Benefits of Automatic Leak Testing
- Automated testing in just 15 minutes enables a daily or on-demand testing schedule. The testing system remains permanently connected to the installation.
- Microcracks smaller than 30 μm are detected before they cause a production failure.
- No special training required, no handling of tracer gases. No additional cleaning of the system needed after testing.
Why Integrity Tests Are Conducted
Integrity testing of plate heat exchangers is carried out at regular intervals to prevent contamination of hygienic products with cooling media. In food production, the consequences of a potential leak are often severe, resulting not only in the loss of a batch but also in a loss of customer trust in the company and brand.
Leak Testing with Process Water
The ExiFlo testing system has been specifically developed for plate heat exchangers in the food and beverage industry. The leak test is performed fully automatically and exclusively with process water.
The testing system remains permanently connected to the heat exchanger units, eliminating the need for disassembly or modifications for individual tests. ExiFlo can be integrated into both new and existing heat exchanger systems.
ExiFlo Installation Diagram: Additional shut-off valves for automatic cleaning of inlet sections can be integrated.
1: Process water, 2: Drain, 3&4: Product circuit, 5: Cooling circuit, A: Shut-off valves
Unlike tests using tracer gases, the ExiFlo test does not require specially trained personnel. Handling of hydrogen/helium gases is unnecessary. Furthermore, no additional cleaning is needed after testing. Thanks to the hygienic setup and the use of water as the test medium, cross-contamination is eliminated.
Process of the Automatic Integrity Test
The ExiFlo integrity test can be started on demand at any time. It is recommended to run an automatic test after each CIP cycle. Before the hydraulic integrity test, the heat exchanger should be filled with water.
- ExiFlo automatically removes any remaining air at the start of the test through controlled pressure buildup. The test pressure typically ranges between 3 - 4 bar, with a maximum setting of 10 bar.
- Shut-off valves isolate the heat exchanger from the rest of the system.
- ExiFlo pressurizes both sides of the heat exchanger and measures with a precision of 0.5 ml/min whether fluid transfer occurs. The process takes approximately 15 minutes, depending on the initial air volume in the system.
- Test parameters and progress can be monitored in real time via browser-based software.
- Upon successful completion, a certificate is issued to document the heat exchanger's integrity.
ExiFlo Test Certificate
ExiFlo Heat Exchanger Integrity Testing System
We are happy to advise you on automated integrity testing and leak detection for your hygienic plate heat exchangers. Contact us now!
