IntelliSizer

IntelliSizer - Intelligent Online Particle Size Analyser

The Xoptix IntelliSizer is an advanced online particle size analyser designed to provide continuous, real-time monitoring and control of industrial production processes. Built specifically for demanding process environments, IntelliSizer combines high-performance laser diffraction technology with self-monitoring and self-cleaning systems to deliver reliable particle size measurement 24 hours a day, 7 days a week.

Unlike traditional laboratory sampling methods, which can take hours between measurements, IntelliSizer delivers immediate particle size data directly from the process line. This allows manufacturers to optimise milling, improve product quality, reduce waste, and significantly lower energy consumption. Real-time feedback to PLC and DCS systems enables fully automated closed-loop process control, helping plants achieve higher throughput and tighter product specifications.

Designed for Modern Industry and Industry 4.0

IntelliSizer has been engineered to meet the requirements of modern smart manufacturing and Industry 4.0 environments. The system continuously measures complete particle size distributions at extremely high speed, producing detailed process data that can be integrated directly into plant automation systems using OPC UA and Ethernet communication protocols.

The analyser’s intelligent software continuously monitors instrument performance, automatically performs diagnostic checks, and initiates cleaning cycles when required. This patented technology ensures maximum uptime and dependable operation even in harsh industrial applications where conventional systems often fail.

Why Real-Time In-Process Measurement Matters?

Particle size is one of the most critical parameters in powder and particulate production. It directly affects product quality, flowability, solubility, reactivity, and overall process efficiency. Traditional laboratory measurement methods are labour intensive, slow, and unable to provide true process control. By the time a lab result is available, large quantities of off-specification material may already have been produced. With IntelliSizer, samples are automatically extracted from the process, analysed instantly, and returned back into the production stream. Continuous second-by-second measurement allows operators to detect changes immediately and make automatic adjustments to maintain optimal process conditions.

Built for Reliability and Maximum Uptime

At the heart of IntelliSizer is a precision optical bench containing high-stability lasers, premium optics, and custom-designed detectors. This unique design delivers exceptional measurement stability and robustness in industrial environments. The instrument is housed within an IP65-rated enclosure and includes ceramic-lined components to resist abrasion and minimise maintenance requirements.

Xoptix’s automatic cell cleaning technology continuously maintains measurement performance without operator intervention. The system’s self-diagnostic capabilities ensure that any potential issues are identified immediately, eliminating uncertainty and reducing downtime.

Reduce Process Variability

This example shows how process variability is progressively reduced as measurement and control capabilities improve.
Initially, particle size was monitored using manual sampling (black points), providing only occasional process information.
After switching to the Xoptix in-process particle size analyser (red points), continuous online measurements gave operators real-time visibility of process performance. Using this information, classifier speed was manually optimised (green points), bringing the product closer to the target specification and reducing variability.
Finally, automatic closed-loop control was activated (blue points), continuously maintaining the target x95 particle size of 74.2 μm with minimal variation and virtually no process drift. The result was improved product consistency, lower energy consumption (49 to 38 kWh/t), and an increase in production rate of up to 10%.

Operational Features

The Xoptix IntelliSizer has been engineered specifically for demanding industrial process environments. Its robust construction and intelligent automation ensure maximum uptime, stable performance, and long-term durability even in harsh production conditions. The system features: a powder path constructed from advanced ceramics and rubber components to maximise wear resistance and maintain performance when handling abrasive materials. Automatic cleaning using compressed air helps prevent build-up within the measurement cell, reducing maintenance requirements and ensuring continuous operation. Designed for true industrial reliability, the IntelliSizer is highly resistant to vibration and does not require routine optical alignment or calibration. Its fully sealed IP65-rated enclosure protects the instrument against dust, moisture, and challenging plant environments, making it suitable for installation directly within the production process. Programmable operating sequences and intelligent self-monitoring functions allow the IntelliSizer to integrate seamlessly into automated manufacturing systems, supporting real-time process optimisation and closed-loop control.

Technical Specifications

1.Particle size range: 0.1 – 1100 microns
2.Sampling rate: 2000 measurements per second
3.Resolution: 16-bit
4.Analogue outputs: 2 opto-isolated 4–20mA outputs
5.Digital inputs: 3 general purpose opto-isolated inputs
6.Digital outputs: 8 general purpose outputs
7.Industrial protection rating: IP65 Supply voltage: 24V DC

XI220P Technical Specifications

XI550P Technical Specifications

Benefits

1.Unmanned operation & Reduce Labor Costs, 2.Increased Production Rate, 3.Reduced waste and rework, 4.Reduced Process Variability, 5.Improved Product 6.Quality Real-time process optimisation and control, 7.Continuous 24/7 online particle size monitoring, 8.Faster product changeovers, 9.Improved product consistency and tighter tolerances, 10.Minimal maintenance with long-life wear components, 11.Seamless integration with PLC and DCS systems,12.Designed for harsh industrial process environments, 13.Reduced over-grinding and lower energy costs, 14.Decreased Specific Power Consumption, 15.Fast response for immediate process control

Industries and Applications

IntelliSizer is used across a wide range of powder processing industries where particle size directly affects product quality, process efficiency, labor costs, and energy consumption.
Cement and Building Materials
Cement grinding, Slag grinding, Limestone processing, Fly ash production, Mineral fillers.
Mining and Minerals
Industrial minerals, Calcium carbonate, Kaolin,Talc, Silica, Feldspar, Barite.
Coal and Energy
Coal grinding Pulverised fuel (PF) monitoring, Coal-fired power stations, Biomass and alternative fuels, Mill and classifier optimisation.
Chemicals
Pigments, Fertilisers, Specialty chemicals, Catalysts.
Powder coatings
Battery Materials, Cathode materials, Anode materials, Graphite processing, Advanced energy materials
Metals and Metallurgy
Metal powders, Mineral beneficiation, Process optimisation in grinding circuits.
Powder Processing
Ball mills, Vertical roller mills, Air classifiers, Grinding circuits, Pneumatic conveying systems.

Pharmaceutical and Food Applications
For pharmaceutical, food, and other hygienic manufacturing environments, Xoptix offers the PharmaSizer — a pharmaceutical-grade version of the IntelliSizer. PharmaSizer incorporates the same proven laser diffraction technology and measurement performance as IntelliSizer, but is manufactured from 316L stainless steel with hygienic tri-clamp connections, enhanced cleanability, full material traceability, and pharmaceutical-grade sealing systems to meet the requirements of regulated industries.

By providing continuous real-time particle size measurement, IntelliSizer helps manufacturers reduce variability, optimise separator performance, improve product quality, consistency, lower energy consumption, and increase production throughput.