Malvern Panalytical’s Mastersizer 3000 is one of the most popular laser diffraction instruments worldwide. Deployed in laboratories across various industries, including pharmaceuticals, chemicals, mining, food, and advanced materials, companies have turned to the Mastersizer for rapid, precise particle-size distribution measurements.
Image Credit: Vision Analytical Inc.
Yet, importantly, some users don’t realize they could improve their system by simply adding the HydroInsight analyzer.
Hydrolnsight is the ideal add-on for the Malvern Mastersizer because it transforms particle sizing into particle counting, concentration, and shape analysis.
In laboratories where the Mastersizer is already in place, HydroInsight may be the key to unlocking a more efficient particle characterization workflow.
Why Mastersizer Users Often Need More Than Particle Size
The high reproducibility of laser diffraction makes it a powerful, trusted method for measuring particle size distributions.
However, at its core, laser diffraction is a composite, volume-based method, meaning:
- Individual particles are not directly counted
- Large particles overshadow the measurement
- Particle concentration is not taken into account
When it comes to PSD, Mastersizer delivers exceptional results but leaves many questions unanswered. The HydroInsight, however, addresses any oversight and adds the extra value and data needed to address the following:
- How to count the total number of individual particles that make up the overall sample
- How to display particle concentration per mL
- How to identify unusual contaminants or unexpected agglomerates
- How to determine if shape and morphology align with expectations
HydroInsight as a Malvern Mastersizer Complement
HydroInsight is an advanced imaging particle size and shape analyzer that offers the dynamics and adaptability to work in parallel with Malvern’s laser diffraction systems.
As a complement to the Malvern Mastersizer, HydroInsight delivers results that the Mastersizer cannot:
- Individual particle counting
- Real-time concentration (per mL) measurement
- Direct images for particle verification
- Particle shape parameters
HydroInsight quickly enhances the Mastersizer's capabilities by providing particle-by-particle insight to complement laser diffraction.
Real-Time Particle Concentration Measurement
One of the key advantages of HydroInsight is its ability to measure particle concentration in real time.
With the capability to count particles individually as they flow through the system, HydroInsight can report:
- Concentration tracking during measurement
- Particles per milliliter
- Variations in particle population over time
This makes HydroInsight an essential tool when determining particle load is just as important as identifying particle size in applications such as:
- Advanced powders and battery materials
- Contamination monitoring
- Dispersion stability studies
- Pharmaceutical suspensions (Api/Excipient concentration differences)
Where Mastersizer tells you “how big”, HydroInsight tells you the specifics of shape, images, and “how many.”
The image below was generated by HydroInsight, which displays the total particle concentration in real time.
Image Credit: Vision Analytical Inc.
The Added Benefit: Concentration by Size Range
In addition to its main features, HydroInsight offers an innovation that makes it the perfect companion for Malvern’s Mastersizer: the ability to calculate particle concentration by size band.
Rather than simply determining the total concentration, HydroInsight can reveal deeper insights such as:
- The number of particles per mL is larger than 50 µm
- The number of particles that fall within an agglomerate range
- The number of oversized contaminants present in the sample
This information is extremely useful when quantifying a specific sub-population.
Agglomerate Monitoring: Example
During dispersion processes, the primary particle population may appear within spec, but even a few rogue agglomerates can significantly impact performance or quality. HydroInsight empowers users by being able to calculate the following:
- Concentration of specific contaminant populations
- Particles/mL of agglomerates
- Particles/mL of oversized material
By determining these elements, HydroInsight delivers direct quantitative control over the particle populations that matter the most.
The example below was taken from HydroInsight. It shows how a user can tailor their dashboard to display specific particle categories and match the concentration across the sample.
To illustrate this, when in possession of an active pharmaceutical ingredient containing excipients, HydroInsight’s built-in classification tool and software enable classification while reporting the overall concentration of a single particle class or the concentration within a particular size range.
Image Credit: Vision Analytical Inc.
HydroInsight + Mastersizer: A Complete Particle Characterization Platform
Mastersizer and HydroInsight work together to deliver one of the leading, high-impact particle analysis workflows available on the market today.
Source: Vision Analytical Inc.
| Capability |
Mastersizer 3000 |
HydroInsight |
| Particle size distribution |
 Excellent |
Individual sizing |
| Fast QC measurement |
Yes |
Yes |
| Particle concentration |
 No |
Yes |
| Particle counting |
No |
Yes |
| Shape analysis |
Limited |
Full morphology |
| Particle images |
No |
Yes |
For labs that require more than simple size quantification, the table above shows that the HydroInsight is the perfect companion to Malvern’s Mastersizer.
Why Many Mastersizer Users Don’t Realize This Capability Exists
Many organizations and laboratories running particle-counting processes believe that an entirely separate contamination instrument is required.
The reality is that Mastersizer users need only add the HydroInsight to their already-existing workflow to achieve the following:
- Particle population analysis
- Concentration measurement
- Imaging verification
For many, this is the most straightforward way to transform PSD into true particle intelligence without interrupting a trusted laser diffraction workflow.
Conclusion: Beyond Size, Toward Particle Intelligence
While particle size will always remain front and center, modern industries increasingly require deeper insight, including:
- Concentration values
- Determining the number of particles
- Shape identification
- Existent sub-populations
HydroInsight is the perfect solution to boost the capabilities of the Malvern Mastersizer because it introduces particle counting, real-time concentration, and concentration-by-size-range analysis to laser diffraction workflows. HydroInsight could be the final piece in the puzzle to complete particle characterization capabilities in laboratories where the Mastersizer is already in use.
Further Asked Questions
Is the HydroInsight a Replacement for the Mastersizer?
No, the HydroInsight was developed as a complement to the Malvern Mastersizer, introducing counting, concentration, and imaging alongside laser diffraction sizing.
Can the Mastersizer Measure Particle Concentration?
Mastersizer delivers volume-based particle size distribution data but cannot measure particle counts per mL or concentration on its own accord.
What does Concentration by Size Range Mean?
HydroInsight calculates particles/mL within a selected size band, such as agglomerates, oversized particles, or contaminants, providing users with the supplementary data they need.
This information has been sourced, reviewed and adapted from materials provided by Vision Analytical Inc.
For more information on this source, please visit Vision Analytical Inc.