In this interview, AZoMaterials speaks with Applications Scientists from Bettersize Instruments about the evolution of particle analysis, the limitations of traditional particle size analysis (PSA), and how modern technologies such as the BetterSizer 2600 Plus are helping laboratories gain deeper insight into material behavior, improve decision-making, and address increasingly complex analytical challenges.
Can you please introduce yourself and your role at Bettersize?
Dr. Beverly Barnum: As Technical Director of Bettersize Inc., I work closely with customers across a wide range of industries to help them solve particle characterization challenges. My role involves driving the technical strategy for our instruments and providing case-by-case application consulting for complex client challenges. I focus on designing tailored analytical solutions, developing advanced methodologies, and authoring foundational technical literature to ensure our global teams and customers are fully supported.
Weichen Gan: My role involves conducting analytical testing, maintaining standard laboratory procedures, and delivering application support for routine operational inquiries. I focus on fine-tuning measurement parameters, translating raw data into clear, actionable reports for our clients, and compiling field data into standardized application notes.
How has particle analysis evolved in recent years?
Dr. Beverly Barnum: Historically, particle size analysis was primarily viewed as a routine measurement focused on generating numerical outputs, such as D10, D50, D90 values and particle size distributions. For many years, this was sufficient because materials were relatively simple and particle size data was mostly used for classification or specification compliance.
Today, however, particle analysis plays a much more critical role. Particle size data directly influences decisions related to product performance, quality, regulatory compliance, stability, dissolution behavior, packing density, flowability, optical properties, and even electrochemical performance. As materials have become more sophisticated, particle analysis has evolved from a supporting measurement into a performance-critical decision-making tool.
What factors are driving higher expectations for particle size analysis?
Dr. Beverly Barnum: Several market forces are contributing to this shift. Advanced materials are becoming increasingly common across industries such as energy storage, cosmetics, specialty chemicals, inks, and pharmaceuticals. These materials often exhibit complex behaviors influenced by particle shape, agglomeration, dispersion state, and microstructure.
At the same time, regulatory requirements continue to become more demanding, requiring greater traceability, consistency, and confidence in analytical data. Faster development cycles also mean laboratories have less time for trial-and-error experimentation, increasing the need for analytical tools that support rapid troubleshooting and informed decision-making.
As a result, users increasingly expect particle analysis systems to provide understanding and context, not simply measurements.
Why are traditional particle size analysis systems becoming less effective for modern materials?
Dr. Beverly Barnum: Laser diffraction remains an extremely powerful and widely trusted technique. However, traditional systems rely on several assumptions that do not always align with the behavior of modern materials.
For example, laser diffraction assumes particles can be represented as equivalent spheres, that samples are fully dispersed, and that particle behavior remains stable during measurement. In reality, many materials contain irregular shapes, fragile agglomerates, or particles that are highly sensitive to preparation conditions.
When these assumptions are not fully met, users may need to rely heavily on experience and interpretation, introducing uncertainty into the decision-making process. Modern materials often require a more complete understanding of particle behavior than size-only measurements can provide.
What practical challenges can arise when relying solely on size-based measurements?
Dr. Beverly Barnum: One common challenge is disagreement between laser diffraction results and other analytical methods, such as sieving or microscopy. Irregularly shaped particles may behave differently depending on the measurement technique, making discrepancies difficult to explain.
Another issue occurs when unexpected changes appear in particle size distributions. Laboratories frequently repeat measurements, modify dispersion settings, or prepare additional samples to verify results. Without additional context, it can be difficult to determine whether observed changes are caused by true sample differences, agglomeration, dispersion effects, or measurement artifacts.
Most importantly, root causes often remain hidden. Factors such as particle shape, agglomeration, or fragile structures may significantly influence performance while remaining invisible in standard size distributions.
What are particle analysis users looking for today?
Dr. Beverly Barnum: Modern users increasingly want verification rather than inference. They want to see what is happening during measurement, confirm the dispersion quality, and understand why the results appear as they do.
Confidence has become more important than speed alone. Tools must help to identify root causes quickly, reduce repeat testing, simplify interpretation, and provide clear evidence to support decisions. Flexibility across a wide variety of materials and applications has also become essential as laboratories are expected to support increasingly diverse workflows.
How was the BetterSizer 2600 Plus developed to address these changing requirements?
Dr. Beverly Barnum: The BetterSizer 2600 Plus was developed as a direct response to the evolving expectations of particle analysis users. It builds on the proven strengths of laser diffraction while adding additional capabilities that help users better understand their materials.
The system is specifically designed to reduce uncertainty by addressing challenges such as hidden agglomeration, dispersion instability, and particle shape effects. Rather than replacing laser diffraction, it enhances the technique by providing additional context that supports evidence-based interpretation.
The goal is to help users move beyond assumption-based analysis toward greater confidence and understanding while maintaining familiar workflows and ease of operation.
What are some of the key features of the BetterSizer 2600 Plus?
Weichen Gan: The BetterSizer 2600 Plus combines high-resolution laser diffraction with a 92-detector array that covers scattering angles from 0.16 ° to 165 °, enabling accurate measurement across a broad particle size range. The system uses a patented optical design that combines Fourier and inverse Fourier configurations to enhance measurement accuracy.
Its modular architecture supports both wet and dry dispersion systems, allowing users to analyze a wide variety of sample types. An optional dynamic image analysis module provides simultaneous particle size and shape information, delivering a more comprehensive understanding of material characteristics.
The system also incorporates advanced software tools that simplify method development, streamline routine measurements, and help users identify potential issues more quickly and confidently.
How does the system improve productivity and workflow efficiency?
Weichen Gan: A major focus of the BetterSizer 2600 Plus is helping laboratories obtain meaningful insight during the initial measurement stage rather than through repeated testing.
The software is designed to reduce dependence on operator experience by making data interpretation more accessible and intuitive. Users can identify potential issues faster, confirm dispersion quality more easily, and gain confidence in results without extensive troubleshooting.
This leads to reduced analysis time, fewer repeat measurements, improved productivity, and faster decision-making across both quality control and research environments.
Which industries can benefit most from these advancements in particle analysis?
Weichen Gan: One of the defining strengths of the BetterSizer 2600 Plus is its versatility. The system supports applications ranging from environmental and geological materials to inks, cosmetics, advanced energy materials, and specialty dispersions.
In geological applications, it can help users correlate laser diffraction results with traditional sieving data. In inks and dispersions, it helps identify agglomeration and stability issues that directly affect product performance.
Cosmetic manufacturers can gain additional insight into formulations that exhibit similar particle size distributions but different sensory properties. Energy materials developers benefit from controlled measurement conditions that preserve sample integrity while ensuring reliable results.
This breadth of capability allows laboratories to standardize on a single platform while supporting a wide range of analytical requirements.
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About the Interviewees
Dr. Beverly Barnum
Dr. Beverly Barnum is a Senior Scientist at Bettersize Instruments with extensive experience in particle characterization and material science. She holds a Ph.D. in Chemical Engineering from the University of Southern California and has over two decades of experience in applying particle analysis techniques to optimize energy storage materials. Prior to joining Bettersize, Dr. Barnum held research positions in both industry and academia, where she focused on materials development for batteries and catalysis. She is a frequent speaker at industry conferences and has authored multiple publications on particle morphology, density, and material behavior in electrochemical systems.
Weichen Gan
Weichen Gan is an Application Scientist at Bettersize Instruments, specializing in the practical deployment of particle analysis tools across diverse industries. With a background in materials science and engineering, Weichen focuses on integrating technologies such as laser diffraction, gas pycnometry, and automated density measurement into real-world laboratory and production environments. He has played a key role in developing glove-box-integrated workflows for handling sensitive battery materials, and frequently supports customers in optimizing analytical accuracy while maintaining safety and reproducibility in process-sensitive applications.
This information has been sourced, reviewed and adapted from materials provided by Bettersize Instruments.
For more information on this source, please visit Bettersize Instruments.
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