Large particle detection

Detecting and sizing large particles in flow

Large particle detection is an essential part of quality control and production monitoring in many manufacturing processes. The BRAVE large particle detector helps you ensure the highest product quality – and gives you valuable insights for troubleshooting potential problems.

The device is also available as a PAT sensor for 24/7 production monitoring online.

Don't let large particles spoil your day

Unwanted large particles or aggregates in your product are a disaster waiting to happen. To avoid losing batches or ruining the whole production day, BRAVE B-Phat is your tireless worker ready to warn you as soon as any large particles are discovered.

use results to optimize your product, with a PAT version available for real-time monitoring
detect large-particle tails, contaminants and anomalies, even in very low concentrations
ensure the correct particle size distribution for your end product
keep on top of fat particles, subvisible and visible particles, i.e. to meet PFAT5, USP 729, USP 788 and USP 787 regulations
get insight into predominant aspect ratio factors (with further shape statistics available on request)

Ideal for pharmaceutical production and more

BRAVE B-Phat was originally developed as the solution for adhering to the PFAT5 regulations and is a powerful tool in pharmaceutical production. Recently it has been at work testing CMP slurries and evaluating environmental samples.
Available as a lab device and online PAT sensor, BRAVE B-Phat helps you eliminate the risk of out-of-spec production and gives insight into your samples without long waiting times or the stress of unreliable offline methods.

Proof-of-concept

This proof-of-concept experiment shows that BRAVE B-Phat measures particle sizes and absolute particle concentration, continuously and in real time.

In the experiment four counting standards (3000 particles/ml) from the 3M series by Applied Microspheres

were added to the sample volume with a recorded time delay.

The measurement ran for a total of 28 minutes at a flow rate of 100 µl/min and with stirring to prevent sedimentation.

The time points at which each counting standard was added to the total volume were as follows:

10 µm added at 00:00
2 µm added at 07:00
25 µm added at 14:00
41 µm added at 21:00

All of the counting standards had a concentration of 3000 particles per milliliter.

The scatter plot clearly shows that the respective standards appear at the correct times. The concentration time series (upper plot) shows the size-specific concentration (colored lines) and total concentration (black line), which remains constant at 3000 particles/ml as to be expected.

The histogram (right plot) displays the size distribution after 28 minutes. The colored bars represent the standards. The violet bars given as “other” are the remaining particle sizes in the sample, whereby the number of these particles is so low that the columns are difficult to see. The resolution of the measurement device is currently around 1.5 µm. Particles smaller than 2 µm are no longer reliably detected.

Figure 1: Proof-of-concept measurement on 4 counting standards which demonstrates that BRAVE B-Phat measures both particle sizes and absolute concentrations in a time-resolved manner

A comparison of three drinking water samples

Bottles of drinking water were acquired at the supermarket and measured without dilution. All 3 samples were measured with the same device settings and the same flow rate (60 µL / minute) which means the same volume of each sample was measured and the results are comparable.

A “clean baseline” of the device was also recorded to show how a sample without large particles looks when measured with BRAVE B-Phat.

Compared to the clean baseline the drinking water samples have a significantly higher number of large particles detected.

Recorded videos for 3 drinking water samples and a "clean baseline" which are evaluated for the measuring report

This is one frame image from a full video of a measurement. It shows how each passing particle is detected and given an ID tag. The software simultaneously evaluates the size of each detected particle and creates continuously updated histograms.

How does BRAVE B-Phat work?

The B-Phat large particle detector observes sample as it flows towards the video camera and sensor. Measurement is continuous and the flow rate is set. The result is a dynamic image which is evaluated by a dedicated software. Each dark “spot” which appears on the screen is a large particle passing through the measuring cell. The particle is tagged, counted and its size determined.

Specifications of BRAVE B-Phat (lab device)

Disrupting conventional approaches to large particle sizing:
this benchtop large particle detector brings a previously unseen capability for continuous measurement on sample in a flow-through cell
Based on light obscuration:
and evaluated using dynamic imaging principles
Saves you time:
with the automated dilution you get results quicker than with conventional methods
Relevant and reliable results:
measure continuously to track changes in real-time; proven throughput up to 1000 particles/minute, measurement over minutes up to hours
Particle range:
from 2 µm to 80 µm (sample-dependent)
No-hassle cleaning:
an automated self-cleaning cycle cleans the device in just 30 seconds
Analyze particle size, particle size distribution, particle concentration, particle count per milliliter, predominant aspect ratio factors (with further shape statistics available on request)
Made to scale up:
using the same measuring principles and routines, the BRAVE B-Phat device is available as a PAT sensor for direct production monitoring

Specifications of BRAVE B-Phat

PARTICLE SIZE RANGE

Particle sizing from approx. 2 µm to 80 µm

MEASUREMENT PRINCIPLE

Based on light obscuration and using dynamic imaging principles for analysis.

SETUP

Too good to be true?

A continuous measurement in a lab instrument?
Single-particle sensitivity?
Additional small-particle or 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 particle processes. Check out how our BRAVE devices are helping these customers in research and industry.
For more information, contact us or book a live demonstration and we will answer all your questions.

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 3 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 characterization of particle populations via Raman spectroscopy.

Modules for sample handling

Every BRAVE device requires a Fluid Automation Module. The specifications and performance of this module depends on your sample and requirements. Get in touch!

PAT solutions

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