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KREBS® OSA

Real-time particle size analyser for smarter grinding control

The KREBS® OSA (Onstream Particle Size Analyser) provides continuous, real-time particle size data directly from within the process stream. It reduces the need for manual sampling, reduces overgrinding and helps operators maximise mineral recovery across all major commodity types.

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Key benefits of KREBS® OSA

  • Maximise recovery and throughput

    Real-time data enables immediate grinding circuit adjustments, while optimal particle size distribution improves flotation and leaching performance. Continuous monitoring also helps prevent surges in coarse or fine particles, reducing overgrinding and associated energy waste.

  • Eliminate manual sampling risk

    Intrusive measurement from inside the process flow removes the need for manual intervention while helping eliminate human error from particle size monitoring. It also improves operator safety by reducing sampling exposure and delivers continuous results instead of hours after conditions have changed.

  • Simple, flexible deployment

    The standalone, plug-and-play system requires no IT or cloud connection and is hard-wired to the control room for secure, stable data transmission. It integrates into existing control systems with minimal set-up, while the subscription model removes the upfront CAPEX barrier with full installation and support included.

Productivity through real-time process control 

Maintaining the correct particle size is critical for efficient grinding circuit operation. Yet many mines still rely on manual sampling and laboratory analysis to monitor particle size — methods that are labour-intensive, prone to human error and deliver results long after process conditions have changed. 

The KREBS® OSA overcomes these limitations by delivering continuous, real-time particle size data. This immediate visibility enables operators to make timely process adjustments, stabilise downstream performance and maximise recovery and product quality. 

How it works 

The KREBS® OSA uses a pulse-based, intrusive measurement principle to determine particle size distribution directly within the process stream. As material flows through the measurement zone, particles interact with a highly sensitive oscillator positioned in the mass flow. Each particle impact generates a measurable vibration response. 

Following initial calibration, these vibration signals are continuously recorded and processed in real time. Advanced algorithms interpret the vibration patterns and convert them into an accurate particle size distribution profile — enabling live process visibility without the delays associated with manual sampling or laboratory analysis. 

Analysed data is displayed via the KREBS OSA user interface, providing operators and process engineers with immediate access to particle size trends and historical performance. The system delivers measurement accuracy with process data stored for up to one year for performance tracking and auditability. 

Subscription plans and features

The KREBS® OSA is available on a subscription basis, removing the need for upfront capital investment. All plans include full installation and calibration, software licence, maintenance with spare parts, and field service and technical support.

Monthly or quarterly billing, with a one-year initial contract duration.

One-time payment available for one, two or five years. 

Operational Advantages and Process Benefits of the KREBS® OSA

Technical Capability

  • Real-time measurement 
  • Intrusive, pulse-based measurement method 
  • Rugged, reliable design 
  • Steady-state continuous monitoring 
  • Simple set-up; integrates into existing control systems 
  • ±5% measurement accuracy 
  • Customisable sieve sizes (20–500 µm) 
  • Up to one year of on-device data storage 

 

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Downloads for KREBS® OSA

Frequently asked questions

FAQs for KREBS® OSA

Real-time particle size data enables operators to make immediate adjustments to the grinding circuit rather than waiting hours for laboratory results. The KREBS® OSA measures particle size distribution continuously from inside the process stream, providing live visibility into feed consistency. This allows operators to prevent surges in coarse or fine particles, maintain steady-state operation, reduce overgrinding and energy waste, and optimise downstream flotation and leaching performance - all without interrupting the process.

The KREBS® OSA removes the need for manual sampling by measuring particle size distribution directly within the slurry flow using a pulse-based, intrusive measurement principle. This eliminates human error, removes operator exposure to moving equipment and process streams, and delivers continuous results rather than periodic snapshots. The system provides measurement accuracy within ±5% and stores process data for up to one year.

Continuous particle size measurement means monitoring particle size distribution in real time, directly from within the process stream, with no need for operators to collect physical samples. The KREBS® OSA achieves this using a sensitive oscillator positioned in the mass flow. Each particle impact generates a vibration response that advanced algorithms convert into an accurate size distribution profile — continuously and automatically.

Optimal particle size distribution is critical for flotation and leaching performance. When particle size drifts outside the target range, recovery drops. The KREBS® OSA gives operators immediate visibility into particle size trends so they can correct deviations before they affect downstream performance. Continuous monitoring also prevents the surges in coarse or fine material that cause inconsistent feed to flotation cells or leach pads, helping stabilise recovery rates. 

Yes. The KREBS® OSA is available through a subscription model that removes the upfront capital expenditure barrier. Two plans are offered: a pay-per-use equipment contract (monthly or quarterly billing, one-year initial term) and a prepaid subscription (available for 1, 2 or 5-year terms). Both include full installation, calibration, software licence, maintenance, spare parts and field service support — so the total cost of ownership is predictable from day one.