How to Conduct a Factory Acceptance Test for a Bottling Line

2026년 8월 31일

Before an automatic bottling line is shipped, it should be carefully tested to confirm that every machine works as specified. This process is known as a Factory Acceptance Test, or FAT.

A well-planned FAT helps identify problems before installation, reduces commissioning time, and ensures that the equipment meets the buyer’s production requirements.

What Is a Factory Acceptance Test?

A Factory Acceptance Test is performed at the equipment manufacturer’s facility before shipment. During the test, the complete packaging line—or individual machines—is operated under conditions that are as close as possible to actual production.

For a bottling line, the FAT may cover:

Bottle feeding and conveying
Filling accuracy
Cap feeding and capping
Label application
Coding or marking
Inspection and rejection
Production speed
Safety and control systems

The customer may attend the test in person or review it remotely through live video, test reports, photos, and recorded operating videos.

1. Confirm the FAT Scope

Before testing begins, both the manufacturer and customer should agree on the acceptance criteria.

The FAT plan should clearly define:

Machines included in the test
Target production speed
Filling volume and accuracy
Compatible bottle and cap sizes
Label positioning tolerance
Required test duration
Products or substitute materials used
Safety and electrical requirements
Documents to be provided

Clear acceptance standards prevent misunderstandings and make the final evaluation more objective.

2. Prepare Representative Samples

Whenever possible, the customer should provide actual production samples, including:

Empty bottles or containers
Caps, pumps, droppers, or triggers
Labels
Product samples
Cartons or secondary packaging materials

Actual samples are especially important for customized bottling lines. Differences in bottle shape, cap structure, label material, or product viscosity can directly affect machine performance.

If the real product cannot be shipped, a material with similar viscosity, foaming behavior, and flow characteristics should be selected for testing.

3. Inspect the Equipment

Before running the line, conduct a visual and mechanical inspection.

Check that:

The machine configuration matches the approved layout
Main components correspond to the agreed specifications
Stainless-steel surfaces are properly finished
Electrical wiring and pneumatic connections are organized
Guards, doors, and emergency stops are installed
Changeover parts and accessories are included
Machine labels and operating directions are clear

Any visible damage, missing component, or specification difference should be recorded before performance testing begins.

4. Test Each Machine Individually

Each unit should first be tested separately before operating the complete line.

For example:

The bottle unscrambler should feed bottles consistently.
The filling machine should deliver the required volume accurately.
The capping machine should position and tighten caps correctly.
The labeling machine should apply labels without wrinkles or excessive deviation.
The coding system should print clear and readable information.
The inspection system should identify and reject unqualified products.

Individual testing makes it easier to identify the source of a problem before all machines are connected.

5. Run the Complete Bottling Line

After the individual machines pass inspection, operate the full line continuously.

A typical process may include:

Bottle Feeding → Filling → Cap Feeding → Capping → Labeling → Coding → Inspection → Finished Product Collection

During the test, observe whether products transfer smoothly between machines. Pay particular attention to bottlenecks, unstable bottle movement, product accumulation, and mismatched operating speeds.

The line should remain stable during continuous operation rather than only producing a few successful samples.

6. Verify Filling Performance

Filling performance is one of the most important FAT items.

Check:

Average filling volume
Filling accuracy and repeatability
Dripping or leakage
Foaming and splashing
Product contact-part suitability
Filling performance at different speeds

Multiple filled containers should be weighed or measured. The results should be recorded and compared with the agreed tolerance.

For viscous, foamy, corrosive, or particulate-containing products, additional testing may be required.

7. Check Capping and Labeling Quality

Caps should be properly fed, positioned, and tightened without damaging the container.

The test should confirm:

Stable cap feeding
Correct cap placement
Consistent tightening torque
No loose, tilted, or damaged caps
Smooth changeover between supported formats

Labeling should also be checked for position, alignment, wrinkles, bubbles, and adhesion. For round bottles, the overlap and rotational position should remain consistent.

8. Test Controls and Safety Functions

The operator interface and control system should be easy to understand and respond correctly.

Test the following functions:

Start, stop, and reset controls
Speed adjustment
Parameter storage
Bottle detection
No-bottle-no-fill function
Alarm messages
Emergency stops
Safety-door interlocks
Overload protection

The line should enter a safe state when an emergency stop is pressed or a protective door is opened.

9. Review Changeover and Cleaning

If the line handles multiple bottle sizes or products, the FAT should include at least one format change when practical.

Evaluate:

Changeover time
Adjustment difficulty
Tool requirements
Part identification
Parameter recall
Cleaning accessibility
Removal of product-contact parts

This test helps determine whether daily operation and maintenance will be practical for the production team.

10. Record Issues and Corrective Actions

All FAT results should be documented. Any issue found during testing should be added to a punch list.

Each item should include:

Description of the issue
Required corrective action
Responsible party
Completion deadline
Verification method

The equipment should only be approved for shipment after critical issues have been corrected and verified.

Final FAT Checklist

Before approving the bottling line, confirm that:

The equipment matches the purchase specifications
All machines operate correctly
Target speed has been demonstrated
Filling accuracy meets the agreed tolerance
Capping and labeling quality are acceptable
Safety devices function properly
Product changeover has been evaluated
Required documents and accessories are complete
Identified issues have been resolved

Conclusion

A Factory Acceptance Test is more than a final machine demonstration. It is an important quality-control stage that verifies whether the bottling line is ready for delivery and real production.

By defining measurable standards, using representative samples, testing the complete process, and documenting the results, manufacturers and customers can reduce installation risks and achieve a smoother production startup.

ZONESUN provides customized automatic bottling lines for different containers, products, capacities, and packaging processes. Each solution can be tested according to the customer’s production requirements before shipment, helping ensure reliable installation and efficient commissioning.

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