Aerosol Micro-Leak Detection: the LDA solution as an alternative to hot water bath testing

In the cosmetic aerosol industry, leak testing is no longer a mere routine check but a key factor in safety, quality, and brand protection. In an increasingly automated and high-speed production environment, traditional technologies show clear limitations, necessitating a new, more reliable approach that can be truly integrated into the production line.

This is the scenario where the new aerosol leak detection system based on Infrared (IR) spectroscopy comes into play. Developed by Antares Vision Group, it provides continuous, non-invasive integrity testing for aerosols.

Designed to inspect 100% of production at line speeds, this solution does not stress the containers or introduce operational complexity. Drawing on extensive experience in gas sensing across various industrial sectors, Antares Vision Group offers an alternative test method that is fully integrated into the line and designed to overcome the limitations of the traditional water bath.

The Operating Principle

The principle is simple and effective: the LDA (Leak Detection Aerosol) solution uses infrared spectroscopy to analyze the presence of escaping propellant gases in critical areas of the container. The system is multi-gas, enabling the detection of a wide range of propellants commonly used in aerosols, including LPG, butane, propane, DME, CO2, HFOs, and HFCs. Since the gas is under pressure, even micro-leaks generate a detectable concentration, allowing for the reliable and repeatable identification of real defects.

Safety and Market Reputation

This approach meets a concrete industry need: intercepting leaks before they become safety, logistical, or reputational issues, all without compromising line productivity. A leaking aerosol is not just a defective product. In the presence of flammable propellants, even minimal leaks can generate dangerous concentrations over time, especially in enclosed environments like warehouses or shipping containers. From a market perspective, a leak in the valve or crimping can cause the progressive self-discharge of the container, resulting in a product that appears intact on the shelf but fails to function, directly impacting the consumer experience.

Preventing Process Defects

Leak testing also plays a fundamental role in preventing process defects. Timely identification of issues related to non-compliant valves, critical crimping, or variations in production parameters prevents an anomaly from being replicated across thousands of units. In this sense, leak detection is not just quality control, but a true tool for production efficiency.

Beyond the Water Bath

The traditional hot water bath immersion test, while the regulatory reference standard, has evident limitations in modern high-speed lines: poor repeatability, difficulty in detecting micro-leaks, large footprints, significant energy consumption, and the need for drying. Consequently, it is often used discontinuously, reducing the overall effectiveness of the control.

In contrast, IR spectroscopy technology overcomes these limits, allowing for continuous, non-invasive inline testing that combines full regulatory compliance with real production needs. Beyond identifying individual defective pieces, it enables continuous process analysis, the identification of defect trends, and the correlation of leaks to specific component batches, making timely and targeted intervention possible.

Leak testing thus becomes a key element of prevention, safety, and manufacturer protection, transforming this quality check into a concrete competitive advantage

Discover the LDA