Canning Line FAT Checklist: What Buyers Should Verify Before Shipment

Canning Line FAT Checklist: What Buyers Should Verify Before Shipment

A factory acceptance test, or FAT, is one of the most important checkpoints in a commercial canning-line project.

By the time FAT begins, the equipment has usually been engineered, assembled, wired, programmed, and prepared for shipment.

But the purpose of FAT is not simply to confirm that the machine turns on.

It is to verify that the system performs against the agreed project scope before it leaves the factory.

For breweries and beverage producers, that means confirming more than headline speed.

A useful FAT should review:

  • Product and package conditions
  • Test duration
  • Throughput
  • Fill consistency
  • Seam performance
  • Controls and alarms
  • Changeovers
  • Cleaning functions
  • Documentation
  • Open deviations
  • Final acceptance

The goal is simple:

Before the equipment ships, both the buyer and manufacturer should understand what was tested, what passed, what remains open, and what will be completed during commissioning.

This guide provides a practical framework for reviewing a commercial canning line before shipment.

1. Start by Defining the FAT Conditions

A meaningful FAT begins before the first can enters the machine.

The test conditions should be documented so everyone understands what the results represent.

Depending on the project, confirm:

  • Can size
  • Can type
  • Lid specification
  • Product or test liquid
  • Product temperature
  • Carbonation condition, if applicable
  • Supply pressure
  • Line configuration
  • Conveyor configuration
  • Installed options
  • Downstream equipment included in the test

If the actual production beverage is not available for FAT, clearly document what test medium was used.

Water testing can verify many mechanical and controls functions, but it does not necessarily reproduce every condition of a carbonated beverage.

That distinction should appear in the FAT record.

Why this matters

A statement such as:

“The line reached 100 CPM.”

does not provide enough information by itself.

A more useful record explains:

What package was running, under what conditions, for how long, and how throughput was measured?

FAT results are most valuable when the operating conditions behind them are clear.

2. Define the Test Duration

A short demonstration can confirm basic machine movement.

It does not necessarily demonstrate sustained production behavior.

Before FAT, define whether the test will include:

  • Short functional checks
  • Continuous production runs
  • Multiple production cycles
  • Start-and-stop operation
  • Changeovers
  • Alarm recovery
  • Cleaning sequences

The appropriate duration depends on the system and approved project scope.

The important point is that test duration should be agreed rather than assumed.

Questions to ask

  • How long will the line run continuously?
  • Will throughput be measured over the entire test?
  • Will stops and restarts be included?
  • Will all major machines operate together?
  • Will the same test be repeated after adjustments?

A well-defined duration makes the FAT result easier to interpret.

3. Verify Throughput the Right Way

Rated speed is important, but buyers should understand how the FAT throughput number is calculated.

Ask:

  • Where is the count measured?
  • Is the rate instantaneous or averaged?
  • Over what period is throughput measured?
  • Are startup and stopping periods included?
  • Are rejected containers included?
  • Is the complete line running or only the filler/seamer?

For example, the filler may mechanically operate at one rate while finished-package throughput is affected by:

  • Container feeding
  • Conveyor accumulation
  • Filling
  • Seaming
  • Rinsing
  • Inspection
  • Labeling
  • Packing
  • Downstream handling

The FAT should make clear whether the acceptance criterion applies to an individual machine or the complete line.

For buyers evaluating anything from a compact Magnolia canning line to higher-speed systems such as Fir , Willow , or Cypress, this distinction becomes increasingly important as line integration becomes more complex.

4. Check Fill Consistency, Not Just Line Speed

A fast line is not useful if fill performance is inconsistent.

During FAT, review how filling performance is evaluated.

Depending on the line and project scope, this may include:

  • Fill volume
  • Fill level
  • Variation between filling heads
  • Product loss
  • Foaming
  • Container handling
  • Repeatability during continuous operation

Measurements should be taken from multiple containers rather than relying on one sample.

If different filling heads are used, it is useful to understand whether samples represent the complete filling system.

Questions to document

  • How is fill consistency measured?
  • How many samples are taken?
  • Are samples taken at different points during the run?
  • Are multiple filling heads represented?
  • What adjustment is available if one position differs from another?

The acceptance method should be agreed before interpreting the result.

5. Verify Seam Performance

For a canning line, seaming is one of the most important production checks.

A seam that looks acceptable from the outside is not enough.

The FAT should confirm that the seamer is:

  • Mechanically operating correctly
  • Properly adjusted for the approved can and lid
  • Producing repeatable seams
  • Ready for detailed seam verification

Depending on the project and available inspection equipment, seam review may include:

  • External visual inspection
  • Seam thickness
  • Seam height
  • Countersink
  • Tear-down inspection
  • Overlap
  • Body hook
  • Cover hook

The exact acceptance criteria should follow the can and lid supplier's specifications.

Why this matters

Seam acceptance should not be based on a generic target copied from another package.

Different can and end specifications may require different limits.

The buyer should therefore confirm that:

  1. The correct container and lid are used.
  2. The applicable specification is available.
  3. Measurements are recorded.
  4. Any seamer adjustment made during FAT is documented.

6. Test Controls, Interlocks, and Alarms

FAT should not test only normal operation.

It should also verify how the system responds when something goes wrong.

Depending on the line, test relevant conditions such as:

  • No can
  • No lid
  • Low product supply
  • Low air pressure
  • Conveyor backup
  • Machine guard open
  • Emergency stop
  • Sensor fault
  • Seamer fault
  • Downstream equipment stopped

For each alarm or interlock, confirm:

  • Is the condition detected?
  • Does the correct machine stop?
  • Does upstream equipment respond appropriately?
  • Is the alarm clearly displayed?
  • Can the operator identify the cause?
  • Is the restart procedure clear?

Why this matters

Normal operation demonstrates what the equipment does when everything is correct.

Alarm testing demonstrates how the system behaves when production is not normal.

Both are important for production readiness.

For a broader discussion of controls, utilities, responsibilities, commissioning, and startup preparation, see What Makes Brewery Equipment Production-Ready?

7. Verify Changeover Procedures

If the canning line will run multiple container formats, FAT should verify the agreed changeover functions.

Depending on the machine, this may involve:

  • Filling-head height
  • Conveyor guides
  • Seamer settings
  • Lid handling
  • Sensors
  • Recipe selection
  • Change parts
  • Downstream equipment

The FAT record should identify:

  • Which formats were tested
  • Which formats were not tested
  • Required change parts
  • Manual adjustments
  • HMI recipe changes
  • Approximate changeover procedure

Do not assume that because a machine supports multiple formats, every format has been tested during FAT.

Document what was actually verified.

Why this matters

Changeover capability affects daily production just as much as maximum speed.

For producers running multiple SKUs, an easy and repeatable changeover may have significant operational value.

8. Verify Cleaning and CIP Functions

Cleaning should be tested before shipment when it is included in the equipment scope.

Depending on the system, verify:

  • CIP sequence
  • Valve operation
  • Pump operation
  • Filling-circuit cleaning
  • Drainage
  • HMI controls
  • Recipe or cleaning-program selection
  • Required manual steps

The FAT does not necessarily replace onsite sanitation validation.

However, it should confirm that the equipment's cleaning functions operate as designed.

Questions to ask

  • Which areas are included in automatic CIP?
  • Which components require manual cleaning?
  • What connections are required?
  • What utility conditions are assumed?
  • What cleaning steps remain the operator's responsibility?

Clearly documenting these responsibilities helps prevent confusion after installation.

9. Review Line Integration

A canning line is usually a collection of machines working as one system.

FAT should therefore review the interfaces between equipment.

Depending on the project, that may include:

  • Depalletizer or container feeding
  • Rinse
  • Filler
  • Seamer
  • Conveyors
  • Can rinse
  • Inspection
  • Labeling
  • Coding
  • Packing
  • Accumulation
  • Palletizing

Check how upstream and downstream equipment communicate.

For example:

  • What happens when downstream equipment stops?
  • Does the filler continue running?
  • Does accumulation provide enough buffer?
  • Does upstream equipment slow or stop?
  • How does the line restart?

These interactions are important because individual machines can operate correctly while the complete line still experiences production problems.

10. Review HMI and Operator Controls

FAT is a good time to review the equipment from the operator's perspective.

Confirm:

  • Main operating screen
  • Production settings
  • Recipe selection
  • Manual controls
  • Alarm history
  • Diagnostic screens
  • User access levels
  • Changeover settings
  • CIP controls

Operators should be able to understand:

  • What the line is doing
  • Why it stopped
  • What needs attention
  • What can safely be adjusted

If operator training will take place onsite during commissioning, identify which functions will be covered again after installation.

11. Confirm Documentation Before Shipment

A mechanically complete machine without the correct documentation can create unnecessary work during installation and startup.

Before shipment, confirm the status of:

  • Equipment manuals
  • Electrical drawings
  • P&IDs, where applicable
  • PLC backups
  • HMI backups
  • Component manuals
  • Recommended spare-parts list
  • Maintenance information
  • Changeover instructions
  • Cleaning instructions
  • FAT records

Not every document necessarily needs to be finalized before the machine ships, depending on the project.

If documentation remains open, identify:

  • What is missing
  • Who is responsible
  • When it will be delivered

For projects still in the RFQ stage, our Brewery Equipment RFQ Guide outlines the information manufacturers need before engineering and quoting a system.

12. Record Deviations Instead of Hiding Them

Not every FAT finishes with zero open items.

That does not automatically mean the equipment is not ready to ship.

What matters is that deviations are visible and managed.

A FAT deviation list should identify:

  • Issue
  • Equipment affected
  • Required corrective action
  • Responsible party
  • Target completion date
  • Verification method
  • Whether correction is required before shipment or can be completed onsite

Examples might include:

  • Software adjustment
  • Sensor repositioning
  • Documentation update
  • Guard modification
  • Change-part adjustment
  • Label correction

A written deviation list creates a shared reference for Engineering, Sales, Production, and the customer.

13. Define FAT Sign-Off

The final step is acceptance.

The FAT record should summarize:

  • What was tested
  • Test conditions
  • Test duration
  • Throughput results
  • Fill checks
  • Seam checks
  • Alarm tests
  • Changeovers
  • Cleaning functions
  • Documentation status
  • Open deviations

Then clearly identify the status of the equipment.

For example:

Accepted for Shipment

or

Accepted for Shipment with Open Items

or

Corrective Action Required Before Shipment

The exact language can vary by project.

What matters is that both sides understand the status before the equipment leaves the factory.

Canning Line FAT Checklist

Use this checklist when reviewing a canning line before shipment.

Product & Package Conditions

☐ Correct can format confirmed
☐ Correct lid/end confirmed
☐ Test product or liquid documented
☐ Product temperature documented
☐ Test pressure documented where applicable
☐ Line configuration confirmed

Test Duration

☐ Functional test duration defined
☐ Continuous run duration defined
☐ Start/stop testing included where required
☐ Complete-line operation verified

Throughput

☐ Target throughput documented
☐ Throughput measurement method defined
☐ Measurement period recorded
☐ Rejects handled consistently
☐ Complete-line vs. machine-level speed identified

Filling

☐ Fill performance checked
☐ Multiple samples measured
☐ Multiple filling positions represented
☐ Fill consistency reviewed
☐ Foaming or product loss observed

Seaming

☐ Correct can and lid specifications available
☐ External seam inspection completed
☐ Seam measurements recorded
☐ Tear-down inspection completed where applicable
☐ Adjustments documented

Controls & Alarms

☐ Emergency stops tested
☐ Guard interlocks tested
☐ Key alarms tested
☐ Sensor conditions tested
☐ Line stop/restart behavior verified
☐ HMI alarm information reviewed

Changeover

☐ Required formats identified
☐ Tested formats documented
☐ Change parts confirmed
☐ Adjustment points identified
☐ Recipe/settings changes verified

Cleaning

☐ CIP functions tested where applicable
☐ Pumps and valves verified
☐ Drainage reviewed
☐ Manual cleaning requirements identified
☐ Operator responsibilities documented

Documentation

☐ Manuals status confirmed
☐ Electrical drawings confirmed
☐ PLC/HMI backup status confirmed
☐ Spare-parts list reviewed
☐ Maintenance information reviewed
☐ FAT results recorded

Deviations

☐ Open items documented
☐ Owner assigned
☐ Corrective action defined
☐ Completion date identified
☐ Verification method agreed

Final Acceptance

☐ Engineering review completed
☐ Sales/project review completed
☐ Customer review completed where applicable
☐ Open items understood
☐ Shipment status approved

FAT Is a Checkpoint, Not the End of Commissioning

A successful FAT is an important milestone.

But it is not the final production test.

After shipment, the canning line still needs to be:

  • Installed
  • Connected to actual utilities
  • Integrated with the customer's production environment
  • Commissioned
  • Tested with actual products and packaging conditions
  • Handed over to trained operators

The purpose of FAT is to reduce uncertainty before shipment.

The purpose of commissioning is to confirm that the system performs correctly in the customer's facility.

Treating these as two connected stages creates a much clearer path from factory testing to production.

Planning a Commercial Canning Line?

Use the checklist above to define what should be verified during FAT before your equipment ships.

If you're planning a new packaging project, Redwood can also review your production requirements, package formats, line speed, controls, integration, and commissioning expectations before the system scope is finalized.

Explore our commercial canning line systems【Internal Link: Canning Line Collection】 or submit your project information for a technical scope review.

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