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<p>Real-time monitoring of particle size distribution (PSD) is a promising tool for the robust control of wet fluidized bed granulation processes, where rapid particle growth and moisture fluctuations limit the applicability of conventional offline analyses. Although real-time laser diffraction (RT-LD) with closed-loop continuous sampling (CLC) is widely used as a Process Analytical Technology (PAT) tool, continuous sampling can introduce process disturbance, contamination risks, and operational constraints, particularly under wet granulation conditions. This Research Letter reports a novel, flexible, and cost-effective RT-LD approach incorporating a micro-sampling probe that utilizes a portable closure mechanism to enable intermittent, low-volume sampling while maintaining stable airflow conditions. The system was evaluated during wet fluidized bed granulation using a model process and directly compared with conventional CLC sampling. The temporal evolution of Dv10, Dv50, and Dv90 measured by the micro-sampling system closely matched those obtained using CLC, demonstrating equivalent particle size tracking throughout granulation. By minimizing sample residence time and reducing sampling-induced artifacts, this flexible RT-LD approach provides a practical solution for real-time PSD monitoring with cross-granulator portability, offering a cost-effective strategy for PAT implementation from development to manufacturing.</p>

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A Flexible and Cost-Effective Real-Time Particle Size Monitoring Approach Using a Portable Micro-Sampling Probe in Fluidized Bed Granulation

  • 期刊论文

  • 发表日期：

    2026年3月10日

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  • Daisuke Sasakura,
  • Fumiaki Sato,
  • Kana. Horie,
  • Koji Nakayama

摘要

Real-time monitoring of particle size distribution (PSD) is a promising tool for the robust control of wet fluidized bed granulation processes, where rapid particle growth and moisture fluctuations limit the applicability of conventional offline analyses. Although real-time laser diffraction (RT-LD) with closed-loop continuous sampling (CLC) is widely used as a Process Analytical Technology (PAT) tool, continuous sampling can introduce process disturbance, contamination risks, and operational constraints, particularly under wet granulation conditions. This Research Letter reports a novel, flexible, and cost-effective RT-LD approach incorporating a micro-sampling probe that utilizes a portable closure mechanism to enable intermittent, low-volume sampling while maintaining stable airflow conditions. The system was evaluated during wet fluidized bed granulation using a model process and directly compared with conventional CLC sampling. The temporal evolution of Dv10, Dv50, and Dv90 measured by the micro-sampling system closely matched those obtained using CLC, demonstrating equivalent particle size tracking throughout granulation. By minimizing sample residence time and reducing sampling-induced artifacts, this flexible RT-LD approach provides a practical solution for real-time PSD monitoring with cross-granulator portability, offering a cost-effective strategy for PAT implementation from development to manufacturing.