The detection of a small number of large particles whose size lies outside
the required size distribution is important in the processing of many mater
ials when those particles result in the deterioration of the product qualit
y. Laser diffraction, which is a very popular technique for on-line monitor
ing and process control, has, however, limited sensitivity to those few lar
ge particles. This paper deals with the improvement of this sensitivity. Th
e fluctuations of the signal received by the detectors were analyzed by bot
h experiment and simulation. Two statistical approaches, crosscorrelation a
nd principal component analysis (PCA), were applied. A detection procedure
is proposed which is based on the combination of sweep selection through PC
A and an appropriate deconvolution of the selected sweeps. The preliminary
experiments with Al2O3 powder showed an improved sensitivity to the large p
articles.