COMPARISON
LEAK DETECTION TECHNOLOGY FOR HVAC CONDENSERS AND EVAPORATORS
How does our new Helium-based system compare to the previous R410a machinery? We compared the performance, and the results speak for themselves – our integrated machine is smaller, more precise, and dramatically cheaper to run, without affecting production rate.
The Challenge
A major HVAC OEM facility operated five high-throughput lines for A-coil condensers and evaporators. The existing leak detection used R410a refrigerant in hard vacuum chambers. This standard method had limited sensitivity due to R410a's large molecular size and its ambient presence in the facility, leading to missed micro-leaks, high warranty claims, and an inefficient factory layout.
The Technical Solution
We replaced R410a with helium, whose smaller molecules detect finer leaks. Each line was equipped with three integrated machines combining pre-charge, vacuum testing, gas charging, and recovery. To manage costs, a closed-loop helium recovery system was deployed, achieving a 92% reclamation rate. A gas mixing module enabled the use of a 30% helium concentration without losing accuracy, cutting annual helium use by ~70%.
Execution & Compliance
A collaborative approach guided development, defining leak-tightness specifications and product lifespan targets. Project execution included detailed layout planning, mechanical and control integration, operator training, and system commissioning. All equipment was certified to ISO9001:2015, UKCA, and CE standards.
EQUIPMENT FOOTPRINT
3XArea
Previous Machinery
Multiple separate machines for gross leak testing, charging, detection, and recovery.0Reduction
Helium System
Integrated machines combine all processes, reducing footprint by two-thirds.PRODUCTION THROUGHPUT
TAKT Time
Production Volume Maintained
Despite the new process and smaller footprint, the system maintained required TAKT times and throughput rates.WARRANTY CLAIMS
Previous Rate
R410a's limited sensitivity caused missed micro-leaks.0Reduction
With Helium System
Superior sensitivity of helium directly addressed the primary performance gap.ANNUAL HELIUM RUNNING COST
HIGHCost
Previous R410a
No gas recovery system was in place for the R410a process.0Reduction
Helium w/ Recovery
Achieved via 92% recovery rate and an efficient 30% helium mix.