Particle size tells you only part of the story. Two samples can produce nearly identical size distributions and still contain completely different materials. In this video demonstration, we run a mixed sample of fibers and garnet abrasive on the Hydro Insight for the Malvern Mastersizer 3000 and show how particle shape, particle count, concentration, and particle classification reveal what a size distribution alone cannot.
What the Hydro Insight Adds to Your Mastersizer
Laser diffraction is fast, repeatable, and widely trusted for particle size. But it reports size by assuming every particle is a sphere. For irregular materials such as fibers, flakes, crystals, and crushed minerals, that assumption hides important information.
The Hydro Insight adds real-time dynamic image analysis to the Mastersizer 3000. In a single analysis you get:
- Particle size measured from images of individual particles
- Particle shape, including aspect ratio, circularity, and other morphology parameters
- Particle count for every particle
- Particle concentration in the sample
- Particle classification to identify the distinct subpopulations in your sample
For more on how count and concentration complement laser diffraction, see HydroInsight: The Perfect Mastersizer Complement for Particle Counting and Concentration.
Running a Sample: Three Steps
The Hydro Insight is designed to be simple to use. To run a sample, the operator presses New Sample, enters a sample name, and presses Start.
As soon as the analysis begins, statistics update in real time and particle images appear as particles pass through the flow cell. You see exactly what is being measured while it is being measured.
The Sample: Fibers and Garnet Abrasive
The sample in this demonstration is a mix of two highly irregular materials: fibers and garnet, a mineral commonly used as an abrasive.
The size distribution is narrow and roughly Gaussian, just what you would expect from a single material. If you looked only at that curve, you might conclude the sample is uniform. The live images show otherwise: elongated fibers and angular garnet particles are moving through the flow cell together. Size alone can’t tell them apart. Shape can.
This is exactly why particle shape is important for any material that is not spherical.
Number-Weighted vs. Volume-Weighted Distributions
The video shows the same results two ways, and each answers a different question.
Number-weighted distribution
Every particle counts equally, regardless of its size. This makes the number-weighted view the most sensitive for detecting fine particles, small contaminants, and shifts in particle population that a volume-based measurement can miss.
Volume-weighted distribution
Each particle contributes according to its volume, so larger particles carry more weight. This view shows where most of the material’s mass is, and it aligns with the volume-based results reported by laser diffraction instruments such as the Mastersizer.
Having both views tells you how many particles of each size are present and how much of the sample they actually make up. To compare sizing methods in more depth, see our overview of particle size measurement techniques.
The Hydro Insight Dashboard
When the analysis is complete, the software automatically opens the Hydro Insight dashboard. From here you can browse every particle thumbnail or go straight to the classification results.
Scrolling through thumbnails gives a quick visual impression of the sample. To truly understand what’s in it, you need quantitative data, and that is where particle classification comes in.
Particle Classification: Counts, Percentages, and Visual Proof
Particle classification is one of the most powerful tools in the Hydro Insight. In this example, the classification results show:
- How many fibers were found
- How many garnet particles were found
- How many particles did not fit either class
Select any class to see its particle count and its percentage of the total. The Hydro Insight then displays the thumbnail of every particle in that class as objective evidence, so you can verify the results for yourself instead of relying on a number alone.
Who Benefits from Size and Shape Together
Any lab analyzing irregular particles with a Mastersizer can gain from adding imaging, including work with:
- Abrasives and minerals
- Fibers and fibrous materials
- Powders, granules, and crystals
- Pharmaceutical ingredients and excipients
- Mixed or contaminated samples where subpopulations matter
For a deeper look at the cost of measuring size without shape, read our white paper, One Eye Shut: Why Particle Sizing Evaluations Should Include Particle Shape.
Frequently Asked Questions
Does the Hydro Insight replace laser diffraction?
No. The Hydro Insight works alongside the Mastersizer 3000. Laser diffraction provides the size distribution, and the Hydro Insight adds images, shape, count, concentration, and classification.
Why can two different materials show the same size distribution?
Size-only methods report an equivalent spherical size. Irregular particles such as fibers and angular minerals can produce similar equivalent sizes even though their shapes are completely different. Imaging reveals the difference.
When should I use a number-weighted vs. a volume-weighted distribution?
Use number-weighted results when fine particles, contaminants, or particle counts matter. Use volume-weighted results to understand where most of the material’s mass is and to compare with laser diffraction data.
See the Hydro Insight on Your Application
Want to see what the Hydro Insight can show you about your materials? Book a technical consultation or contact us to request a live demo. You can also learn more on the Hydro Insight product page or read about adding imaging to your Malvern Mastersizer 3000.
Mastersizer is a trademark of Malvern Panalytical. Vision Analytical Inc. is not affiliated with Malvern Panalytical.