Hydro Insight for Malvern Mastersizer 3000 Particle Size Analyzers

The Hydro Insight accessory provides dynamic image analysis (DIA) for Malvern Panalytical Mastersizer 3000 particle size analyzers. Developed in conjunction with Malvern Panalytical this is installed inline with the wet dispersion systems. The Hydro Insight generates real-time particle images, shape metrics, and concentration measurements using the same circulating sample used for laser diffraction. This ensures that complementary data from the Hydro Insight is given on the same aliquot of sample analyzed with the Mastersizer 3000.

The combination of laser diffraction (size distribution) and dynamic imaging (size, shape, count and concentration) delivers a more complete understanding of particle behavior—especially for polydisperse materials, samples with agglomerates, or materials whose morphology affects performance.

Why Add a Hydro Insight to the Malvern Mastersizer 3000?

Laser diffraction provides fast, repeatable particle size distributions (PSD). However, diffraction data alone cannot reveal:

Whether large particles are true single particles or agglomerates
Whether fine particles are being masked by coarse particles
Whether bubbles, fibers, or foreign contaminants are present
Whether changes in PSD are due to dispersion, breakage, or process variation

The Hydro Insight addresses these limitations by supplying direct visual confirmation and shape-based interpretation of the sample under the same dispersion conditions used by the Mastersizer.

Dynamic Imaging Reveals Particles Laser Diffraction May Miss

Dynamic image analysis is particularly effective for identifying:

Sub-populations of small particles not visible in volume-weighted laser diffraction
Agglomerates versus primary particles
Non-spherical particles (e.g., flakes, needles, platelets)
Bubble contamination or air entrainment
Foreign particles in quality control environments

The Hydro Insight provides number-weighted size distributions that complement the volume-weighted laser diffraction data from the Mastersizer 3000.

Video: It’s the Small Things That Matter

Dynamic imaging shows small particles hidden by diffraction

How the Hydro Insight Works with Mastersizer Particle Size Systems

Hydro Insight is installed as an inline flow cell connected to the Mastersizer’s Hydro series wet dispersion units. During a standard measurement:

The dispersion unit circulates the sample through the Hydro Insight flow path.
The onboard camera captures images of particles in motion at high frame rates.
Software extracts particle size, shape, count, and morphology descriptors.
Results are displayed alongside the Mastersizer’s diffraction PSDs for comparison.

This integration allows operators to evaluate dispersion quality, sample stability, and particle morphology without altering existing measurement protocols.

Real-Time Particle Images and Morphology Analysis

Hydro Insight provides:

High-resolution particle thumbnails for visual confirmation
Morphology distributions based on 32+ parameters
Automated classification of particle types (e.g., agglomerates vs. primaries)
Counts per mL and total particle concentration
Correlation tools linking PSD to shape trends

These outputs enable deeper root-cause analysis in R&D, QC, and troubleshooting.

Video: Overview and Workflow Explanation

Key Features for Mastersizer Users

Wide Effective Measurement Range

Two magnification options allow broad applicability:

Standard magnification: ~1–300 µm
Low magnification: ~10–800 µm

This supports materials from fine powders to coarse particulates.

High Frame Rates and Large Sample Statistics

Dynamic imaging captures large numbers of particles, improving number-based statistics and supporting heterogeneous materials.

Shape Parameters Derived from Each Particle

Examples include:

Aspect ratio
Circularity
Elongation
Convexity
Feret dimensions
Surface roughness indicators

Automated QC / Pass–Fail Tools

Hydro Insight enables definition of tolerance limits for shape, size, or concentration, supporting robust QC processes.

Video: Hydro Insight Software Demonstration

Applications Enhanced by Hydro Insight + Mastersizer 3000

Hydro Insight for Pharmaceutical Powder Development and QC

Detect agglomerates vs primary particles
Identify fines masked in volume-weighted PSD
Confirm dispersion quality (critical for dissolution and blend performance)
Track shape distributions that influence flow, compaction, and filling

Then include pharma-specific “search bait” terms:

API particle size and shape
excipient morphology
inhalation powders (DPI)
granulation monitoring
dissolution variability
blend uniformity

Battery & Advanced Materials

Assess graphite and cathode/anode powder morphology
Improve density, packing, and conductivity predictions

Metal Powders & Additive Manufacturing

Identify satellites, misshapes, and fines affecting recoating
Validate powder reuse and recycling impacts

Abrasives, Minerals, and Geological Samples

Characterize platelets, needles, or irregular shapes not captured by size-only data

Contamination Detection

Rapid identification of foreign particles based on shape + imagery

Video: Example Application Case

Data Visualization and Interpretation Tools

Hydro Insight includes several visualization modes:

Correlation Plots

Overlay particle size vs. shape to isolate outliers.
Clicking any region shows the corresponding particle thumbnail.

Shape Distributions

Number-based and volume-based shape histograms help explain functional differences in:

flowability
packing behavior
particle–particle interactions

Population Separation

Cluster algorithms separate sub-populations, improving interpretability of polydisperse materials.

Video: Correlation and Shape Analysis Tools

Instrument Integration and Workflow

Hydro Insight is engineered to integrate seamlessly:

Uses the same dispersion conditions as the Mastersizer
No change to established SOPs or measurement methods
Works as an orthogonal verification tool
Supports root-cause investigations when PSD results appear unusual

Video: Setup and Integration Walkthrough

Video: Additional Demonstration

Frequently Asked Questions

Is Hydro Insight compatible with the Malvern Mastersizer 3000?

Yes. Hydro Insight is designed as an accessory for the Malvern Mastersizer 3000 wet dispersion systems and operates in parallel with laser diffraction.

Does Hydro Insight replace laser diffraction?

No. It provides orthogonal image-based data that complements the Mastersizer’s PSD.

What particle sizes can Hydro Insight measure?

The system supports ranges from approximately 1–300 µm (standard) and 10–800 µm (low magnification).

Why combine particle size and particle shape?

Particle shape influences flow, packing, breakage, settling, and performance. Image-based shape metrics help explain PSD changes and improve QC.

Can Hydro Insight detect agglomerates?

Yes. Image-based classification enables reliable differentiation between primary particles and agglomerated structures.

Does Hydro Insight provide number-based PSD vs volume-based PSD?

Yes, the Hydro Insight will provide number-based data. This allows users to view all the fine particles in their sample, as well as the large agglomerates and be able to quantify them by count or count per milliliter.

Can Hydro Insight detect bubbles or contamination in wet dispersion?

Yes, bubbles and contamination is easily detected, captured, measured and thumbnail images saved for objective evidence.

How does Hydro Insight compare to Morphologi 4-ID?

The Hydro Insight is a dynamic system capable of analyzing tens of thousands of particles in minutes or seconds. the Morphologi system is a static image analyzer. Although analysis time takes longer, the image quality of a static system will be slightly better than a dynamic system.

What’s the smallest particle size Hydro Insight can image?

The Hydro Insight has extremely high-quality lenses, cameras, and optical components allowing it to detect and measure particles down to 1 micron in size.

Can Hydro Insight support GMP / regulated environments?

Yes, the Hydro Insight has an IQ/OQ system verification process that the Malvern Panalytical trained engineer will use upon installation and training. This includes all the required objective evidence documentation required by any regulatory body.

How does Hydro Insight help with dissolution or flowability prediction?

Dissolution and flowability are important characteristics for any pharmaceutical ingredient or excipient. Both are greatly impacted by the shape of the particle. Particles with more irregular surfaces tend to have higher surface area making dissolution faster. Also, irregular particles tend to flow worse than smooth particles. For such situations measuring shape parameters such as Circularity, Surface Uniformity, and Aspect Ratio is important.

To learn more about particle shape, click here to view our educational videos.

Contact Vision Analytical

For sample evaluations, demonstrations, or technical discussions regarding Hydro Insight and Mastersizer workflows:

👉 Contact us

Image of Hydro Insight paired with the Mastersizer 3000+

Image of Hydro Insight Paired with Mastersizer 3000

The Hydro Insight is a dynamic imaging accessory that sits alongside the Mastersizer 3000, providing insights that go beyond particle size distribution to particle images and quantitative particle shape data for the Malvern particle size analyzer.

Laser diffraction is a valuable tool for particle size analysis. But to develop truly high-performance products, scientists often need a more comprehensive overview than laser diffraction alone can provide. Specifically, to understand what influences packing, flow, and dissolution rate, researchers need to understand how the combination of particle size and shape affects their materials’ behavior.

The Hydro Insight accessory enables this by combining Vision Analytical’s dynamic imaging expertise with Malvern particle size analyzer. Particles suspended in a flowing stream by the Mastersizer 3000’s dispersion unit flow through the Hydro Insight, and are then photographed and analyzed in real-time for shape.

Features

You can also view information on the Hydro Insight on the Malvern Palaytical website by clicking here

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