Production monitoring

Take the waiting out of quality control & eliminate out-of-spec production

Wouldn’t it be great to stop worrying …

Online monitoring and optimization of your particles with BRAVE sensors puts you back in control of your production – without having to wait for results from the lab.

BRAVE sensors overview

Particle sizing and PSD
50 nm* to 5 µm* (*sample-dependent)
Small particle counts
5 nm* to 50 nm* (*sample-dependent)
Large particle detection, PFAT5
approx. 2 µm to 80 µm
In-flow Raman analysis
Nanoparticles (<1 µm) and microplastics (1 µm to 50 µm)

Make the right decisions at the right time ...

Imagine having the information you need just when you need it. Having a PAT sensor in your production line gives you a window into the real-time composition and behavior of your product and gives you enough time to intervene if necessary- before product goes out-of-spec and you lose precious time and resources.

Monitoring particles online during production is not just a beautiful future dream – it is possible now and brings immense financial benefits. Online montoring lays the foundation for real-time release testing.

... to keep production running smoothly

The first steps to immediate and direct particle monitoring

At BRAVE Analytics we have experience in integrating PAT sensors into industrial plants but we know … every plant is different and every production has its unique challenges and requirements.

The very first step to online monitoring of your production is a conversation with our engineers, physicists, IT experts, the CEO and CFO. We will get everyone on board. Testing your product in the lab first is essential. We will have lots of questions and we are sure you will as well. Topics to be covered: product parameters, dilution, cleaning, interfaces and more.

The solution for your plant will be custom-tailored and the result of our dialog.

Direct measurement of particle size distributions

Take your production to another level with online particle sizing e.g. of high-pressure homogenization processes or emulsion polymerization processes. Keep your production under control to ensure high-quaity end product, meet your regulatory requirements and achieve batch release without headaches.

Talk to us about your target size distributions. Depending on the PAT model and sample, we provide particle monitoring from 5 nanometers to 80 micrometers.

For more information on the technologies involved, see the laboratory versions for particle detection and sizing from 5 nm to 5 µm and our large particle detector for monitoring particles from 2 µm to 80 µm.

Detect and identify anomalies, aggregates and large-diameter particles

To minimize the risk of your product containing unwanted large particles or potential contaminants, BRAVE Analytics provides two modules for the detection and identification of these: BRAVE B-Phat and BRAVE B-Elementary.

All of the BRAVE PAT sensors operate in-flow, directly at the production line in a bypass. Sample dilution – if needed – is done automatically by a sample handling module.

BRAVE B-Phat and BRAVE B-Elementary PAT modules

With BRAVE B-Phat there is no chance of large particles ruining your specifications.
BRAVE B-Phat was designed to fulfill the pharmaceutical regulations for PFAT5 - and is also ideal for detecting other large-particle tails, low-concentrated contaminants and anomales. It even gives you information on predominant aspect ratio factors
BRAVE B-Elementary reads out the Raman spectra of your product flow so you can detect and chemically identify the particle substances within.
As the BRAVE PAT sensors are built as a modular platform, you can combine modules to suit your requirements

Benefits of BRAVE PAT sensors:

You can reduce rejects as you now have total control of the particle sizes and are able to continuously monitor and adjust them.

Interim testing in the lab loses its urgency as you can now optimize your processes in real-time. Measurement data is visible on your network in a matter of seconds.

You obtain a better understanding of your production processes, as you constantly collect precious data for process optimization.

You are able to monitor the health of your production plant and carry out maintenance in good time.

You ensure the quality of your final product, as anomalies, aggregates and oversized particles will be detected and identified.

You can integrate checks on the filtration and dilution systems and use Raman analysis to troubleshoot anomalies.

Immediate results directly from the production line establish the solid basis for RTRT (Real-Time Release Testing).

You can fully concentrate on your other duties knowing that your production is doing as it should and the quality of your product is guaranteed.

A BRAVE example of monitoring and controling production processes

Take a look at this introduction to BRAVE B-Continuous, our online particle analyzer for monitoring and control of production. It provides single-particle sensitivity, delivers complete sizing histograms and even detects large-particle counts.

The challenges of analyzing particle size during production

The idea of monitoring particle sizes inline and/or online is not new – or easy to implement. In-process measurement means in-flow measurement, and this brings a number of challenges for the established methods of particle characterization, which rely on measuring Brownian motion to gain results (like Dynamic Light Scattering or Nanoparticle Tracking Analysis). There are three challenges inherent in in-process particle characterization that do not pose a problem for the BRAVE PAT sensors.

The challenge of
the volume of flow

The problem

Process analytics need to be representative. The measured value over time has to represent the product at the moment it has been measured. Conventional light scattering methods fail to consider sufficient volume to be representative of all the particle populations present.

The solution

BRAVE B-Continuous measures up to 3000 particles per minute with single-particle sensitivity in order to deliver statistically valid results for all the particle populations present.

The challenge of
changing concentration

The problem

To complicate things even more, process analytics need to deal with changes in the concentration of the product. Bottom-up production processes start out with very low concentration for particle onsets / particle formations whereas top-down production processes tend to increase the particle concentration. This behavior limits lots of characterization approaches.

The solution

BRAVE Analytics has chosen an online not inline approach: BRAVE B-Continuous continuously takes a small sample via a bypass system and then automatically prepares the concentration for a subsequent statistically valid measurement.

The challenge of
the speed of flow

The problem

Measurement directly inline is difficult due to the rapid movement of the particles. Methods based on evaluating the Brownian motion of particles (i.e. dynamic light scattering, nanoparticle tracking analysis) have only milliseconds to record the light scattering before the particle(s) in question have moved on. Particle movement due to Brownian motion is hardly obtainable as a detailed picture valid for the whole particle population.

The solution

As OF2i® is not based on detecting and analyzing Brownian motion, values are determined instantaneously and in real-time. Results are representative for the whole particle population present in the flow cell.

Taking some of the pain out of industrial production

The BRAVE PAT sensors were first designed to meet the strict demands of pharmaceutical manufacturing. The BRAVE B-Continuous particle sizing sensor is already implemented in a pilot plant for producing parenteral nutrition formulations in high-pressure homogenization steps. Regulations require the particle size distribution of such formulations to be within a defined narrow band. Online measurement and control of the PSD contributes to significant savings in time and raw materials.

The BRAVE B-Phat large particle detector was originally developed to help manufacturers of pharmaceutical formulations fulfill the PFAT5 regulations. This stipulates the volume of fat globules permitted in the end product and is a safeguard for patient health. Since its product launch, interest from other industries has been great. BRAVE B-Phat is ideal for the detection of large-particle tails, contaminants and unwanted aggregates whatever the product.

The additional in-flow Raman sensor, BRAVE B-Elementary, is another tireless worker when it comes to detecting unwanted “surprises” in your production. Analysis of the particle substances is highly interesting for both product quality control and preventive and proactive plant health maintenance.

Examples of use for BRAVE PAT sensors

Continuous monitoring of production (e.g. cosmetics, pharmaceuticals)
Meeting strict regulations on particle size and product purity
Monitoring the product development in fermentation tanks and batch reactors (e.g. emulsion polymerization processes)
Monitoring mixing, dilution and filtering systems
Gathering real-time data for process optimization (data lake)
Detecting contamination in production lines (predictive maintenance)
Quality control of ultra-pure water and of water for injections

BRAVE PAT sensors in action

Structure and specs of BRAVE PAT sensors

BRAVE B-Continuous base station

Measures number-based, hydrodynamic particle size distribution

Additional BRAVE B-Aware module

Measures small object signals and concentrations, detects small particles

Additional BRAVE B-Elementary module

For in-flow Raman analysis of particles and particle populations

Additional BRAVE B-Phat module (or standalone)

For detecting large-particle tails and large-diameter particles

Time and flow parameters for modules

These specifications are plant-specific, as a guideline only:

BRAVE products for a BRAVE world

Overview of BRAVE modules and sensors

The BRAVEst modules of them all

Time-resolved PSD and particle sizing

Allows the monitoring of PSD continuously and directly out of containers. Ideal for monitoring agglomeration, formation, dissolution, aggregation, dissociation, self-assembly and more. Size range: 50 nm* to 5 µm* (*sample-dependent)

Particle concentration and particle counts

Allows the detection of small particles from approx. 5 nm to 50 nm. Gives insight into agglomeration and aggregation behavior.

Large-particle tails & PFAT5

Allows the detection and sizing of large-particle tails, LPC, large aggregates and anomalies. Also for PFAT5 detection. Size range: 2 µm* to 80 µm* (*sample-dependent)

Raman analytics

Allows the detection, identification and analysis of particle populations via Raman spectroscopy.

Modules for sample handling

To make your life easier, use the BRAVE modules for automatic sample handling and sample dilution.

PAT solutions

For 24/7 production monitoring BRAVE Analytics provides custom-tailored online solutions.

H.A.N.S. - the software for BRAVE B-Continuous

Back in the very early days of BRAVE Analytics, Christian Hill, now CEO and CTO, needed help counting the particles in many different samples so he enlisted the help of Hans, a lab technician at the Institute for Biophysics at the Medical University of Graz. As not everyone has a Hans to help, our nanoparticle devices now come with H.A.N.S. (High-Throughput Analysis Nano-Characterization Software). This software controls the PAT sensor and delivers measurement reports. H.A.N.S. has understandable workflows and intuitive interfaces as well as preset and definable device parameters for individual application and method development.

H.A.N.S. protects, analyzes and reports your data

H.A.N.S. connects to laboratory information management systems (LIMS) and other industrial process control interfaces like the Message Queuing Telemetry Transport (MQTT) standards. He supports you in your daily work:

H.A.N.S. provides more:

Brave Analytics - Graph zu Methodenvergleich OF2i

Too good to be true?

The continuous measurement of particles in-flow just like you always wanted?
Single-particle sensitivity?
Additional small-particle and large-particle detection as well as Raman analysis?

You’ve never heard of it before and yet the real-time insights from this new approach could save you money and greatly improve your production.
For more information, contact us or book a live demonstration and we will answer all your questions.

You are just one click away from improving your production processes!

Make the right decisions at the right time ...

... to keep production running smoothly

The first steps to immediate and direct particle monitoring

Detect and identify anomalies, aggregates and large-diameter particles

A BRAVE example of monitoring and controling production processes

The challenges of analyzing particle size during production

The challenge ofthe volume of flow

The challenge ofchanging concentration

The challenge ofthe speed of flow

Taking some of the pain out of industrial production

Examples of use for BRAVE PAT sensors

BRAVE PAT sensors in action

Structure and specs of BRAVE PAT sensors

Overview of BRAVE modules and sensors

The BRAVEst modules of them all

H.A.N.S. - the software for BRAVE B-Continuous

H.A.N.S. protects, analyzes and reports your data

Too good to be true?

The challenge of
the volume of flow

The challenge of
changing concentration

The challenge of
the speed of flow