Factory acceptance testing and site acceptance testing are most useful when the protocol is agreed before manufacture is complete. The test should represent the approved pack, production conditions and quality criteria closely enough to expose the real handling risk.
Start with an approved requirement and format matrix
List every bottle, pump, tube and closure revision included in the project. Identify the most difficult format by tube length, curvature, actuator geometry, bottle stability, direction requirement or batch variation. State the required sustained output, operator tasks, changeover expectation and quality checks.
The FAT should test the agreed scope, not an informal collection of samples introduced on the day. New or changed formats should follow a documented review so the effect on tooling, controls and timing is understood.
Use representative samples and normal bulk presentation
Pumps should come from routine supply in the bags, trays or cartons used in production. Include expected variation rather than selecting only straight tubes and perfect actuators. Bottles should represent the final geometry, decoration and filled-weight condition, using a safe substitute or ballast where actual product cannot be used.
Confirm sample quantities early. Automatic pump feeding needs enough components to establish bulk behaviour, replenishment, steady running and recovery. The sample plan should also retain material for adjustments, quality checks and any agreed retest.
Define sustained output rather than a short cycle rate
Write the run duration, counted output, permitted operator tasks, replenishment method, planned stops, quality sample frequency and treatment of rejects. Record every intervention by cause. A momentary machine speed or hand-fed demonstration does not establish saleable output from a complete pump-capping cell.
Use the output capacity planning guide to create the measurement basis. Where several machines are linked, include the relevant upstream and downstream behaviour rather than isolating the capper from the line constraints.
Agree the finished-pack quality plan
The protocol should define the method and acceptance basis for the checks that matter to the pack.
| Check | Define before testing |
|---|---|
| Pump presence and seating | How a missing, tilted or incompletely seated closure is identified. |
| Thread engagement | Visual or dimensional evidence that cross-threaded and high closures are rejected. |
| Torque or removal torque | Instrument, sample conditioning, method, timing and approved limits where applicable. |
| Actuator direction or lock state | Reference datum, tolerance and condition in which the pump should leave the machine. |
| Leakage or handling | Product-specific or representative method agreed by the pack owner. |
| Cosmetic condition | Permitted marks on the collar, actuator, bottle, label and decoration. |
| Reject handling | How a failed pack is identified, removed and confirmed out of the saleable flow. |
Test normal stops, faults and recovery
Include a controlled pump misfeed, bottle absence, downstream blockage and restart where safe and relevant to the machine. Confirm the machine stops in the intended state, identifies the fault, retains or clears in-process components correctly and restarts without double feeding or producing an untracked pack.
Fault testing must follow the supplier’s safe method and must not require defeating safeguards. The purpose is to confirm the designed recovery sequence, operator information and reject disposition.
Prove a representative changeover
Where multiple formats form part of the project, select a change that exercises the main tooling and recipe differences. Record the parts changed, settings loaded, time basis, first-off checks and approval authority. The FAT should show that the machine can return to an approved condition, not only that parts can be physically exchanged.
If one format cannot be fully tested at FAT because components are unavailable, record the limitation and the plan for later validation rather than treating the untested format as accepted.
Record deviations, responsibilities and evidence
Use a signed protocol or controlled record containing the test condition, observed result, deviations, agreed actions, owner and target date. Photographs, videos, data logs and sample packs can support the record, but they do not replace a clear statement of whether each acceptance point passed, failed or remained open.
Distinguish corrections required before dispatch from items intentionally deferred to site. Changes made after FAT should be reviewed for their effect on the approved test evidence.
Use SAT for installation-specific confirmation
Site acceptance should verify utilities, machine position, actual conveyors, control signals, production environment, operator training and the behaviour of the connected line. Repeat only those factory checks needed to show the machine remained correct after transport and installation or where the real site condition changes the result.
The installation and site-preparation guide helps make the site ready. Final safety, compliance and operating acceptance remain dependent on the actual machinery, installation and competent site assessment.
Close the test with a controlled handover
Confirm manuals, drawings, recipes, format-part lists, spare-parts information, training records and open actions. Agree who may alter settings, how future formats are assessed and what evidence the production team records during early running.
A completed FAT or SAT is not a guarantee that untested components will run. It is a controlled statement about the approved configuration, samples, conditions and results at the time of testing.
Acceptance must describe the tested condition.
Record the exact pack, machine arrangement, run conditions, quality method, interventions and open actions. That evidence is more useful than a pass statement without context.