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Understanding Key Powder Characterization Techniques

May 26, 2025

Powder behavior is governed by a complex interplay of physical properties including particle size, surface area, density, shape, flowability, and porosity. Whether you're working in pharmaceuticals, chemicals, materials science, or food production, understanding these parameters is essential to ensuring process consistency, product performance, and regulatory compliance. This blog breaks down the most important powder characterization techniques and highlights how ATS-Scientific supports technical teams with precision instrumentation and expert support.

Why Powder Characterization Matters

Powders are used extensively in both product formulations and manufacturing processes. The way a powder flows, packs, dissolves, or compacts can have significant effects on processing efficiency and final product performance. For example, in tablet manufacturing, poor flowability may result in inconsistent dosing, while in catalysts or adsorbents, insufficient surface area can reduce reactivity.

By characterizing key attributes such as particle size distribution, surface area, porosity, and density, engineers and scientists can better design materials, fine-tune production methods, and troubleshoot process issues.

Particle Size and Shape Analysis

Laser Diffraction (LD) and Dynamic Image Analysis (DIA) are two of the most widely used methods for determining particle size and morphology.

  • LD measures the angle and intensity of scattered light to determine a particle size distribution. It is fast, reproducible, and suitable for a wide range of sizes.

  • DIA uses high-speed imaging to capture shape and size information, including parameters like circularity and elongation, which affect flow and compaction.

ATS-Scientific offers systems like the Microtrac SYNC, which combines both techniques in a single platform, providing a comprehensive profile of powder samples.

Surface Area and Porosity: Gas Adsorption Methods

Brunauer–Emmett–Teller (BET) analysis is the gold standard for measuring specific surface area via nitrogen adsorption. The larger the surface area, the more reactive or absorbent the powder typically is.

Pore Size and Volume can be assessed through BJH or DFT methods, giving insights into a material’s porosity—a key property in applications like catalysis, filtration, and controlled-release formulations.

ATS-Scientific supplies BET and gas sorption analyzers suitable for high-throughput and high-accuracy measurements, offering automated dosing, degassing, and software analysis.

Density and Packing Behavior

Powder density influences storage, transport, and process efficiency. Key measurements include:

  • True Density (measured via gas pycnometry): Represents the density of the solid material excluding pore spaces.

  • Bulk and Tapped Density: Represent how powders behave under gravity and compaction. These are critical for dosing, blending, and packaging operations.

ATS offers automated pycnometers and bulk/tapped density analyzers that conform to USP and ASTM standards, enabling consistent and compliant results.

Flowability and Compressibility

Powder flow properties directly affect process performance, especially in feeding, blending, and tablet pressing. Techniques include:

  • Hausner Ratio and Carr Index: Derived from bulk and tapped densities, these provide quick indicators of flow properties.

  • Shear Cell Testing: Provides deeper insights into interparticle friction and flow under stress.

Poor flowability can lead to inconsistent fills, segregation, or equipment blockages. ATS supports this area with instruments for both basic and advanced powder flow analysis.

Additional Characterization Parameters

Other relevant techniques in powder analysis include:

  • Moisture Content: Using thermogravimetric or halogen moisture analyzers.

  • Electrostatic Charge: For powders prone to static buildup.

  • Thermal Analysis: Differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) for understanding heat stability and solvent content.

These complementary methods help build a complete understanding of powder behavior, especially in sensitive applications.

ATS-Scientific's Powder Characterization Solutions

ATS-Scientific provides a comprehensive range of equipment tailored to powder characterization needs:

  • Microtrac SYNC for particle size and shape analysis

  • BELCAT and BELSurface series for BET and porosity

  • BELPYCNO L for true density via gas pycnometry

  • SVM and GLT instruments for bulk/tapped density and flowability

  • Moisture analyzers and thermal analysis systems for compositional analysis

With these tools, ATS helps labs design efficient processes, reduce variability, and meet strict product specifications.

Looking for Powder Analysis Solutions?

Powder characterization techniques are essential for understanding how materials behave during processing and in final applications. Techniques like laser diffraction, BET surface area, and bulk density testing offer actionable insights for engineers, formulators, and quality control professionals.

ATS-Scientific offers the instrumentation, technical expertise, and compliance-ready platforms to support reliable powder analysis across industries. Whether you’re optimizing a pharmaceutical formulation or improving materials for filtration, ATS has the tools and support to help you achieve consistent, high-quality outcomes.