Download the FAT checklist
Use the blank checklist to agree the project evidence before the witness test. It deliberately contains no invented speed, torque or leak limits.
Factory acceptance
Factory acceptance testing for a ROPP capping machine.
A ROPP factory acceptance test should prove the contracted machine scope with controlled packaging, agreed quality methods and defined line conditions before shipment. It should also identify what remains to be proven at the customer’s site.
Purpose
Turn the quotation and sample trial into a witnessed release decision.
The FAT is a structured check against the agreed machine specification. For ROPP capping it normally combines document review, functional checks, closure-quality evidence, timed operation, abnormal-state testing and a recorded action list. The test scope must name the bottles, closures, cap feed, conveyors, guards, controls and inspection devices that are actually included.
A FAT is not the same as final site acceptance. Utilities, connected machines, product conditions and the customer’s production environment may only be available after installation. Those remaining items should be transferred into a clear site acceptance test rather than left implicit.
FAT prerequisites
- Approved machine and line scope
- Production-equivalent bottles and closures
- Packaging drawings and identified sample lots
- Agreed accepted-bottle definition
- Opening, leak and visual test methods
- Timed-run and reject-counting rules
- Named witnesses and sign-off authority
- Known exclusions and site-only tests
Test structure
A practical ROPP capper FAT sequence.
The order matters: verify the build and functions before using production samples, then retain raw evidence rather than only a summary statement.
Review scope and documentation
Confirm machine identity, drawings, change-parts list, manuals, component schedule, included safety functions, utilities and the outstanding action list. Record any variance from the agreed scope.
Exercise machine functions
Check normal controls, mode selection, access devices, alarms, bottle and cap detection, no-bottle/no-cap logic where specified, line-ready signals and controlled stops. Safety verification must follow the project risk assessment and applicable competence requirements.
Approve first-off closures
Use the identified bottle and closure format to establish cap placement, compression, thread and pilfer-band settings. Compare the first-off samples with the agreed visual and performance methods before a timed run starts.
Run the agreed production condition
Define whether the output is gross cycles, accepted finished bottles or net production after planned stops. State the cap replenishment method, line feed, inspection frequency and treatment of rejects.
Test abnormal states and recovery
Where included in the scope, demonstrate low caps, missing bottle, downstream blocked, controlled emergency stop, restart and jam recovery. Check that a restart does not release uninspected or double-capped bottles.
Complete changeover and handover
Demonstrate the agreed format change, labelled parts, settings and first-off approval. Record results, deviations, owner, due date and whether each item must be closed before shipment or transferred to SAT.
Acceptance matrix
Separate equipment function, pack quality and line performance.
These evidence groups answer different questions and should not be collapsed into one pass/fail line.
| Evidence group | Typical checks | Record |
|---|---|---|
| Equipment completeness | Identity, included options, change parts, manuals, drawings, controls, guards and project utilities. | Scope checklist and deviation register. |
| Closure formation | Cap height, liner contact, thread definition, pilfer-band tuck, bridge condition and decorative finish. | Approved samples and close-up images linked to machine settings. |
| Finished-pack performance | Project-approved opening method, leak or pressure method and any storage/conditioning requirements. | Raw measurements with bottle, closure, head and lot identity. |
| Production behaviour | Timed run, cap replenishment, bottle flow, rejects, stops, restart and downstream block. | Run log, accepted-output definition, fault log and reject classification. |
| Format change | Parts, settings, access, cleaning, first-off approval and retained sample. | Changeover record and format-specific set-up sheet. |
General FAT reference
Independent inspection guidance describes FAT as verification against technical and contractual requirements before equipment leaves the factory. The exact test plan remains project-specific.
FAT versus SAT
Define where each acceptance question will be answered.
| Question | Factory acceptance test | Site acceptance test |
|---|---|---|
| Machine build and controls | Check against the agreed supply scope using factory utilities and simulations where necessary. | Confirm installed condition, local isolations, connected signals and final risk-control interfaces. |
| Packaging compatibility | Prove the approved bottles and closures on the supplied tooling. | Confirm current production lots and site handling have not introduced a new variable. |
| Line behaviour | Test the included feeder and conveyor arrangement or a defined simulation. | Prove the actual filler, transfers, inspection, coding, labelling and accumulation interfaces. |
| Output | Record the agreed factory run condition and accepted-bottle definition. | Confirm the connected line can sustain the agreed condition at the customer’s site. |
| Training and records | Demonstrate set-up and retain trial evidence. | Train the named operators and maintenance team on the installed equipment. |
Important: a FAT does not replace a site-specific risk assessment, installation verification or customer quality approval. The responsible parties should agree those boundaries before the order is released.
Related preparation
Build the FAT from controlled pack evidence.
The strongest acceptance plan starts before the witness date. First complete the ROPP sample trial, define the finished-cap inspection plan, confirm the cap-feed interface and record the site handover requirements.
FAT enquiry information
- Machine and option scope
- Formats and change parts
- Required witnesses
- Test product or safe substitute
- Accepted-bottle definition
- Run duration and interruption rules
- Site-only tests and handover owners
Buyer questions
ROPP machine FAT questions.
Does the FAT prove every site condition?
No. The FAT proves the agreed factory scope. Final utilities, connected machines, local environment and production procedures may need to be verified during installation and SAT.
Should every capping head be sampled?
For a multi-head machine, samples should be traceable to each relevant head or station so a local setting problem is not hidden by an overall average.
How should output be reported?
Define whether the result is gross cycles or accepted finished bottles and state stops, rejects, cap replenishment, inspection and line-feed conditions.
What happens to FAT deviations?
Each deviation should have a disposition, responsible owner and due date, with a clear decision on whether it must close before shipment or can transfer to site acceptance.
Can the customer bring its own test equipment?
Yes, provided the instrument, method, calibration status and result interpretation are agreed before the test.
Define a ROPP FAT that produces usable evidence.
Send the machine scope, packaging formats, acceptance methods, run definition and site interface list for review.