How can I get a quotation for the High Pressure Leak Testing Machine?

You can request a quotation for the High Pressure Leak Testing Machine by contacting Neometrix Engineering Pvt Ltd through https://neometrixgroup.com/products/high-pressure-leak-testing-machine or by reaching out via email or phone.

High Pressure Leak Testing Machine / Pneumatic · 1.2–20L Components / 20–250 Bar Circuit / Noida · India

HPLT · PNEUMATIC LEAK TEST

High Pressure Leak Testing Machine, built for 250 bar precision.

A fully automated pneumatic test system for precise leak detection in industrial components from 1.2 to 20 liters, at pressures up to 250 bar. An air-driven booster, dome-loaded regulator, and Schneider PLC with 10″ touchscreen HMI deliver static leak, pressure-hold, and stepwise pressure test modes with automatic pass/fail reporting.

Request proposal Full specifications

High pressure leak testing machine - industrial and defence hydraulic and pneumatic component high-pressure leak detection and integrity test system by Neometrix

Fig · 01 Machine overview — control cabinet, HMI panel, and air booster enclosure

Built to serve requirements under:

MIL-STD ISO IS

Test Pressure

250BAR MAX

DUT Volume

20L MAX

Amplification

44:1 RATIO

HMI Display

10INCH

Relief Valve

344BAR MAX

Overview

Precision leak detection, fully automated.

In critical industries such as automotive, aerospace, railways, and defense, ensuring pressure integrity is vital. The High Pressure Leak Testing Machine provides accurate and repeatable performance validation under demanding operating conditions.

High pressure leak testing machine product view - automated pressure intensifier and pressure decay leak detection system for aerospace and defence components by Neometrix

Fig · 02 Photograph · pressure intensifier and control assembly, close-up view

The High Pressure Leak Testing Machine performs automated leak testing as an air leak testing machine, a fully automated pneumatic test system designed for precise leak detection in industrial components ranging from 1.2 to 20 liters in volume. Operating at pressures up to 250 bar, it features an air-driven booster, dome-loaded pressure regulation, and a 10″ touchscreen HMI with PLC-based automation.

The system supports multiple test modes — including static leak, pressure hold, stepwise pressure, and real-time pressure vs. time profiling — making it ideal for quality control and endurance testing in automotive, aerospace, railways, and defense sectors.

Built with premium components and advanced safety features for reliable performance, high repeatability, and operator safety.

Engineers rely on this class of automated leak tester, one of the more capable industrial leak testing machines, to validate structural endurance while simulating extreme operating pressures — supporting in-line quality inspection, batch testing, and endurance testing across a broad operational envelope.

System Architecture

Four subsystems, one test cycle.

An air-driven, Haskel-equivalent gas booster and dome-loaded regulator generate test pressure; precision instrumentation, PLC control, and fail-safe relief protection complete the loop.

High pressure leak testing machine component detail - pressure intensifier valve manifold and digital pressure indicator assembly by Neometrix

Fig · 03 Photograph · valve manifold and digital pressure indicator assembly

Sub · 01

Pressure Generation

Air-driven, Haskel-equivalent gas booster with a 44:1 dome-loaded regulator delivering up to 5000 psi; 6 L @ 350 bar HP and 6 L @ 16 bar LP receiver tanks.

Sub · 02

Instrumentation

WIKA 0–400 bar SS316L glycerine-filled gauges and 0.25% FS digital transmitters (4–20 mA) with SS316 wetted parts for precise pressure monitoring.

Sub · 03

Control & Automation

Schneider PLC with 10-inch touchscreen HMI drives Festo 3/2 & 2/2 solenoid valves and Ham-Let pneumatically actuated ball valves through automated sequences.

Sub · 04

Safety Systems

Spring-loaded relief valve (275–344 bar), pilot pressure switch at 300 bar, emergency stop, interlocked venting, and tower light with buzzer.

Test Capabilities

Four protocols. Every failure mode, covered.

Each mode is governed by a safety-verified PLC logic sequence and offers manual override, digital diagnostics, and emergency handling.

T · 01

Leak Testing (Static Pressure Decay)

Operator defines target pressure, hold time, and maximum allowable drop. The DUT is filled to setpoint via the booster, and pressure decay is monitored by precision transmitters, flagging any drop beyond threshold with automatic pass/fail feedback.

T · 02

Pressure vs. Time Profiling

Programmable pressure rise, holding durations, and decay measurements with real-time graphical plotting to identify material behaviour under load — used for endurance, fatigue, and burst-pressure limit evaluation.

T · 03

Direct Outlet Pressure Mode

Real-time control of pressure directly to the outlet port for tuning, calibration, or single-point validation — especially useful for components with dynamic internal valves, chambers, or flow paths.

T · 04

Stepwise Pressure Ramp

Multi-stage pressure increases in programmable increments, each held for a defined duration to simulate cyclic loading — useful for parts undergoing fatigue testing or with pressure-dependent deformation.

Key Features

Built for production-line reliability.

Industry-grade instrumentation and fail-safe design ensure repeatable results and operator safety.

1.2–20 L / 20–250 bar: tests components using clean dry air or nitrogen via a Haskel-equivalent air booster.
44:1 dome-loaded regulator: delivers up to 5000 psi with 6 L @ 350 bar HP receiver storage.
Precision monitoring: WIKA 0–400 bar SS316L glycerine gauges and 0.25% FS digital transmitters (4–20 mA).
Schneider PLC + 10″ HMI: with Festo 3/2 & 2/2 solenoid valves for automated, programmable test sequences.

Static pressure decay leak testing: monitors drop against user-defined thresholds for automatic pass/fail determination.
Stepwise pressure ramp mode: applies multi-stage programmable increments to simulate cyclic fatigue loading.
Fail-safe overpressure protection: Ham-Let actuated ball valves and spring-loaded relief valve (275–344 bar).
Broad application range: automotive, aerospace, railways, and defense components including solenoid valves, actuators, and brake systems.

Gallery

Component-level detail views.

Close-up photographs of the pressure intensifier, valve manifold, and digital pressure indicator assembly.

Fig · 04–05 Photographs · pressure intensifier and manifold detail views

Downloads

Design drawings.

Machine design drawings, available as PDF for procurement and technical review.

Drawing · Design 1

High Pressure Leak Testing Machine — Design Drawing 1

PDF

Drawing · Design 2

High Pressure Leak Testing Machine — Design Drawing 2

PDF

Specifications

Full technical parameters.

Key system parameters for the standard High Pressure Leak Testing Machine configuration.

Test Pressure Range	20 to 250 Bar (adjustable)
Component Volume Capacity	1.2 Liters (min) to 20 Liters (max)
Test Medium	Clean Dry Compressed Air / Nitrogen
Pressure Generation	Air-driven gas booster system (Haskel equivalent)
Dome-Loaded Regulator	Amplification Ratio: 44:1, Max Output: 5000 psi, Connection: 1/4" NPT
Air Receiver Tanks	6 Liters @ 350 Bar (High Pressure), 6 Liters @ 16 Bar (Low Pressure)
Analog Pressure Gauges	0–16 Bar and 0–400 Kg/cm², Glycerine-filled, SS316L, 100 mm dial (WIKA)
Digital Pressure Transmitters	0–400 Bar, Output: 4–20 mA, Accuracy: 0.25% FS, SS316 Body & Wetted Parts
Pilot Pressure Switch	Set at 300 Bar, 1/4" NPT
Control Panel	Touchscreen HMI (10″) + Schneider PLC
Solenoid Valves	Festo 3/2 & 2/2, Normally Closed/Open, 1/4″ & 1/2″ BSP, 220–230 VAC
Actuated Ball Valves	1/4″ OD, Pneumatically actuated, Ham-Let make, NO/NC configuration
Safety Relief Valve	Range: 275–344 Bar, 1/4″ tube OD, Spring-loaded fail-safe design
I/O Monitoring	Live diagnostic screen for digital inputs/outputs, valve states, and alarms
Safety Features	Emergency stop, pressure vent logic, tower light with buzzer (R/Y/G indicators)
Emergency Venting	Pneumatic pressure exhaust path with interlocked control
Mounting & Safety Cage	Table-mounted enclosure with interlock; optional grouted floor cage for larger DUTs
Compressed Air Requirement	6–8 Bar filtered dry air
Electrical Requirement (Control)	230 V AC (Solenoid valves), 24 V DC (Control logic & indicators)

Applications

Where it runs.

From production-line quality control to endurance validation, the machine serves across every sector requiring pressure integrity assurance.

A · 01Automotive Industry — brake and clutch actuators, EGR valves, air suspensions

A · 02Aerospace & Defense — pneumatic control valves, actuator canisters, launch interface subsystems

A · 03Railways — door actuators, brake distributor valves, compressed air tanks

A · 04Medical & Gas Systems — oxygen/nitrogen valve assemblies, pressure reducers

A · 05Heavy Industry & Automation — pneumatic cylinders, regulators, control valves

In Depth

The complete technical read.

Engineering narrative for quality teams, service engineers, and R&D groups evaluating the machine before procurement.

1. Introduction

The High Pressure Leak Testing Machine is a precision-engineered, fully automated pneumatic test platform designed for high-accuracy, high-reliability leak detection in industrial components exposed to elevated internal pressures. Equipped with a sophisticated control ecosystem — featuring a PLC-based logic system and an intuitive 10″ HMI touchscreen — the machine offers programmable test sequences, digital pressure monitoring, automated safety control, and data-driven process validation.

Designed to accommodate components ranging from compact solenoid valves to large pneumatic actuators, the machine enables high-pressure testing across a broad operational envelope (1.2 liters to 20 liters in volume). With flexible mounting and connection options, it is suitable for in-line quality inspection, batch testing, and destructive or endurance testing in sectors such as automotive, aerospace, railways, defense, and industrial automation.

The system’s rugged mechanical structure, high-grade instrumentation (WIKA, Haskel, Festo, Norgren), and built-in safety mechanisms make it ideal for high-frequency industrial use, ensuring compliance with international test protocols while maximizing operator safety and operational uptime.

2. Automation & Software

HMI Interface: responsive 10-inch touchscreen with multi-language support (expandable), test configuration, monitoring, and historical data access.
PLC Control Logic: reliable, deterministic control for sequencing valves and monitoring sensors, with safeguarded interlocks preventing unsafe operation; expandable for future I/O, data logging, and remote access integration.
Data Visualization: real-time pressure vs. time plots, clear test status indicators, and on-screen pressure decay representation.
Data Handling (optional upgrade): exportable test logs, USB/SD/cloud connectivity options, and calibration record storage with automated alerts.

3. Service & Maintenance Schedule

Before each use: visual inspection, check oil level and tightness of fittings.
Weekly: leak detection (spray or drop method), clean exterior and HMI screen.
Monthly: test pressure sensors for drift, verify system zeroing post-depressurization.
Quarterly: full booster inspection, re-torque adapters, check wiring, inspect dome regulator.
Semi-annual: replace clogged filters, recalibrate gauges and transmitters, PRV testing.
Annual: overhaul of all pressure circuit components, update firmware if applicable.
Every 5 years: major maintenance on booster, PRV, dome regulator, and system-wide leak test.

4. Advantages at a Glance

High precision: ±0.25% full-scale measurement with SS316L components.
Total automation: one-touch test cycles with no manual intervention.
Industry-grade build: globally trusted brands — WIKA, Norgren, Festo, Haskel, Ham-Let.
Modular platform: future integration of burst testing, hydrostatic, or climate conditioning possible.
Operator safety: interlocked enclosures, emergency shutdown, auto-venting logic.
Application flexibility: compatible with a wide range of geometries and test setups.
Documentation & traceability: can be integrated with barcode/QR-based test log systems.

Conclusion

The High Pressure Leak Testing Machine delivers the repeatability, safety, and precision demanded by modern quality assurance programs. By reproducing real-world pressure conditions across static decay, profiling, direct-outlet, and stepwise-ramp modes, it provides clear, data-backed insight into component integrity — and can be custom-configured to meet unique testing requirements across automotive, aerospace, railways, defense, and industrial sectors.

FAQ

Common questions.

Plain-language answers from the engineering team.

Q · 01 What is the High Pressure Leak Testing Machine?

A fully automated pneumatic test system designed and manufactured by Neometrix Engineering Pvt Ltd, India, used for precision leak detection, validation, and quality assurance of industrial components from 1.2 to 20 liters, up to 250 bar.

Q · 02 Who manufactures the High Pressure Leak Testing Machine?

The machine is designed and manufactured by Neometrix Engineering Pvt Ltd, a leading test equipment manufacturer based in India.

Q · 03 What industries use the High Pressure Leak Testing Machine?

It is used across automotive, aerospace, railways, medical/gas systems, and heavy-industry automation sectors for testing components such as solenoid valves, actuator canisters, brake and clutch actuators, EGR valves, and pneumatic cylinders.

Q · 04 What test pressure and component size range does the machine cover?

The machine tests components from 1.2 liters to 20 liters in volume, at pressures adjustable from 20 to 250 bar, using clean dry compressed air or nitrogen via an air-driven, Haskel-equivalent gas booster.

Q · 05 Is the High Pressure Leak Testing Machine customizable?

Yes, Neometrix offers customized versions of the High Pressure Leak Testing Machine tailored to specific client requirements, operational parameters, and industry standards.

Q · 06 What test modes does the machine support?

The machine supports static pressure decay leak testing, pressure vs. time profiling, direct outlet pressure mode, and stepwise pressure ramp testing, each governed by a safety-verified PLC logic sequence.

Q · 07 Does the High Pressure Leak Testing Machine comply with relevant standards?

Yes, the machine is designed to comply with applicable national and international standards including MIL-STD, ISO, and IS, along with customer-specified test requirements.

Q · 08 What are the key features of the High Pressure Leak Testing Machine?

Key features include a 44:1 dome-loaded regulator, WIKA gauges and digital transmitters, a Schneider PLC with 10-inch HMI, Festo solenoid valves, Ham-Let actuated ball valves, and a spring-loaded relief valve for fail-safe overpressure protection.

Q · 09 Can the machine be integrated with data acquisition systems?

Yes, the machine can be integrated with advanced DAQ systems for real-time monitoring, automated reporting, and traceability of test results, with optional USB/SD/cloud connectivity.

Q · 10 How can I get a quotation, and does Neometrix export this machine internationally?

Yes, Neometrix Engineering Pvt Ltd exports the High Pressure Leak Testing Machine to global customers in defence, aerospace, and industrial sectors. You can request a quotation through https://neometrixgroup.com/products/high-pressure-leak-testing-machine or by reaching out to Neometrix directly by email or phone.

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and test requirements.

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