A Factory Acceptance Test (FAT) is the structured, documented verification that a packaging line built by the manufacturer meets your technical specification before it ships to your facility. For a turnkey filling, capping, and packaging line, the FAT is the single most important risk-reduction step between order placement and production. This guide explains what a FAT covers, the test items you should expect, and the deliverables you should require from your supplier.
What is a Factory Acceptance Test (FAT)?
The FAT takes place at the manufacturer’s workshop, on their floor, with their utilities and your agreed test protocol. You (or your delegate) witness the run. The purpose is to prove that the equipment performs to specification under controlled conditions before it is disassembled, crated, and shipped. Catching a design or integration gap at FAT is far cheaper — and faster — than fixing it after installation at your plant.
Why FAT matters for packaging lines
A packaging line is a system: fillers, cappers, labelers, conveyors, controls, and software must talk to each other. A FAT catches:
- Mechanical interference between stations at production speed.
- Control logic errors (rejection, interlocking, safety gates).
- Wrong sensors, missing guarding, or incorrect HMI labeling.
- Documentation gaps (CE, manuals, spare parts lists).
For background on how line integration is scoped, see automated packaging line integration guide.
Standard FAT test items for a packaging line
| Test category | What is verified | Pass criterion |
|---|---|---|
| Safety & guarding | Interlocks, e-stops, guards, warning labels | All devices trigger and reset per spec |
| Mechanical run | Line speed, bottle flow, no jams at target BPH | Stable run at specified output |
| Filling accuracy | Fill volume across 30–50 containers | Within ±1% nominal (or agreed tolerance) |
| Capping torque | Torque consistency across caps | Within agreed torque window |
| Rejection system | Off-spec containers rejected correctly | 100% rejection of bad units |
| Controls / HMI | Recipes, alarms, counters, access levels | All functions perform as specified |
| Documentation | Manuals, CE, spare parts list, as-built drawings | Complete and handed over |
The FAT process, step by step
- Pre-FAT protocol review — buyer and supplier agree on the test plan, acceptance criteria, and witness list.
- Site visit (supplier workshop) — buyer witnesses the line running on agreed containers and product.
- Performance testing — run at target speed; measure fill accuracy, capping torque, rejection rate.
- Documentation review — verify manuals, CE certificates, spare parts lists, as-built drawings.
- Discrepancy log — any gap is recorded, assigned, and scheduled for correction before shipment.
- Sign-off — both parties sign the FAT report; equipment released for crating and delivery.
For related guidance on avoiding integration pitfalls, see packaging machinery integration mistakes to avoid.
What deliverables to require from your supplier
A professional supplier hands over a complete FAT package. Insist on:
- Signed FAT test report with pass/fail per test item.
- As-built mechanical and electrical drawings.
- CE declaration of conformity (or applicable regional certificate).
- Operation and maintenance manuals.
- Recommended spare parts list with part numbers.
- PLC program backup and HMI recipe documentation.
FAT vs Site Acceptance Test (SAT)
The FAT is at the factory; the Site Acceptance Test (SAT) repeats key checks at your facility after installation and commissioning. The SAT confirms that the line still performs on your floor, with your containers, your product, and your operators. Together, FAT + SAT give you the highest confidence that your investment is protected. For OEE expectations after commissioning, see calculating OEE for packaging lines.
Bottom line
A well-run Factory Acceptance Test is not a formality — it is your contractual and technical safety net. Define the test protocol in advance, witness the run, require complete documentation, and sign off only when every test item passes. For turnkey line engineering, see our front-end packaging line solutions.