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Residual Gas Analysis

Residual gas analysis (RGA) is crucial for maintaining the purity and stability of vacuum systems. Whether you are monitoring processes in vacuum chambers or ensuring quality control in high vacuum environments, understanding and controlling residual gases is essential.

How RGA works with quadrupole mass spectrometers

Quadrupole mass spectrometers (QMS) consist of three main components – the ion source, a mass filter, and the detector – which together form the actual analyzer. What sets QMS apart from other mass spectrometers is its quadrupole rod system.

Requirements: Working pressures of 10⁻⁴ hPa (mbar) or lower are critical. If the connected vacuum chamber does not naturally reach this pressure, a dedicated vacuum system – typically combining a backing pump and a turbomolecular vacuum pump – is required to maintain optimal conditions. Operating at higher pressures can damage the QMS, so integrating total pressure measurement is strongly recommended.

More about the working principle of QMS

Residual gas analysis starting from ambient pressure

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Processes that do not reach high vacuum conditions can still use residual gas analysis. Standard or bespoke systems combine a backing pump, a turbopump, a gas inlet, and a total pressure gauge in one housing to create stable conditions and protect the mass spectrometer. This ensures reliable measurements, even when starting from ambient pressure.

Reliable gas analysis for vacuum applications

Residual Gas Analysis (RGA) supports a wide range of vacuum-based processes by ensuring process stability, contamination control, and vacuum quality. Whether in freeze drying, vacuum heat treatment, or cutting-edge EUV lithography, RGA provides crucial insights for process monitoring and quality assurance.

Ensuring purity in pharmaceutical production

Freeze drying in pharma

Pharmaceutical freeze drying is used to preserve temperature-sensitive substances such as vaccines, antibiotics, and biopharmaceuticals.

The process takes place under deep vacuum to prevent thermal degradation and ensure long-term product stability. During primary drying, typical pressures range from 0.5 hPa (mbar) to 10⁻² hPa (mbar) at temperatures below 0°C. Secondary drying follows at pressures as low as 10⁻³ hPa (mbar) and temperatures up to 30°C or higher.

Residual gas analysis (RGA) supports this process in several critical ways. It enables early detection of silicone oil contamination from leaking heating circuits and it allows precise monitoring of water vapor concentration, helping to determine the end point of drying more reliably than traditional pressure-based methods. With real-time analysis capability and reliable vacuum handling, they support high product safety and process efficiency.
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Residual gas analysis in thermoforming processes

In thermoforming processes, materials like polyvinyl chloride (PVC) are heated to 100 to 250 °C to form the desired shapes, often under vacuum down to 1 to 10 hPa (mbar). During heating, thermal decomposition can occur, releasing gases such as hydrogen chloride (HCl) and chlorinated aromatic compounds. Monitoring these emissions is crucial for both quality control and environmental safety.

Residual Gas Analysis (RGA), particularly when combined with thermogravimetric analysis (TGA), provides real-time insights into evolved gases. Coupling TGA with a quadrupole mass spectrometer enables manufacturers to identify decomposition products, ensure material consistency, optimize process temperatures, and reduce unwanted emissions – all while gaining a clearer understanding of thermal material behavior.
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Preserving quality in food processing

Freeze drying in food processing

Freeze drying is widely used in the food industry to extend shelf life while preserving flavor, color, and nutrients. Instead of evaporating liquid water like conventional drying, freeze drying removes moisture by converting ice directly into vapor – a process known as sublimation.

This gentle method protects even delicate products like raspberries from structural and nutritional damage by avoiding heat-induced degradation. Products like coffee or fruit are dried under vacuum at pressures between 0.5 and 10⁻² hPa (mbar) and at temperatures typically below 0 °C.

Residual Gas Analysis (RGA) enables real-time monitoring of water vapor concentration, allowing accurate end-point detection and process control. It also helps identify contamination or system leaks early – crucial for avoiding batch loss in high-throughput production.
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Ensuring process stability and clean surfaces

Vacuum heat treatment

In vacuum heat treatment processes such as brazing, sintering, or crystal growing, metals are treated at temperatures of 600 to 1,300 °C with vacuum levels typically between 10⁻² and 10⁻⁵ hPa (mbar). Maintaining clean, stable atmospheres is critical for product quality.

Residual Gas Analysis (RGA) provides real-time insights into the gas composition during heating. It helps detect outgassing from parts, leaks (e.g., cooling water, air ingress), and residual contamination, all of which may lead to discoloration, poor bonding, or part rejection. RGA also allows monitoring of gas phase reactions, supporting more precise control of metallurgical processes and repeatability between batches.
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Working principle of QMS

1. Previously neutral gas particles are ionized by bombarding them with electrons via the ion source (electron impact ionization).

2. The resulting ions are separated in the quadrupole mass filter, which consists of four precisely aligned metal rods. By applying a combination of AC and DC voltages, an oscillating electric field is created between them. This field selectively stabilizes or destabilizes ions based on their mass-to-charge ratio (m/z), allowing only specific ions to pass through.

3. The detector behind the separation system counts the ion current which reflects the partial pressure of each gas species or its fragments. Detection is done via a Faraday cup or, for higher sensitivity and speed, a secondary electron multiplier (SEM).

Only one mass range is measured at a time, with different masses analyzed sequentially rather than simultaneously. User-friendly software supports efficient operation and further data analysis.

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Learn more about residual gas analysis

What is residual gas analysis and how does it work?

Residual gas analysis (RGA) is a method used to determine which gases are present in a system and in what quantities. It relies on mass spectrometry, where molecules are ionized and the resulting ions are sorted by their mass-to-charge ratio (m/z) using a quadrupole mass filter. This allows the system to detect individual gas species, fragments, and isotopes based on their characteristic mass peaks.

To identify the gas composition, the detected mass spectrum must be interpreted – a process that links measured peaks to known gases or molecular fragments. This makes RGA a powerful tool for understanding vacuum quality, detecting contaminants, and monitoring process gases in real time.

Learn more in our vacuum technology book

What does RGA stand for?

RGA stands for Residual Gas Analysis, referring to the detection and identification of gases that remain – or are released – inside a system. These residual gases can come from leaks, outgassing materials, process by-products, or contamination. RGA is used to monitor and analyze these gases to ensure vacuum integrity, detect contaminants, or track process gas behavior in applications like freeze drying, heat treatment, or high vacuum research.

Can residual gas analysis be used if my process does not reach high vacuum?

Yes. Residual gas analysis can be adapted to different pressure ranges, depending on the application. In high vacuum systems, RGA typically analyzes low concentrations of background gases in a closed, static environment. But in processes at or near atmospheric pressure – such as thermal decomposition studies or gas reaction monitoring – RGA can be used in combination with specially designed inlet systems to handle continuous gas flow and reduce pressure before the analyzer.

This means that whether you are analyzing trace gases in a sealed UHV chamber or monitoring by-products in a heated atmospheric process, RGA can be configured accordingly to provide meaningful and reliable results.

What is the difference between RGA and leak detection?

Technically, both devices are mass spectrometers, but they serve different purposes.

A leak detector is optimized to look for one or two tracer gases – typically helium or hydrogen. This makes it simpler and faster to pinpoint leaks in vacuum systems, with a mass filter tailored to detect only those specific gases.

A residual gas analyzer (RGA), on the other hand, detects a wide range of gas species and fragments across a broader mass range. It can be used for leak detection too, but doing so with a QMS is often over the top unless you are also interested in identifying other gas species.

In short: A leak detector is a focused, cost-effective tool for helium or hydrogen detection, while an RGA gives you full gas composition insights.

Which gases can be detected with a quadrupole mass spectrometer?

A quadrupole mass spectrometer detects gases based on their mass-to-charge ratio (m/z), starting from mass 1 u (unified atomic mass unit). This includes individual gas molecules, their isotopes and fragments produced during ionization. Depending on the device and configuration, different upper mass limits apply:

  • The PrismaPro covers mass ranges up to 100, 200, or 300 u, depending on the selected rod system and generator.
  • The HiQuad Neo, with its larger and more precise quadrupole rods, extends this up to 512 u with higher resolution.

In practice, this allows the detection of most common residual gases, process gases, and organic vapors relevant in vacuum applications – ranging from hydrogen, nitrogen, and water vapor to hydrocarbon fragments and silicone compounds.

What is partial pressure and why is it important in RGA?

Partial pressure refers to the individual pressure contribution of a single gas in a mixture of gases. In a vacuum system, the total pressure is made up of the sum of all partial pressures from each gas species present.

Residual gas analysis (RGA) measures these partial pressures to determine which gases are present and in what quantity. This is crucial for identifying contaminants, monitoring process gas composition, and evaluating vacuum quality. Unlike total pressure measurements, RGA provides gas-specific insights – essential for applications where even trace amounts of certain gases can affect product quality or process stability.

What are the advantages of RGA solutions by Pfeiffer?

Pfeiffer offers a broad portfolio of RGA solutions, from compact setups to fully integrated high-end systems - each tailored to meet the application’s needs as precisely as required, and no more. This modular approach ensures an excellent cost-to-value ratio, whether you’re monitoring trace gases in food production, optimizing pharmaceutical freeze drying, or conducting high-sensitivity UHV analysis.

A key advantage across all systems is the PV MassSpec software. It enables real-time gas analysis with intuitive operation, customizable scan profiles, and detailed data logging. Designed for seamless integration into existing QMS systems, it supports remote access, automated routines, and precise control over measurement conditions. This makes it an ideal tool for both process-driven industries and research environments requiring reliability, transparency, and flexibility in vacuum diagnostics.

Pfeiffer products for residual gas analysis

Pfeiffer offers a comprehensive and modular portfolio of residual gas analyzers to meet the full spectrum of vacuum diagnostic needs – from routine monitoring to high-end process qualification.


 
Single device
Complete solution
Standard (modular)
Customizable
OmniStar/ ThermoStar
 
PrismaPro
 
 
HiQuad Neo
 
 
HiCube Neo RGA
 
OmniGrade
 

Single analyzers

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Flexible core components.

At the heart of every RGA system is the analyzer itself. Pfeiffer offers the PrismaPro and HiQuad Neo quadrupole mass spectrometers, each tailored to different sensitivity and mass range requirements. These are modular systems, allowing you to combine the appropriate ion source, mass filter, and detector (Faraday or C-SEM) to suit your process. Mass ranges span from 1 to 100 u up to 512 u, depending on the model and configuration.

Discover our single analyzers

Compact systems

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Plug&play and portable.

If you are seeking quick deployment and high mobility, Pfeiffer offers standalone RGA solutions:

  • HiCube Neo RGA: A compact, portable unit combining a mass spectrometer, a turbomolecular vacuum pump unit, and total pressure monitoring. It is ideal for mobile diagnostics, on-site leak tests, and contamination analysis.
  • OmniStar and ThermoStar: Ready-to-use systems optimized for process monitoring at higher pressures, such as in thermal decomposition or TGA coupling, with heated inlets and gas-tight construction.
Discover our compact systems

Tailor-made RGA systems

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Everything from a single source.

In addition to standard and modular systems, Pfeiffer also supplies fully customized RGA setups tailored to specific applications. This includes complete systems with selected vacuum chambers, backing and turbopumps, high-precision gauges, and the appropriate mass spectrometer – such as the PrismaPro or HiQuad Neo.

For advanced requirements, the OmniGrade system offers a fully engineered, multi-chamber solution with automation, sample handling, and integration into process control environments. All components – valves, feedthroughs, control electronics like OmniControl, and the PV MassSpec software – are available from a single source, ensuring seamless compatibility and reliable performance across the system.

Learn more about the HiCube Neo RGA and the OmniGrade – specifically designed as customized gas analyzer systems.

Discover our RGA systems
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Shared benefits across all systems

Regardless of the form, all Pfeiffer RGA systems share:

  • Standardized communication interfaces (Ethernet, analog, digital)
  • Compatibility with the PV MassSpec software, offering real-time visualization, scan customization, data logging, remote access, and process integration
  • Support from the Pfeiffer expert application team to help configure each system exactly as needed.