LeakFree · Project

Automated Low-Cost Leak Detection for Plastic Fuel Tank Production Lines

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Imagine you're making plastic fuel tanks on a factory floor, and you need to check every single one for leaks. Right now, that means someone with a handheld tool testing each tank manually — slow, inconsistent, and expensive. LeakFree built an automated system that listens for tiny sounds escaping from a pressurized tank (like a doctor using a stethoscope) and catches leaks faster and cheaper than a human operator. The technology was already proven on real production lines, and this project pushed it toward full market readiness with certification and ERP integration.

By the numbers

100%

Industry ratio in the consortium

SME partner (single-company project)

Month project duration

Total project deliverables

The business problem

What needed solving

Plastic fuel tank manufacturers need to test every tank for leaks, but current high-sensitivity methods are too expensive for mass production, while affordable methods rely on manual operators — making them slow, inconsistent, and hard to scale. The industry needs an automated, affordable leak detection system that can keep up with production line speeds without sacrificing accuracy.

The solution

What was built

An automated leak detection system based on Acoustic Emission (AE) technology, designed for mass production of plastic and composite fuel tanks. The project produced dissemination materials and a system designed to integrate with factory ERP systems, with activities spanning from prototyping through validation, demonstration, and standards certification.

Audience

Who needs this

Plastic fuel tank manufacturers (rotomolding, blow molding)Automotive Tier 1/2 suppliers making sealed plastic componentsComposite pressure vessel producers (hydrogen, CNG, LPG tanks)Quality control equipment integrators for automotive production linesRotomolding companies producing large hollow plastic products

Business applications

Who can put this to work

Automotive fuel tank manufacturing

SME

Target: Plastic fuel tank producers using rotomolding or blow molding

If you are a fuel tank manufacturer dealing with slow, manual leak testing that depends on individual operators — this project developed an automated acoustic emission inspection system that eliminates operator variability and speeds up quality control in mass production. The system was demonstrated in a real fuel-tank production environment and designed to connect directly to your ERP system.

Automotive parts & components

mid-size

Target: Tier 1/Tier 2 automotive suppliers producing sealed plastic containers

If you are an automotive parts supplier producing sealed plastic components like reservoirs, coolant tanks, or AdBlue containers — this project developed an acoustic-based leak detection method that replaces expensive helium or vacuum testing with a low-cost, automated alternative. The system is traceable and designed for mass production throughput.

Composite pressure vessel manufacturing

any

Target: Producers of composite tanks for hydrogen, CNG, or LPG storage

If you are a composite tank manufacturer struggling with the cost of high-sensitivity leak testing — this project developed an acoustic emission system proven in a production setting that offers fast, accurate results without the high investment costs of traditional methods. It was built to integrate into existing production workflows and ERP systems.

Frequently asked

Quick answers

How much does this leak detection system cost compared to current methods?

The project explicitly targets bringing a 'low cost' leak detection system to market, designed to replace techniques where high investment and operational costs outweigh benefits. Specific pricing is not disclosed in available project data, but the entire value proposition is built on being economically feasible for automotive QC where existing high-sensitivity methods are not.

Can this system handle mass production volumes?

Yes — the system was specifically designed for mass production environments in fuel tank manufacturing. It was demonstrated in a real fuel-tank production environment and the project included activities for validation, demonstration, and performance verification at production scale.

What is the IP situation — can I license this technology?

The project was executed by a single SME (FLOTEKS PLASTIK SANAYI VE TICARET AS, Turkey), which likely holds the IP. Licensing or commercial acquisition would need to be negotiated directly with them. The SME-2 funding scheme supports commercialization, so they are positioned to sell or license.

Does this meet automotive industry standards and regulations?

The project included standards certification as a specific activity. Based on available project data, the system was designed to fall within accepted leak detection sensitivity requirements for the automotive sector. Specific certifications achieved are not detailed in the objective.

How does this integrate with our existing factory systems?

The project explicitly included ERP integration as a deliverable — connecting the LeakFree system to the Enterprise Resource Planning system of a rotomolding production company. This suggests the system was built with factory IT integration in mind from the start.

What is the detection method and how reliable is it?

The system uses Acoustic Emission (AE) technology — essentially listening for the sound signature of escaping gas from pressurized tanks. It is automated and traceable, eliminating the variability of manual operator-dependent techniques. The technology was demonstrated in a real production environment before this project began.

What was the project timeline and current status?

The project ran from June 2015 to March 2017 (approximately 18 months) and is now closed. Since it was funded under SME Instrument Phase 2, the focus was on bringing an already-demonstrated technology to market readiness.

Consortium

Who built it

This is a single-company project run entirely by FLOTEKS PLASTIK SANAYI VE TICARET AS, a Turkish SME classified as a private commercial company. With 1 partner from 1 country and 100% industry composition, this is a focused commercialization effort — not a research collaboration. The SME Instrument Phase 2 funding confirms the company already had a proven technology and used EU funding to push it toward market. For a potential buyer or licensee, this means you'd be dealing directly with the technology owner, with no university or multi-partner IP complications.

FLOTEKS PLASTIK SANAYI VE TICARET ASCoordinator · TR

How to reach the team

FLOTEKS PLASTIK SANAYI VE TICARET AS is a Turkish plastics manufacturer — contact their R&D or business development team via their corporate website.

Order a report on this consortium See FLOTEKS PLASTIK SANAYI VE TICARET AS profile →

Next steps

Talk to the team behind this work.

Want an introduction to the LeakFree team? SciTransfer can connect you directly with the technology owner and help structure a licensing or supply conversation.

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