Precision Particle Size Monitoring with Metso RockSense 2D™

In crushing and aggregate operations, precision matters. Maintaining consistent particle size throughout the crushing process is critical to equipment performance, product quality, and overall plant efficiency. Without accurate, real-time insight, even small variations can lead to uneven wear, inefficiencies, and costly downtime.

At Marion Machine, we understand the importance of precision-driven solutions. That’s why technologies like Metso RockSense 2D play an important role in helping operations monitor and control particle size directly on conveyor belts in real time.

What Is Metso RockSense 2D™?

Metso RockSense 2D™ is an online particle size measurement system engineered specifically for crushing applications. Using advanced 2D image analysis, it continuously monitors particle size distribution as material moves through the process.

Unlike traditional sampling methods that rely on delayed feedback, RockSense 2D™ provides instant, accurate data, allowing operators to make informed adjustments while production is running.

How the System Delivers Real-Time Accuracy

RockSense 2D™ uses high-resolution cameras mounted above the conveyor belt to capture detailed images of material in motion. These images are analyzed immediately to calculate particle size distribution and identify changes as they occur.

This continuous monitoring allows operators to:

• Track crusher discharge performance in real time
• Detect size deviations early
• Maintain consistent gradation and output quality

The result is greater process control without interrupting production.

Benefits for Crushing Operations

Continuous, Real-Time Monitoring

• Measures particle size on active conveyor belts
• Instantly identifies changes in material size
• Designed for the demanding conditions of crushing environments

Improved Equipment Performance

• Helps identify process issues before they cause equipment stress
• Supports faster optimization of crusher settings
• Contributes to improved uptime and reduced wear

Consistent, High-Quality Output

• Maintains target particle size distribution
• Reduces variability that can affect downstream processes
• Supports more predictable and efficient production

By delivering real-time insight, RockSense 2D™ enables operators to respond quickly and keep crushing circuits running smoothly.

Why Image-Based Particle Size Analysis Is Essential

Manual particle size sampling is often time-consuming, disruptive, and inconsistent. It provides limited insight and can miss rapid changes that impact equipment performance.

Image-based analysis with RockSense 2D™ offers a more reliable approach by providing:

• Continuous, non-intrusive measurement
• Accurate, repeatable data
• Real-time visibility without stopping production

This level of insight supports better decision-making and long-term equipment reliability.

The Marion Machine Perspective

Reliable crushing performance starts with accurate data. Metso RockSense 2D™ gives operators the real-time visibility needed to improve efficiency, protect equipment, and maintain consistent product quality.

At Marion Machine, we support solutions that enhance precision, extend equipment life, and drive dependable performance across crushing operations. Contact us today to find out more about how Metso RockSense 2D™ could benefit your operation!