UK Specialists in Optitest Pressure Decay Testing — Serving Manufacturing Since 1993
Optimeasure has been supplying air leak testing equipment since 1993. We provide instruments, integration services and bespoke systems for some of the UK’s largest manufacturing institutions across multiple sectors — and we pride ourselves on a responsive service network that keeps you producing.
Today we offer two leading Optitest air leak testing systems, chosen for the perfect balance of capability, cost and build quality:
- Optitest — entry-level, pure air leak detection, balancing economy with quality
- Optitest IQ — multifunctional air test device with market-leading capability
▶ Optitest vs Optitest IQ — Technical Specifications
| Specification | Optitest | Optitest IQ |
|---|---|---|
| Measurement System | Absolute pressure | Differential & Absolute pressure |
| Pressure Range | -1 barG to 10 barG | -1 barG to 50 barG |
| Accuracy | 0.3% of full scale | 1% of measuring span (absolute); 2% (differential/mass flow) |
| Repeatability | 0.3% of full scale | 1% of full scale |
| Test Types | Absolute pressure leak testing | Absolute pressure, differential pressure, mass flow, vacuum, volume determination, occlusion, burst, sequential linking (up to 8, no PLC) |
| Gross Leak Detection | Default on all programmes + 15% of test pressure | Assignable per programme; fully customisable |
| Programmable I/O | 8 digital in / 8 digital out, expandable to 40 | 8 digital in / 8 digital out, expandable to 40 — with ~250 output and 100+ input functions |
| Communication | LAN, 5× USB, 2× RS232, HDMI, VGA, PROFIBUS/PROFINET, Digital I/O | RS232, USB-A, USB-B, PROFIBUS/PROFINET, Digital I/O, Ethernet |
| Barcode Compatibility | Yes | Yes |
| Programme Slots | 127 (default 20, configurable) | 127 freely programmable |
| Operating Temperature | 10°C to 40°C | 10°C to 45°C |
Why Choose Optimeasure for Air Leak Testing?
We are more than a supplier. Our full-cycle support model means you get specialist guidance at every stage:
- Training — application-specific leak test training delivered on-site or at our Bedford facility
- Instruments — supply of Optitest air leak testing systems with full technical specification matching
- Integration — in-house team to integrate systems into existing production lines and PLC environments
- Service & Support — North and South hubs for rapid-response UK coverage
- Calibration — traceable calibration services using certified leak masters
Request a Technical Specification »
Air Leak Testing Application Areas
Optitest air leak testing systems are used across a wide range of manufacturing sectors.
▶ View all application areas and sectors
| Market Sector | Sub-Category | Applications & Components Tested |
|---|---|---|
| Automotive & Motorcycles | Engine & Powertrain | Engines, cylinder heads, engine blocks, compression testing, engine lines |
| Transmissions & Clutches | High-performance clutches, transmissions, axles and gears | |
| Fuel & Exhaust | Fuel systems, injection systems, exhaust systems, catalytic converter dosing | |
| Cooling & HVAC | Radiators, vehicle HVAC assemblies, thermostats | |
| Oil & Filtration | Oil absorbers, oil filters, valves and filters | |
| EV & Chassis | Brakes, axles, steering pumps, battery module water-cooling jackets | |
| Air Management | Turbochargers, actuators, automotive jalousies | |
| Crankcases | Leak and mass flow for crankcases | |
| Medical & Healthcare | Surgical & Intravenous | Catheters, IV equipment, multi-lumen and endotracheal catheters |
| Consumables & Accessories | Ostomy bags, plastic bags, pipettes, medical valves, dialysis accessories | |
| Medical Packaging | Burst and leak testing for flexible medical device packaging and pouches | |
| Aerospace & Aviation | Complex Components | Complex aerospace manifolds and geometries |
| Fuel & Propellant Delivery | Aircraft fuel tanks, flexible fuel lines, rocket propulsion components | |
| Hydraulic & Flight Control | Landing gear actuators, braking systems, hydraulic actuation loops | |
| ECS & Life Support | Cabin pressurisation ducts, oxygen distribution networks, bleed air valves | |
| Turbine & APU | Engine housings, lubrication paths, oil filter housings | |
| Avionics & Instrumentation | Hermetic connectors, sealed sensor housings, pitot-static probes | |
| Electric Home Appliances | White Goods | Washing machines, boilers, coffee machines |
| Plumbing | Showers, urinals, washing basins, RAC components | |
| Consumer Electronics | Inkjet cartridges | |
| Chemistry & Foodstuff | Food Packaging | General food packaging, flexible pouch testing |
| Containers | Bottles and aerosol containers | |
| General Industrial | Gas & Fluid Infrastructure | Gas pipes, water pipes, tanks, building gas regulators |
| Industrial Heating | Gas heating systems | |
| Heavy Machinery | Volumetric and leak measurement of oil-filled gears | |
| Offshore/Marine | Large-volume undersea and subsea manifolds |
Sensitivity Thresholds Under EN 1779 / ISO 20485
Under EN 1779 (superseded by ISO 20485), leak testing methodologies are categorised by physical principles and detection limits. For pressure change techniques — including absolute and differential pressure decay testing — the realistic sensitivity threshold spans from 10⁻² mbar·l/s down to 10⁻⁵ mbar·l/s under highly optimised, laboratory-grade conditions.
What This Means in Practice
In a production environment, achieving 10⁻³ mbar·l/s requires strict discipline: well-maintained couplings, hoses and valves; adiabatic control; trained operators; and a product volume and test parameter set suited to detecting that leak rate via air decay.
Legacy Equipment Cross-Reference & Migration Guide
Plant modernisation programmes frequently require replacing obsolete hardware — including equipment from ATEQ, Furness Controls, USON, Qualitek, J.W. Froelich, Zeltwanger and Schreiner — without altering existing PLC code, IO maps or physical bench footprints.
The Optitest series functions as a drop-in functional replacement for major international brands. For more complex applications, the Optimeasure in-house integration team can manage the full migration.
Overview
Optibox is designed to meet the rigorous demands of industrial leak detection, offering a high-precision solution for ensuring product integrity. Engineered to match specific process requirements, it delivers reliable and repeatable performance for applications ranging from air pressure decay testing to functional checks. This aligns with our core mission to provide optimised measurement solutions that directly improve quality and safety across the manufacturing sector.
As part of our wider product portfolio, Optibox is backed by decades of application expertise and our in-house technical support team. Whether integrated into a larger bespoke system or utilized as a standalone unit for production support, it is fully supported by our structured service and calibration packages. This ensures that your critical testing equipment remains compliant, accurate, and effective throughout its operational lifecycle.
Frequently Asked Questions
Air leak testing is the industry standard for high-volume production environments where speed, cleanliness, and cost-effectiveness are paramount. It is best used when:
Production Speed is Critical: Air-based methods like pressure decay offer rapid cycle times suitable for 100% in-line testing.
The Object is Dry/Sealed: You need to test electronics, automotive components, or packaging that would be damaged by liquid-based "bubble" tests
Quantifiable Pass/Fail Data is Required: You need digital, traceable records of leak rates for quality auditing or regulatory compliance (e.g., IP67 or ASTM F1140).
Production Speed is Critical: Air-based methods like pressure decay offer rapid cycle times suitable for 100% in-line testing.
The Object is Dry/Sealed: You need to test electronics, automotive components, or packaging that would be damaged by liquid-based "bubble" tests
Quantifiable Pass/Fail Data is Required: You need digital, traceable records of leak rates for quality auditing or regulatory compliance (e.g., IP67 or ASTM F1140).
To ensure your data is defensible, Optimeasure systems are calibrated using an unbroken chain of comparison to national and international standards. This is achieved by:
Traceable Leak Standards: We use precision orifices (Calibrated Leak Masters) that have a certified, known leak rate at a specific pressure, traceable to national standards.
Regular Verification: The system is programmed to perform daily or shift-based self-checks against these master leaks, ensuring the sensors remain accurate between formal annual calibrations.
Traceable Leak Standards: We use precision orifices (Calibrated Leak Masters) that have a certified, known leak rate at a specific pressure, traceable to national standards.
Regular Verification: The system is programmed to perform daily or shift-based self-checks against these master leaks, ensuring the sensors remain accurate between formal annual calibrations.
While tracer gas (such as Helium or Hydrogen) offers extreme sensitivity for micro-leaks, air leak testing is often the superior choice for:
Cost Management: Air is free and requires no specialized recovery or venting systems, making the "cost per test" significantly lower.
Simplicity and Safety: Air testing avoids the complexities of gas handling, concentration monitoring, and potential flammability risks associated with some tracer gases.
Larger Leak Detection: If your tolerance for leakage is within the range detectable by pressure decay (~1e-2 mbar l/s), air testing provides a more robust and faster solution without the "background noise" issues often found in high-sensitivity gas testing.
Cost Management: Air is free and requires no specialized recovery or venting systems, making the "cost per test" significantly lower.
Simplicity and Safety: Air testing avoids the complexities of gas handling, concentration monitoring, and potential flammability risks associated with some tracer gases.
Larger Leak Detection: If your tolerance for leakage is within the range detectable by pressure decay (~1e-2 mbar l/s), air testing provides a more robust and faster solution without the "background noise" issues often found in high-sensitivity gas testing.
Complex Testing Requirements?
Our expert engineers are available to advise on system design, product selection, and technical integration for your specific application.
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