Solutions in Particle Sizing

CAMSIZER®

Particle analysis with digital image processing

The superior alternative

With hundreds of systems implemented worldwide, the CAMSIZER is themost successful instrument for particle size and particle shape measurementof dry, pourable bulk materials using dynamic digital image analysis. Due tothe wide measuring range from 30 µm to 30 mm and the sophisticated sievecorrelation, the CAMSIZER is a high-performance alternative to traditionalsieve analysis.

The main fields of application of the CAMSIZER are to be found in qualitycontrol, research and production monitoring. It is possible to partially orcompletely automate the measuring procedure making continuoussample analysis achievable with substantial economic benefits.

NEW FEATURES

■ 100% higher resolution■ New LED-stroboscope

light source with 20times higher intensity

■ Extreme depth of sharpness

■ Improved shape andsize analysis across theentire measuring range

■ Optimised, process-oriented software

■ Excellent compatibility to sieve analysis

■ Easy to reproduce■ Several language

versions

30 µm

The CAMSIZER® systemParticle size and particle shape analysis

100% Quality control

The CAMSIZER is a time and cost-saving alternative whenever permanent qualityassurance is demanded during production, immediate checks on incoming andoutgoing goods are required or meaningful laboratory measurements are to bemade on a wide range of different samples. Typical examples of applications are:

■ Salt/sugar ■ Sand ■ Polystyrene■ Plastics ■ Carbon black/coal ■ Glass/ceramics■ Catalysts ■ Coffee ■ Fertilisers■ Abrasives ■ Refractory products ■ Drugs■ Carbon products ■ Foodstuffs ■ Metal powder

The robust construction and interference-proof measuring principle of theCAMSIZER allow operation even under rough industrial conditions. Therefore,Retsch Technology also supplies online versions for the continuous monitoringof production processes.

The CAMSIZER has been developed to comprehensively characterisedry, pourable bulk materials. For example, whereas traditionalsieve analysis can only determine the approximate particle size, theCAMSIZER simultaneously determines both the particle size andshape – very detailed and at a high resolution. The CAMSIZER is the result of cooperation between Retsch Technology GmbH, Haanand Jenoptik AG, Jena.

Unique design

Patented measuring methodwith 2 adaptive full-framematrix cameras■ Maximum resolution■ Extremely large dynamic

measuring range■ Complete and therefore exact

particle recording with eachdigital image

Software-controlled Venturi air flush■ Avoids instrument contamina-

tion even with very dustysamples

■ Optimal particle focusing■ Representative measurements

even with strongly varyingdensities and particle sizes

Certified calibration standard■ High degree of measuring

accuracy and reliability withmore than 50 reference objects

■ Calibration throughout thewhole measuring range

■ Compatibility with national andinternational standards andother measuring methods

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CAMSIZER® versus sieve analysis – maximum benefits from minimal effort

The CAMSIZER is virtually maintenance-free. Continuous air flushing of the opticalcomponents together with the contact-free measuringprocedure ensure convenientwork.

The measuring procedure of theCAMSIZER is fully automatedto prevent random errors.Manual operating steps arereduced to filling the hopperand removing the material.

■ Feed in sample material

■ Start measurement

■ Remove sample material

■ Assemble sieve tower

■ Weigh/tare sieves

■ Feed in sample material

■ Start sieving

■ Weigh fractions

■ Evaluate

■ Clean sieves

■ Detailed particle size analysis

■ Simultaneous analysis of theparticle shape and volume

■ Highest degree of accuracy and reproducibility

■ Very fast: results in real time

■ Avoidance of random errors byextremely simple handling

■ Drastic reduction in the amount of work and time

■ Automatic, individual evaluation ofsize, shape, density, transparencyand number

■ Contact-free and therefore nondestructive analysis

■ Online measurement is thebest possible process and quality monitoring

■ Self-cleaning and almost wear-free

■ Can be recalibrated in seconds

■ Further analysis of individual fractions possible

■ Wet sieving possible

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■ Particle size distribution from a few sieving fractions

■ Sample fractioning

■ High reproducibility

■ Established measuring method

Effort Results Benefits/Advantages

Zoom

Basic

The patented CAMSIZER® principle

The innovative CAMSIZER measuring system is based on the digital image processing principle. The bulk material flow falls between light source and cameras. The particles are optically recorded,digitised and processed in the connected computer.

From 30 µm to 30 mm: accurate – quick – reliable

The basic camera detects the larger particles.

The complete particle flow is recorded bytwo cameras.

The zoom cameraanalyses the smallerones.

The patented measuring setup of the CAMSIZER – two digital camerasas an adaptive measuring unit –improves and optimises particleanalysis by digital image processing.Therefore, it is possible to measure awide range of particles from 30 µmto 30 mm with extreme accuracy,without having to switch mea-suring ranges or make adjust-ments.The sample is fed in from the feedchannel so that all particles fallthrough the measurement field.During the measurement procedure

the two digital cameras (CCD) performdifferent tasks. The basic camera(CCD-B) records large particles, thezoom camera (CCD-Z) records thesmall ones. The contact-free opticalmeasurement is carried out in realtime and simultaneously obtains all the required information aboutparticle size and particle shape.

A modularly configurable online version of the instrument has beendeveloped to allow automated mea-surements to be conductedcontinuously.

Simultaneous analysis of number, size and shape

Maximum resolution

The resolution capacity of the CAMSIZER lies in the micrometrerange. This means that detailedstudies are easily possible even onvery narrow and multi-modal parti-cle size distributions. After the digitalimages have been processed elec-tronically, the analytical results aresaved in more than 1,000 sizeclasses according to the density ofinformation. The user can define thesize class to be shown convenientlyand individually according to the features that are relevant to the particular sample.

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Quick analysis ofrepresentative samples

The sample amount can vary fromgrams to kilograms per minute.The size range being analysed is animportant factor. For small particlesizes a very small amount of thesample may be adequate. The feed hopper has a capacity of3.5 litres but for a CAMSIZERmeasurement there is no limit to themaximum sample volume. With the 75 mm feed chute, themeasurement field is used to fullcapacity which helps to measurevery big particles. Therefore, a highsample throughput is guaranteed. By using two cameras the highestpossible resolution is achieved overthe entire measuring range. Noadjustment of the instrument isrequired.Depending on the sample and theparticular requirements, a measuringtime of approximately 3 minutes istypical. This means that real-timemonitoring of the production processis possible at any time.

LongLife light source

The high intensity of the CAMSIZER’snew LED strobe light source (90 Hz)allows for extremely short exposuretimes and very sharp images withoptimum depth of sharpness andstrong contrast. In this way theCAMSIZER ensures precise shapeanalyses even of very fine particles.After each measurement the lightsource is switched to the standbymode, which enables a service life ofalmost 20 years of the light source.

Certified calibra-tion standard

By using a high-precision referenceobject (precision±0.1 µm) made by elec-tronic lithography, whichsimulates differently sizedparticles, the CAMSIZERcan be recalibrated quicklyat any time. This means thatthe requirements of moderntest agent monitoring are fulfilled.

Auto adjustment

The automatic height adjustment ofthe filling hopper guarantees correctfeeding of the sample and eliminatesmanual working steps. This enablesthe CAMSIZER to provide measuringresults with excellent reproducibility.

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Real-time results

A major advantage in the practicalapplication of the CAMSIZER is theevaluation of the results in real time.Graphical presentation of the resultsis even available while the measure-ment is still running. At the sametime the measurement process canbe checked visually by observing thedigital images. Any irregularities detected in the sample material canbe archived and evaluated at thetouch of a button. Retsch Technologysupplies the CAMSIZER with apowerful, process-oriented controland evaluation software. Export ofthe results to office programs isquick and convenient.

Process-oriented entry maskQuick and simple parameter entry due to intuitive user interface

Quality control during measurementComparison of the measurement result with upper and lower specification limits

Trend analysis of production processesUp to 4 selectable parameters of the sample material can be continuouslymonitored

Simple and reliableoperation

Setting measurement and evalua-tion parameters is made easy by a“Wizard” function in the softwarewhich guides the user through thisprocess. Product-specific settings forthe measurement parameters can besaved which simplifies the changebetween different repetitive measur-ing tasks, which are known as stan-dard operating procedures (SOPs).These SOPs can be protected againstmanipulation by a password that en-sures that the same instrument set-tings and output formats are alwaysused with the highest degree of relia-bility. This effectively eliminates oper-ator errors.

CAMSIZER® results Evaluation and documentation

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33.7%

66.3%

The basis of the precise and quickmeasuring results is the processing ofthe particle projections in real time. At arecording rate of 60 images per second,each with more than 780,000 pixels,the CAMSIZER processes informationfrom more than 45 million measuringpoints per second. In the presentationof the results as graphs, tables, cha-racteristics or digital images, a widerange of customers’ wishes have beentaken into account.The computer calculates all standardparticle distributions (volume, areaand number-related) as well as thecharacteristics of the particle size,particle shape and their distributionsand standard deviations.

The results obtained can be presentedgraphically and in tabular form as sizefractions, frequency distribution orcumulative distribution.

In addition, the CAMSIZER can deter-mine the number of particles in thesample as well as the specific surfacearea, the density and transparency ofthe sample material. All measuredvariables are determined precisely andwith excellent reproducibility. TheCAMSIZER software also allows thepresentation of daily reports, trendanalyses, mean value calculations andmuch more. A clear, individually con-figurable measuring protocol based onDIN 66 165 can be produced.

■ determination of fractions of mixture components (see graph)e.g. of ion exchangers and active charcoal for water filters as well asglass beads and corundum in colours used for road markings

■ determination of edge-holding property (angularity)e.g. quality assessment of abrasives as a preliminary to further processing

■ analysis of the broken fraction of granulese.g. as a replacement for time-consuming breakage studies on the rolling properties of granules

■ simultaneous determination of diameter/length distributionof extrudates (“rods”)e.g. determining the volumetric density of catalysts in reactor containers

■ prediction of flow and compacting behavioure.g. press-molding powders and granules in the form of tablets

Particle shape analysis and its applications

Examples of particle shape analysis applications are:

Smooth changeover from sieve analysis to CAMSIZER®

The traditional sieve analysisfrequently forms the basis forquality standards and productspecifications on which thecommunication between suppliersand customers is based.

A rapid and efficient alternative to sieve analysis must take thisinto account and produce resultsthat are fully compatible. This iswhy the CAMSIZER software isprovided with algorithms forsimulating sieve analysis. In thisway many users have been able toreplace the time-consuming sieveanalysis by using the CAMSIZERwithout having to dispense withthe familiar quality features. The automated and wear-freemeasurement means that theresults obtained are more reliableand reproducible.

As a result of the high information content obtained from the digital imagesmade during the measurement procedure, the particle projections can beevaluated in many different ways. Depending on the application, theCAMSIZER measures the particle projections according to various areas,circumferences and lengths by making a high-resolution scan of each individ-ual particle in 64 directions. The results obtained can be, for example:

■ chord length ■ width/length aspect ratio■ Martin diameter ■ roundness■ Feret diameter ■ symmetry■ straight length ■ convexity

The advantages of the full-framecameras used in the CAMSIZER for the distortion-free recording of all theparticle projections is particularly ob-vious when measuring the particleshape.

In many applications particle shape information provides an impor-tant process and quality indicator. Based on digital image processingthe CAMSIZER is immediately able to analyse the particle shape ofthe sample material in a detailed and representative manner.

More detailed information due to efficient technology

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The AutoSampler – automatic, reliable, flexible

Whenever varying sample materialsare to be analysed or seriesmeasurements need to be carriedout, the AutoSampler adapts itselfperfectly to the defined measuringroutine. The hopper positionautomatically adjusts to give thecorrect material feed gap, even forsamples with a greatly differingparticle size distribution. The sampleis fed in by an electro-pneumaticrobot arm which lifts the beakers

and empties them into the feedhopper. A built-in shaking functionensures complete emptying. Thesample beakers are collected in acontainer for reuse. Duringoperation a laser-based samplerecognition device enables the userto alter the priority of individualsamples on the conveyer belt. Theuse of the AutoSampler maximisesthe utilisation of the CAMSIZER.

AutoSampler and online version

CAMSIZER® automation options

The use of the CAMSIZER is very economical, particularly with high sample throughput. In combination with the AutoSampler efficiency can be increased due to the automated sample measurement. A further improvement is possible by using continuous quality monitoring in online operation.

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Optimised safety

With Retsch Technology, safety isnot limited to the analytical process.The CAMSIZER and AutoSamplersafety devices comply with therelevant guidelines and standards.Moveable parts are located be-hind covers which are perma-nently monitored by safetyswitches. If anything unexpectedshould occur, an emergency stop-button brings all moving parts to an immediate standstill.

Due to its robust construction and interference-free measuringprinciple, the CAMSIZER is par-ticularly suitable for integration in the production line in online op-eration. In such applications, theonline version of the CAMSIZER ismatched to the specific “on-site”needs. Usually, this includes someindividual adjustments to the de-sign, electronics and software.Typically, a representative sampleof the bulk material is removedfrom the process for online analy-sis and fed to the CAMSIZER.

Immediately after the measure-ment has been completed, the nextbatch of the product is automati-cally transferred and analysed.Thus, an up-to-date measurementresult is available at all times,which guarantees uninterruptedquality control.

The process parameters can thenbe continuously optimised througha closed loop control circuit, whichmeans that the reject quota canbe minimised.

In order to ensure long operatingperiods even in a dusty environment,the online version is equipped withan additional air flushing device andan automatic cleaning system. Therobust housing usually stands onvibration absorbers which means thatthe system can also be used at sitessubjected to intensive vibrations.Air conditioning is also available at different performance levels asan option. This guarantees that the system can function properlythroughout an extended tempera-ture range of -20 °C to +50 °C.

Control centre

Partial flow

Controlled variableManipulatedvariable

CAMSIZER®

Process

Online application

The barcode reader ensures thatdefined instrument and measure-ment settings (SOPs) are readautomatically for all the productsto be analysed. Even specificevaluations, depending on theidentification of the product orbatch number, can also be carriedout automatically. This effectively avoids operator errors and ensures constant measuring conditions for each analysis.

Even in the powder and granule processing and production sector many customer requests indicate a trend towards continual process automation in order to optimise quality costs and to avoid rejectmaterial. This requires continuous and integral quality assurance within the framework of onlineregistration of product features.

Enclosed CAMSIZER for extremeoperation conditions

Schematic diagram showing the inclusion of the CAMSIZERin a continuous quality monitoring system

Increased flexibility due to barcode reader

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CAMSIZER® accessoriesRetsch Technology offers a comprehensive range of accessories for the CAMSIZER in order to fulfil theindividual requirements for each and every application. The individual components are selected accordingto the sample material properties.

The flow behaviour of the sample can be considerablyimproved by a favourable choice of feed chute surfacematerial and shape. Feed chutes made from high-qualitystainless steel are used as standard, but even difficultmaterials such as coffee or cocoa can be fed in uniformlyand continuously by choosing the most suitable chutecoating. For example, for oily/fatty materials chutes madefrom aluminium hard-coat are recommended. The push-fitattachment means that the feed chute can be exchangedwithin a few seconds whenever necessary.For the effective feed of different-sized particles chuteswith different widths are available.

1. 40/40 mm feed chute (stainless steel) with holder

2. 40/40 mm feed chute 3. 40/15 mm feed chute

(aluminium hard-coat)

4. 75/40 mm feed chute(aluminium hard-coat)

5. 75/60 mm feed chute(stainless steel)

Push-fit feed chutes

Sample division – as impor-tant as the analysis itself

A non-representative sample will not give a correctresult, even using the most up-to-date analyticalinstruments. This is why Retsch Technology offers arange of sample dividers for obtaining representativepartial samples.

Our application laboratory will be pleased to adviseyou about choosing a suitable sample divider.

Push-fit feed chutesWidth at Width at for

hopper side feed side Holder Application Aluminium hard-coat Stainless steel

Feed chute 120 mm 75 mm –* for coarse materials – ✓

Feed chute 75 mm 75 mm 75 for coarse materials – ✓

Feed chute 75 mm 60 mm 75 for coarse materials ✓ ✓

Feed chute 75 mm 40 mm 75 for medium-sized granules ✓ ✓

Feed chute 40 mm 18 mm 75 for powders and finely grained samples ✓ ✓

Feed chute 40 mm 40 mm 40 for medium-sized granules ✓ ✓

Feed chute 40 mm 15 mm 40 for powders and finely grained samples ✓ ✓

Holder for push-fit feed chutes Aluminium hard-coat Stainless steel

Holder 75 for 75 mm feed chutes (width at hopper side) – ✓

Holder 40 for 40 mm feed chutes (width at hopper side) – ✓

*No holder necessary, feed chute will be screwed on

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Different hopper sizes are available for different amountsof sample. Hoppers can be supplied with a capacity from0.4 litres up to 7.8 litres. For optimal sample feed thesehoppers are available in different materials and withdifferent coatings (stainless steel, aluminium hard-coat,etc.).

Feed hoppers

Further information about us and our products can be found at: www.retsch-technology.com

Feed hoppersHopper capacity Ø Outlet Aluminium hard-coat Stainless steel

Feed hopper for 120 mm feed chutes (width at hopper side) 7.8 litres 100 mm – ✓

Feed hopper for 75 mm feed chutes (width at hopper side) 3.5 litres 60 mm – ✓

Feed hopper for 40 mm feed chutes (width at hopper side) 2.8 litres 30 mm – ✓

Feed hopper for 40 mm feed chutes (width at hopper side) 0.4 litres 30 mm ✓ ✓

The use of a feed guide ensures that even the finestmaterials fall through the focusing range of the cameraswithout any unwanted turbulence and can therefore bemeasured accurately. For special applications feed guidesare available to orient the particles in a preferreddirection. For example, this allows the precise anddirect measurement of the length and width whenanalysing extrudates.

Feed guides

Feed guidesStainless steel

Feed guide “Standard” ✓

Feed guide “Extrudate” ✓

As additional information we recommend our CAMSIZER and AutoSampler video presentations.

The videos are available at www.retsch-technology.comfor downloading or can be requested as a CD-ROM free-of-charge.

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Retsch Technology GmbHRheinische Straße 4342781 Haan, Germany

Telephone +49 21 29 / 55 61 - 0Telefax +49 21 29 / 55 61 - 87

E-mail technology@retsch.comInternet www.retsch-technology.com

Retsch Technology – your specialistfor particle analysis offers you acomprehensive range of instruments.We would be pleased to provide youwith further information about ouranalytical instruments for size andshape measurement.

Technical dataCAMSIZER®

Measuring range: recommended range 30 µm to 30 mm

Parameters: particle size, shape, density, transparency and number

Measurement: 60 images/s, each with more than 780,000 pixels

(corresponds to more than 45 megapixels per second)

Measuring time: approximately 2 to 3 min (depends on required measurement statistics)

Instrument data: dimensions (H x W x D) approximately 650 x 850 x 350 mm

weight (without PC): approximately 40 kg

The CAMSIZER is CE-tested and follows the relevant guidelines and standards.

It can be supplied with software complying with FDA rule 21 CFR Part 11.

AutoSampler Compressed air supply: min. 6 bar

Compressed air consumption: max. 10 l/min

Instrument data: dimensions (H x W x D) approximately 900 x 1450 x 490 mm

weight: 60 kg

Sample feed: control of the endless conveyor belt by light barrier interruption during sample

container positioning, sample feed by electro-pneumatic robot arm,

emergency stop-button

The AutoSampler is CE-tested and complies with the relevant guidelines and standards.

CAMSIZER®-OnlineMeasuring data: see CAMSIZER for measuring range, measurement, measuring time

Working range: temperature range -20 °C to +50 °C (air-conditioned),

enclosed for rough surroundings by housing (IP 54),

shock and vibration-absorbing installation

Instrument data: dimensions (H x W x D) approximately 800 x 1600 x 600 mm

weight: approximately 250 kg

compressed air supply: 4 - 8 bar

Interfaces: Ethernet, Profibus, various digital and analogue contacts and signals (e.g. 4 -20 mA)

Fields of applicationScope and purpose: rapid and exact particle size and shape analysis of all dry,

pourable bulk materials and powders

Sample material: e.g. salt/sugar, plastics, catalysts, abrasives, carbon products,

sand, carbon black/coal, coffee, refractory products, foodstuffs,

polystyrene, glass/ceramics, fertilisers, pharmaceuticals,

metal powder, etc.

Operating sites: factory laboratories, research institutes, locations close to the production

line as well as online for optimal quality control of products and processes

CAMSIZER® at a glance

SkanLab ApS · Kvinderupvej 30 · 3550 SlangerupTelefon: 4738 1014 · Telefax: 4738 1064

Mobil: 2011 1514 · E-mail: birte@skanlab.comHjemmeside: www.skanlab.com