Assessing leak detection and localization techniques for application in end-of-line leakage stations in the industrial sector

Leak localization is a crucial step to ensure product quality and operational efficiency in end-of-line (EOL) leakage testing stations. Traditional fuel-based leakage tests are being gradually replaced by compressed air testing due to its environmental benefits and cost-effectiveness. However, accurately detecting and localizing leaks with compressed air-based systems remains challenging, primarily because conventional detection methods rely on the presence of hydrocarbons. This review provides a comprehensive analysis of existing leak detection and localization techniques, assessing their technical feasibility and economic viability for EOL testing stations. Furthermore, it highlights key considerations related to safety and risk assessment. To identify the most effective methodologies for compressed air-based EOL leakage testing, an adaptability evaluation was performed, considering key criteria such as compatibility with EOL stations, localization accuracy, ease of implementation, and cost-effectiveness. Acoustic technology and infrared thermography were found to be the most suitable solutions for this specific scenario, providing real-time leak detection and localization with high accuracy and seamless integration into existing testing stations without requiring major structural alterations. Ultimately, this review emphasizes the importance of selecting cost-effective and adaptable leak detection technologies to enhance production efficiency and sustainability. Future research should focus on further refining these methods, focusing on automation and integration with artificial intelligence-based tools to further improve leak localization in industrial EOL environments.