What Should a Factory Acceptance Test Include for a Packaging Machine?

Purchasing a packaging machine involves more than reviewing technical specifications, comparing quotations, or checking whether the equipment can run. Before shipment, buyers also need to know whether the machine can meet the agreed production requirements under realistic operating conditions.

A Factory Acceptance Test (FAT) helps verify the equipment before it leaves the manufacturer's factory. For automatic food packaging equipment, this may include testing with the actual product, checking filling accuracy, evaluating finished package quality, measuring production speed, and recording any problems identified during the trial.

However, a machine running successfully during a short demonstration does not automatically mean it meets every project requirement. The test needs clearly defined objectives, suitable testing conditions, measurable acceptance criteria, and documented results.

In this guide, we explain what a packaging machine FAT should include, how buyers can prepare for it, and what should be agreed upon with the manufacturer before production begins.

1. What Is a Factory Acceptance Test (FAT)?

A Factory Acceptance Test is a series of inspections and functional tests conducted at the equipment manufacturer's facility before shipment. Its purpose is to check whether the machine meets the agreed technical specifications and project requirements.

For a packaging machine, a FAT may cover:

• Mechanical and electrical configuration.

• Machine functions and safety-related features.

• Product feeding, filling, weighing, and dosing performance.

• Packaging speed and finished package quality.

• Operation with the specified packaging material.

• Alarms, adjustments, and relevant changeover functions.

• Test results, outstanding issues, and corrective actions.

The exact scope depends on the machine type, product, automation level, and purchase contract.

For example, a vertical form fill seal (VFFS) machine packaging powder requires different performance checks from a liquid filling machine or a complete bottle filling and capping line.

Buyers should therefore avoid relying on a generic FAT checklist alone. The test plan should reflect the actual equipment configuration and the production conditions the machine is expected to handle.

FAT vs. SAT: What Is the Difference?

FAT and Site Acceptance Test (SAT) serve different purposes.

A successful FAT does not eliminate the need for site commissioning. Actual production performance may also depend on site power supply, compressed air, upstream feeding systems, downstream equipment, operator training, and environmental conditions.

For projects involving complete packaging lines, it is useful to define both FAT and SAT responsibilities before signing the contract.

2. Confirm the Technical Configuration Before Testing

Before starting a FAT, both parties should confirm that the machine being tested matches the agreed quotation, technical proposal, and purchase contract.

This step is important because performance results are meaningful only when the tested configuration is the one the buyer expects to receive.

The pre-test review should cover:

Machine configuration: Confirm the model, dosing system, automation level, and any agreed options.

Product contact materials: Verify the specified materials for the hopper, filling components, product pathways, and other relevant parts.

Electrical components: Check the agreed PLC, HMI, servo motor, inverter, sensors, and other key components where specified.

Packaging specifications: Confirm the bag style, dimensions, film structure, sealing requirements, and other relevant packaging details.

Utilities and operating conditions: Clarify the required voltage and frequency, compressed air supply where applicable, and any other operating requirements.

Documentation: Identify which drawings, manuals, electrical documents, spare-parts lists, and test records will be supplied.

Not every FAT requires a detailed inspection of every internal component. The inspection scope should be proportional to the project and based on the agreed technical documentation.

Resolving configuration discrepancies before testing helps prevent disagreements during final acceptance.

3. Test the Machine with the Actual Product

One of the most important parts of a packaging machine FAT is the product trial.

A machine may run well with a convenient test material but behave differently when handling the buyer's actual product. Variations in density, particle size, viscosity, temperature, moisture, or flow characteristics can affect feeding, filling, dosing, and packaging performance.

Whenever practical, buyers should provide representative product samples before the FAT.

Why Real Product Testing Matters

For powder packaging machines, bulk density, flowability, particle size, and moisture sensitivity may influence dosing consistency and filling speed.

For granules, particle size distribution and flow characteristics can affect the repeatability of filling and the risk of product becoming trapped in sealing areas.

For liquids and pastes, viscosity, temperature, suspended particles, and foaming behavior can influence filling accuracy, dripping, and sealing quality.

For products containing oil, pulp, or sticky ingredients, residue around the filling outlet may also affect cleaning requirements and production stability.

The product trial should use the agreed product or a representative material whose differences from the actual product are understood and documented.

What Should Be Recorded?

During the trial, record:

• Product name and relevant characteristics.

• Sample quantity and any limitations.

• Product temperature or other controlled conditions, where relevant.

• Dosing settings and machine parameters.

• Packaging material and bag dimensions.

• Any product feeding, residue, leakage, or sealing issues observed.

If the actual product is unavailable, the FAT report should clearly state which substitute material was used and which performance requirements still need confirmation.

A successful test with a substitute material should not automatically be treated as proof that the machine will achieve identical results with the actual product.

4. Verify Filling Accuracy and Weighing Performance

Filling accuracy is a critical acceptance item for many food packaging applications because it affects product giveaway, compliance with declared net quantity, and production consistency.

The test method depends on the dosing system and product.

For example:

• Auger fillers: Evaluate the consistency of powder doses under the agreed operating conditions.

• Multihead weighers: Check the distribution of individual package weights and the relevant weighing performance.

• Volumetric cup fillers: Evaluate whether the selected cup configuration provides acceptable results for the specified product.

• Liquid filling systems: Measure the delivered quantity using a suitable method for the product and dosing system.

How Should Filling Accuracy Be Tested?

First, agree on the target fill weight or volume and the permitted deviation.

Then define how samples will be collected and measured. A typical procedure may involve collecting consecutive packages at the agreed machine settings, weighing each package with a suitable calibrated instrument, and recording the results.

The test plan should specify:

1. Target weight or volume.

2. Sample size and sampling frequency.

3. Measurement equipment and method.

4. Permitted deviation or statistical acceptance criteria.

5. Whether the results refer to gross weight, net product weight, or another defined measurement.

6. Operating conditions under which the test is valid.

For example, a buyer may request that a powder packaging machine fill a target of 500 g per bag within a specified tolerance. The actual tolerance and sampling method must be agreed upon based on the product, dosing system, applicable regulations, and project requirements.

There is no single filling accuracy figure that applies to every packaging machine.

It is also important to distinguish between average fill weight and package-to-package variation. An acceptable average does not necessarily mean that individual packages meet the agreed limits.

A useful FAT report records the individual measurements, not just a statement that filling accuracy is acceptable.

5. Verify Packaging Speed and Continuous Running

A packaging machine's advertised maximum speed may differ from the speed achievable with a particular product, bag size, and packaging material.

Actual performance can be affected by product flow, dosing time, sealing conditions, film handling, bag dimensions, and operator intervention.

For this reason, buyers should agree on the performance metric before testing.

Define the Required Production Speed

Specify whether the target refers to:

• Machine cycles per minute.

• Packages produced per minute.

• Good packages per minute.

• Total packages produced per hour.

These measurements are not always equivalent. For example, a multi-lane machine may produce several packages per cycle, while rejected packages reduce the number of acceptable finished packs.

The test conditions should identify the product, package size, packaging material, and machine settings used to measure speed.

Why Continuous Running Matters

A brief demonstration may show that the machine can start, fill, and seal a package. A longer test provides more information about whether it can maintain stable operation.

Depending on the project, the FAT may include a defined continuous-running period during which the team records:

• Actual production rate.

• Unexpected stops and their causes.

• Product feeding interruptions.

• Film tracking or tension problems.

• Sealing defects.

• Alarm frequency and recovery time.

• Operator adjustments required during operation.

The required duration should be agreed upon in advance. There is no universal running period suitable for every packaging machine or project.

For example, a buyer may specify a 60-minute continuous test at an agreed production speed, with a defined method for counting downtime and rejected packages. A more complex line may require a longer test or additional operating scenarios.

The objective is not simply to run the machine for a certain number of minutes. It is to determine whether the machine can meet the agreed performance requirements under reproducible conditions.

6. Inspect Finished Package Quality

Even when filling accuracy and production speed meet the targets, the finished package must also satisfy the agreed packaging requirements.

Package quality checks should reflect the bag style, film material, product characteristics, and intended use.

For flexible food packaging, common inspection items include the following.

Seal Integrity

Check whether the seals are complete, consistent, and free from visible defects such as wrinkles, contamination, burn-through, or incomplete sealing.

Where leakage resistance is important, define an appropriate leak or seal-integrity test. Visual inspection alone may not detect every leak.

The test method should suit the package structure and the product. A package intended to contain liquid may require different checks from a dry powder pouch.

Bag Dimensions and Appearance

Verify the finished bag dimensions against the approved specification.

Inspect the position of seals, cutting accuracy, film tracking, and overall appearance. For printed film, check the registration of printed graphics against the agreed reference points.

For products that require a specific bag shape or presentation, include those requirements in the acceptance checklist.

Product Contamination in the Seal Area

For powder, granule, and sticky-product applications, inspect whether product residue enters the sealing area.

Contamination between the sealing surfaces may compromise seal quality and contribute to leakage.

Testing should cover the product and operating conditions expected in production, rather than relying solely on clean, empty film trials.

Functional or Transport Tests

Where required, additional checks may include opening behavior, compression resistance, drop testing, or other tests relevant to the package's intended handling and distribution.

Not every test is necessary for every project. The appropriate tests and acceptance limits should be selected based on product risk and packaging requirements.

7. Check Machine Functions, Alarms, and Safety Features

A FAT should also evaluate the machine's normal operation and relevant abnormal conditions.

Depending on the equipment, this may include:

• Start, stop, and emergency-stop functions.

• Operation of the HMI and agreed recipe settings.

• Detection of film or product feeding problems.

• Relevant temperature alarms and sealing controls.

• Fault messages and recovery procedures.

• Interlocks and guards specified for the machine.

• Changeover and adjustment functions.

• Agreed automatic or integrated line-control functions.

Safety-related tests should follow the manufacturer's documented procedure and applicable requirements. They should not involve bypassing protective devices or exposing personnel to unnecessary hazards.

For automated lines, buyers should also check how the packaging machine interacts with upstream and downstream equipment where these functions are included in the supply scope.

For example, if a downstream conveyor or checkweigher stops the line, the FAT may need to verify the agreed response of the packaging machine and its control system.

The report should identify any functions that could not be tested at the factory because the required external equipment, site utilities, or integration interfaces were unavailable.

8. Record Faults, Adjustments, and Corrective Actions

A FAT is not only a demonstration. It is also an opportunity to identify issues before the machine is shipped.

During testing, maintain a record of unexpected stops, packaging defects, parameter changes, and corrective actions.

A useful fault log includes:

Not every adjustment indicates a machine defect. Some adjustments are part of normal setup for a specific product or packaging material.

The important distinction is whether the machine can achieve the agreed requirements through normal, documented adjustments or whether an unresolved issue prevents acceptance.

If a critical test fails, the parties should agree on the corrective action and whether a full or partial retest is required.

Outstanding items should be documented with clear responsibilities and deadlines rather than being left as informal promises.

9. Agree on FAT Acceptance Criteria Before Signing the Contract

One of the most common sources of disagreement is an acceptance requirement that is too vague to measure.

Terms such as "high speed," "accurate filling," "stable operation," or "good sealing" may mean different things to the buyer and manufacturer.

To avoid this problem, define the acceptance criteria before manufacturing begins.

A project-specific FAT specification should identify:

• The machine configuration and scope of supply.

• The product and packaging materials used for testing.

• The required package dimensions and fill quantity.

• The agreed speed and measurement method.

• Filling accuracy limits and sampling procedures.

• Package quality and seal-integrity requirements.

• The duration and conditions of continuous running.

• The required functional and safety checks.

• The documentation to be delivered.

• Procedures for failed tests, corrective actions, retesting, and final sign-off.

The contract should also clarify the relationship between FAT acceptance, shipment authorization, payment milestones, and any remaining site acceptance obligations.

Example of a FAT Acceptance Matrix

The following is an illustrative template, not a universal specification. The figures and conditions must be adapted to the actual machine and contract.

Acceptance criteria should be measurable, realistic, and consistent with the capabilities of the specified equipment and the requirements of the product.

Where testing involves statistical sampling, define the sampling plan and the method used to determine whether the results pass.

10. Prepare the FAT: What Should the Buyer Provide?

Good preparation makes the FAT more efficient and improves the value of the test results.

Before the scheduled test, the buyer and manufacturer should exchange the necessary technical information.

Product Information

Provide the product name, ingredients or relevant characteristics, target fill weight, product temperature where applicable, and any special handling requirements.

For powders, include information about bulk density, particle size, flowability, and moisture sensitivity when available.

For liquids and pastes, provide viscosity, temperature range, particle characteristics, and any relevant foaming or residue behavior.

Packaging Samples

Provide the approved bag dimensions, packaging film specifications, drawings, or physical samples.

For printed film, confirm artwork registration and any special requirements for cutting and sealing.

For premade pouches, confirm the pouch structure, dimensions, opening design, and closure requirements.

Production Targets

Clarify the expected output, acceptable fill-weight variation, required package quality, and intended operating conditions.

If the project includes an integrated production line, specify the expected line speed and the responsibilities of upstream and downstream equipment.

Acceptance and Witnessing Arrangements

Agree on the FAT date, test plan, responsible participants, documentation, and sign-off process.

If the buyer cannot attend in person, consider whether a live video demonstration, recorded evidence, or third-party inspection is suitable for the project.

Remote witnessing should still follow an agreed test procedure and provide sufficient evidence to evaluate the specified requirements.

Conclusion: A Well-Defined FAT Reduces Project Risk

A Factory Acceptance Test gives buyers an opportunity to verify packaging equipment before shipment and resolve problems while the machine is still at the manufacturer's facility.

An effective FAT goes beyond checking whether the machine starts and runs. It evaluates the agreed configuration, performance with representative product, filling accuracy, production speed, finished package quality, continuous operation, machine functions, and documented corrective actions.

The most important step is to define measurable acceptance criteria before manufacturing begins. This helps both parties understand what will be tested, how the results will be evaluated, and what must happen if a requirement is not met.

At Keypack Intelligent, we work with customers to understand their products, packaging formats, production targets, and technical requirements when preparing packaging equipment proposals.

If you are planning a new packaging project, preparing a FAT specification, or evaluating a machine before purchase, sharing your product sample, target bag dimensions, required output, and acceptance criteria can help make the technical discussion more precise.

Contact Keypack Intelligent at shkpack.com to discuss your packaging project and identify the appropriate testing requirements before shipment.