample Handling and Automation Experience

Ask whether the engineering team can design sampling, feeding, transfer, dispersion, and cleaning systems for your material.

10.3 Instrument Integration Capability

The supplier should be able to assess communication interfaces and coordinate integration with the selected analyzer.

10.4 Control and Software Development

Check whether the supplier can provide PLC control, industrial software, data management, and communication with existing production systems.

10.5 Testing and Commissioning

A complete project should include workflow testing, measurement verification, cleaning evaluation, and acceptance against agreed requirements.

10.6 After-Sales Support

Confirm the availability of technical documentation, spare parts, maintenance, software support, and troubleshooting services.

11. Custom Particle Size Analyzer Solutions from Exceed Testing

Exceed Testing focuses on laboratory automation system integration and customized testing workflows.

Its particle size analyzer automation solutions can be developed around project-specific requirements, including:

• Particle size analyzer automation

• Wet laser particle size analysis automation

• Automatic sample preparation

• Multi-point sampling systems

• Automated liquid handling

• PLC-based equipment control

• Laboratory instrument integration

• DCS/MES communication based on project requirements

The appropriate configuration depends on the material, analyzer model, sampling frequency, laboratory workflow, and production interface.

For projects involving existing instruments, the feasibility of automation retrofit can also be evaluated before deciding whether new equipment is necessary.

Explore related solutions:

• Particle Size Analyzer Automation: https://www.exceed-testing.com/ypqclzdh

• Laboratory Automation Solutions: https://www.exceed-testing.com/news/41

• Smart Laboratory Automation System Integration: https://www.exceed-testing.com/news/40

• LFP Slurry Particle Size Automation Case: https://www.exceed-testing.com/news/43

• Exceed Testing Company Profile: https://en.exceed-testing.com/about

12. Frequently Asked Questions

Q1. What is a custom particle size analyzer?

A custom particle size analyzer system is an application-specific solution that combines a suitable measurement instrument with customized sampling, sample preparation, feeding, cleaning, control, and data integration functions.

Q2. Can a particle size analyzer be customized for a specific material?

Yes. The sampling and preparation workflow can be designed according to the material's properties, including viscosity, moisture sensitivity, agglomeration, dispersion behavior, and chemical compatibility.

Q3. Can an existing particle size analyzer be automated?

In many cases, yes. External automation may be added for sample loading, liquid addition, dispersion, cleaning, and data collection. Feasibility depends on the analyzer's mechanical and communication interfaces.

Q4. What is the difference between wet and dry particle size analysis?

Wet analysis disperses particles in a suitable liquid medium, while dry analysis uses a gas or air-based dispersion process. The appropriate method depends on material properties and the intended measurement procedure.

Q5. Can a custom particle size analyzer system connect to MES or DCS?

It may be possible when the analyzer and control system provide compatible communication interfaces. The required protocol, data structure, signal mapping, and security requirements should be confirmed during engineering design.

Q6. How long does it take to build a custom particle size analyzer system?

Project duration depends on the complexity of sampling, preparation, mechanical design, software development, instrument integration, manufacturing, and validation. A timeline should be established after reviewing the technical requirements.

Q7. What information is needed for a custom particle size analyzer quotation?

Typical information includes material characteristics, sample form, particle size range, testing frequency, number of sampling points, existing analyzer model, automation requirements, and desired communication interfaces.

Q8. Is a custom particle size analyzer system suitable for battery slurry?

It can be suitable when the sampling, dilution, dispersion, and measurement procedures are validated for the specific slurry. Special attention should be paid to sample representativeness, particle stability, and cleaning.

Q9. Does a custom system always require a new particle size analyzer?

No. If an existing instrument meets the measurement requirements and supports the necessary interfaces, it may be integrated into a customized automation system.

Q10. What should be included in a particle size analyzer automation project?

A project may include the analyzer, sampling equipment, sample preparation unit, transfer mechanisms, cleaning system, control hardware, software, data integration, commissioning, and validation documentation.

Conclusion

A custom particle size analyzer system should be designed around the complete measurement workflow rather than the analyzer alone.

For laboratories and manufacturers with complex sample characteristics, multiple sampling points, high testing frequency, or production data integration requirements, customization can help connect sampling, preparation, measurement, cleaning, and data management into a coordinated process.

The most suitable solution depends on the material, measurement method, existing equipment, and required level of automation. A detailed application assessment and validation plan should therefore be completed before equipment selection and system implementation.