When you invest in a new machine, such as a CDA monobloc, commissioning involves more than just installation. To ensure your equipment operates at peak performance, it’s recommended to follow two key steps: FAT (Factory Acceptance Test) and SAT (Site Acceptance Test). CDA USA offers full support in implementing these processes.
These two procedures, typically initiated by the machine operator, provide added assurance that the machine meets technical specifications and performs flawlessly in your production environment. It’s crucial for the manufacturer to fully understand all details to respond quickly and ensure the equipment’s compliance.
What is FAT (Factory Acceptance Test)?
FAT is conducted at our facility before the machine (filler, capper, labeler, monobloc, or complete line) is shipped, and it takes place with the client present. Several tests are carried out to verify the machine’s proper operation and compliance with the specifications set at the time of order. This test simulates near-real conditions, requiring a significant number of samples to run the machine over a specified period.
At CDA USA, your project manager and the production team responsible for building the machine will assist you throughout the testing and verification process.
Main Objectives of FAT:
- Compliance with technical specifications: FAT ensures the machine meets the order’s criteria, not just in terms of speed and precision but also in key areas like safety checks, mechanical plan compliance, and electrical verifications. It also includes validating mandatory technical documents (manuals, electrical and pneumatic diagrams) and ensuring the machine meets specific project requirements.
- Functionality validation: FAT ensures that all functions listed in the quote or project specifications are present and working correctly in all operating modes: automatic, semi-automatic, and degraded. For example, if a marking presence control is required, it’s important to confirm that the sensor is installed, works properly for all formats, and can only be deactivated by authorized personnel.
- Performance verification: During FAT, the machine is tested under conditions that closely simulate real production. For example, with a filler, the accuracy of the dosage and filling speed is tested. For a capper, the torque control is verified, and for a labeler, the speed and accuracy of label application are checked.
Why is FAT Important?
FAT allows the client to validate the machine’s components and confirm compliance before shipment, reducing the risk of issues after installation at the client’s site. By identifying and resolving any potential issues before delivery, FAT ensures the machine is ready for smooth integration into the production line.
What is SAT (Site Acceptance Test)?
SAT is performed after the machine is installed at the client’s facility, unlike FAT, which takes place at our site. This final check ensures that any adjustments made during FAT are effective and that the machine works optimally in its specific production environment.
It’s important to note that our machines are manufactured and adjusted under the specific conditions of our workshop (temperature, pressure, humidity, lighting, etc.). When a machine is installed in a region where these conditions differ, some components may need further adjustments to ensure smooth operation. These adjustments are necessary to guarantee optimal performance in the new environment.
Main Objectives of SAT:
- Installation Qualification (IQ): IQ verifies that the equipment has been installed according to the approved specifications and the manufacturer’s recommendations. This includes verifying the necessary documentation, installation plans, and the proper assembly of all components.
- Operational Qualification (OQ): OQ ensures that the equipment operates correctly within its intended operating ranges. It includes testing safety devices, user interfaces, and performance under both normal and degraded conditions.
- Performance Qualification (PQ): PQ checks that the machine achieves the specified performance levels consistently under real production conditions. It also ensures that the final product meets the required quality standards.
Why is SAT Important?
Although FAT validates the machine’s functionality, SAT is essential to confirm that the equipment integrates smoothly into the client’s production line and operates effectively in real-world conditions.
FAT vs. SAT: What Are the Key Differences?
|
FAT (Factory Acceptance Test)
|
SAT (Site Acceptance Test) |
|---|---|
| Conducted at the manufacturer’s site |
Conducted at the client’s site
|
| Verifies technical specifications |
Verifies integration into the production environment
|
| Tests general functionality and performance |
Tests performance under real conditions
|
| Validates the machine before shipment |
Validates the machine in its final environment
|
Conclusion
FAT and SAT are both essential and complementary steps in the integration process of your packaging machines, whether it’s a filler, capper, or labeler. FAT ensures the machine is compliant and functional before shipment, while SAT confirms it operates properly on-site under real production conditions.
At CDA USA, we are dedicated to supporting our clients at every stage, from FAT to SAT, to ensure a successful installation and optimal production. For more information about our machines or our FAT/SAT services, feel free to contact us.
