The AccuSizer counts and sizes particles one at a time over a large size range, so a product’s true particle size may be studied prior to production and distribution.  The benefits that result are a high quality product – and the ability to reformulate products to increase the efficiency of your processes. 

Examples

Situation:

Many times the main peak of a distribution can be detected but there are many situations when I know I have aggregates in the tail of my sample.

 

Result:

 

This is a Fat Emulsion that was spiked with a 1 micron latex standard.  The AccuSizer was able to find the main peak of the distribution but most importantly it was able to find the aggregates that existed in the tail of the distribution.  It is the aggregates in the tail that can spell disaster.

 

 Situation:

CMP slurries are often filtered as part of their production process and during their use.  Using classical light scattering particle sizers it is impossible to see if the filtration process is working and removing the large particle tail that has been directly related to scratches.  In some cases the life time of the filter is compromised and large particle form after filtration causing defects on wafers.  Without a method to monitor and quantify the tails of large particle pre and post filtration companies have resorted to changing the filters more often wasting time and money. 

Result:

The AccuSizer has the sensitivity to detect these large particles in a sea of particles that are present as part of the main peak of the distribution and can also quantify the tail to provide information on the efficiency of the filter as well as its removal rate.  The use of the AccuSizer tool to monitor filters has increases their life span and, in many cases, the return on investment for the tool is paid for in a matter of months.  The accompanying graph clearly displays the ability of the AccuSizer to both quantify and resolve the amount of large particles in the tail of the CMP slurry pre and post filtration.

Situation:

Kaolin Clays are used in many industries and have varied applications because they change the properties of the materials that they are combined with.  Products range from organic pesticides, where fruit can be protected from pests with a fine layer of Kaolin to rubber where Kaolin is used as a filler that adds strength, flexibility and increases the wear properties of rubber.  In both of these applications the presence of large oversized particles causes defects that reduces the effectiveness of the product.  Most current light scattering ensemble measurements do not have the sensitivity and resolution to see the small differences in the large particle tail of these Kaolin materials that are responsible for the quality of the product.  As a result many manufacturers have resorted to the time consuming and the inconsistent human element that accompanies the use of microscopy to identify and count these large particles.

Result:

During the processing of Kaolin many different methods are employed to reduce the particle size some of these include grinding, centrifugation and filtration.  The effectiveness of these processing methods can easily be determined by the AccuSizer. 

The accompanying graph displays a series of Kaolin results where product failed due to the presence of large particles, in varying amounts by mass, in the tail of the distribution.  The AccuSizer was able to track the addition of the bad material from 0.01 to 5% added by weight.  Other light scattering devices did not pick up the presence of large particles until the amounts reached over 3% and in most cases it took over 5% for them to detect the presence of the large particle tail.  This lack of sensitivity and resolution in classical light scattering devices was deemed unacceptable by the customer.

 

 

 

 

 

 

Situation:

High pressure homogenization is used in the process of making beverage emulsions.  Unfortunately the process of homogenization cannot be modeled.  In many cases using the same input materials and same processing parameters the output from the homogenizer can be a stable solution that meets the requirements of the beverage emulsion or it can be unstable to varying amounts causing product failure.   A few large emulsion globules can often cause the emulsion to destabilize and separate before it reaches the marketplace.  Furthermore over processing the emulsion by passing through the homogenizer for additional passes can cause it to destabilize even faster.

Result:

The AccuSizer has the ability to monitor the large particle tail at the point of use when the material is exiting from the homogenizer.  By being able to count and size the large globules of oil that have not been properly processed in the homogenization process one can determine the stability of the emulsion and whether or not it needs further processing.  The AccuSizer APS with the DLS module is the perfect instrument that not only provides a method to monitor the endpoint of the homogenization process but can also quantify the large particle tail that is directly related to the stability of the product.  The use of this technology by one of the major beverage emulsion manufactures has resulted in saving time and money related to reprocessing and shelf life stability of the product.