Tracer Gas Leak Testing

We design, manufacture and integrate bespoke leak detection systems for demanding production and laboratory environments.

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Overview

When air pressure testing reaches its physical sensitivity limits, Optimeasure’s Tracer Gas Sniffer systems provide the ultimate solution for high-precision integrity verification. Specialising in the detection of “micro-leaks” that are invisible to traditional pressure decay methods, our systems utilise advanced multi-gas sensor technology to identify leak rates as small as 1 × 10^-7 mbar·l/s. This precision is vital for industries where maintaining a specific containment level is critical for safety, environmental protection, or product longevity.

Designed and built in accordance with the ISO 20485 standard, our sniffer systems are uniquely versatile. Our technology allows for the simultaneous searching of traditional tracer gases (Helium and Hydrogen/Forming Gas) as well as a wide range of industrial Refrigerants. This makes our systems the ideal choice for the HVAC, automotive, and refrigeration sectors, where the ability to pinpoint the exact location of a leak on a complex assembly—rather than just detecting its presence—is essential for efficient rework and quality assurance.

At Optimeasure, we recognise that every component has a measurable leak rate; our goal is to help you ensure that rate remains within your specified tolerances. We provide bespoke sniffer stations ranging from manual, hand-held probe setups to fully integrated, automated robotic cells. By utilising high-performance mass spectrometers and specialized infrared (IR) sensors, we ensure your testing process is not only compliant with international standards but also perfectly optimised for your specific production throughput.

Choosing between the two common tracer gases? See helium vs hydrogen leak detection for a direct comparison of sensitivity, running cost and supply.

Quantitative or Qualitative: Which Method You Need

Tracer gas testing splits into two approaches, and the one you need is often dictated by the standard you test to rather than by preference.

Vacuum testing is quantitative. The part is evacuated or placed in a vacuum chamber and a mass spectrometer measures the helium drawn through any leak. It tells you whether a part leaks and by how much, which is what you need for a pass or fail against a specified leak rate.
Sniffing is qualitative. The part is pressurised with tracer gas and an operator passes a probe over the exterior. It tells you where the leak is, which is what you need for rework on a large or awkward assembly.

Many manufacturers use both: vacuum testing to decide pass or fail on the line, sniffing to locate the fault on anything that fails.

When Tracer Gas Is the Right Choice

Tracer gas is the answer when air pressure decay cannot reach the leak rate you have to prove. Typical triggers are:

A specified leak rate below the practical floor of pressure decay testing.
Products carrying refrigerants, hydrogen or high-pressure fuels, where a small leak is a safety or environmental liability rather than a quality defect.
Components with large internal volumes, where pressure decay would need an impractically long soak time to give a stable reading.
Assemblies where the leak has to be pinpointed for rework, not just detected.

Equipment and Support

Systems are built around INFICON instrumentation, from hand-held probes through to integrated production cells. See the INFICON range, the LDS3000 for integrated production testing, or the UL1000 where a mobile unit suits the job better. If you would rather not buy outright, instruments are available through rental and leasing, and we also run testing as a helium leak testing service.

Reference leaks and instrument calibration are covered under calibration, traceable to national standards.

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

When to use tracer gas leak testing

Tracer gas testing is preferred when the "allowable leak limit" of your product is too small for air pressure sensors to detect reliably. You should choose this method when:

High Precision is Required: Your product must meet strict containment standards (e.g., HVAC systems, fuel rails, or battery enclosures).

Multi-Gas Detection is Needed: You need to detect specific refrigerants or switch between different tracer gases across various product lines using a single system.

Exact Localisation is Needed: You need to pinpoint the specific weld, joint, or seal that is failing within a complex assembly to facilitate fast and accurate repairs.

How is a tracer gas leak system calibrated to traceable standards?

To ensure compliance with ISO 20485, our systems are calibrated using Physical Reference Leaks.

Internal Calibration: Our high-end sniffer systems feature internal reference leaks for automated, daily sensitivity checks.

Traceable Verification: We provide UKAS-traceable external leak masters (for Helium, Hydrogen, or specific refrigerants) to verify the sniffer probe's sensitivity at the start of every shift.

Digital Traceability: Every calibration event is logged, providing a digital audit trail that confirms your sensors were accurate and functioning correctly at the time of testing.

When is tracer gas testing preferred to air leak detection?

While air testing is excellent for speed and cost, tracer gas is the superior choice for:

Micro-Leak Sensitivity: It can detect leaks 1,000 to 1,000,000 times smaller than standard pressure decay systems.

Temperature & Volume Independence: Unlike air testing, tracer gas results are not skewed by changes in ambient temperature or the "stretch" of flexible parts, providing a more stable and repeatable result.

Complex Geometry: In assemblies with multiple joints, air testing only tells you if it leaks. Tracer gas sniffing tells you where it leaks, significantly reducing downtime in the rework process.