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“CLeo” Develops Automated Inspection Technology for Next-generation Membrane Modules
(Dresden, 05/20/2025) A new testing system shall detect leaks in filter modules automatically, non-destructively, and in real time. DBI Gas- und Umwelttechnik spearheads the CLeo project, where the system is currently under development. The Fraunhofer Application Center for Optical Metrology and Surface Technologies AZOM contributes a laser-based leak detection method and an AI-driven analysis process. The system aims to fundamentally improve the currently manual quality control in membrane production. It will help reduce production costs, meet environmental standards, and ensure the long-term quality of industrial filtration systems – efficiently, precisely, and sustainably.
The demand for high-performance filtration systems continues to rise. New EU directives, such as the upcoming wastewater regulation mandating a fourth purification stage, drive this trend. However, current quality control methods rely on manual testing. These procedures remain labor-intensive, time-consuming, and unsustainable. Conventional tests like bubble testing in water baths lack scalability, automation, and reliability. The BMBF-funded joint project “Cyber-Physical System for Inline Leak Detection in Membrane Filtration Modules Using Spatially Resolved Diode Spectroscopy” (CLeo) addresses this challenge. The goal: a cyber-physical inline inspection system that detects and analyzes leaks during production without damaging the sensitive membranes.
“Our goal with CLeo is to enable high-precision leak detection fully integrated into industrial production,” explains Dr. Tobias Baselt, Head of Optical Fiber Technologies at Fraunhofer AZOM. “Combining laser spectroscopy, intelligent data processing, and automated mechanics results in a robust solution that ensures quality while saving time, resources, and costs.”
Digital Innovation Meets Industrial Practice – for the Environment, Industry, and Society
The technology uses spatially resolved diode spectroscopy. A test gas flows through the filter module; leaks are visualized via specific absorption signals. The system evaluates data in real time and precisely locates each defect. Operators can then repair modules or remove faulty units from the line. Beyond economic efficiency, the system supports resource conservation: Inspection and repair times drop significantly, and the modules’ post-treatment becomes obsolete due to the water bath. Automated detection and selective rework reduce waste, advancing sustainable production. The system adapts across industries – from water management to food processing, pharmaceuticals, and chemical manufacturing – wherever leak-tight components are critical.
Interdisciplinary Consortium Driving Innovation
The two-year project launched on January 1, 2025, with total funding of €1.4 million as part of the BMBF’s “KMU-innovativ: Future of Value Creation” program. The consortium brings together expertise in materials science, mechanical engineering, metrology, and digitalization:
- Fraunhofer AZOM: Laser-based leak detection and AI analysis
- DBI Gas- und Umwelttechnik GmbH: Project coordination, gas flow development
- ibl Maschinenbau GmbH: Robotic handling of membrane modules
- WTA UNISOL GmbH: System integration, development of test modules with defined leaks
- University of Applied Sciences Zwickau (WHZ): Design of protective textiles for optimized
measurement conditions
Dr.-Ing. Tobias Baselt
Fraunhofer-Anwendungszentrum für Optische Messtechnik und Oberflächentechnologien AZOM
Phone +49 375 536-1970
Keplerstr. 2
08056 Zwickau
tobias.baselt@iws.fraunhofe
https://www.iws.fraunhofer.de/en/newsandmedia/press_releases/2025/press-release_...
The laser-based technology combines optical spectroscopy with AI-supported analysis, enabling automa ...
©Fraunhofer IWS
An employee of project partner WTA Unisol performing manual quality control on filtration membranes. ...
©WTA Unisol GmbH
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