A trial, FAT and SAT should not be treated as the same event

An application trial investigates whether a product, film and pack concept can be handled. A factory acceptance test checks the agreed machine scope before dispatch. A site acceptance test confirms installation and integrated performance at the customer’s site. The project should state which risks each stage is intended to close.

Fix the test basis before materials arrive

Name the product variants, product condition, film supplier and structure, reel direction, print repeat, bag format, infeed method and acceptance criteria. Include enough material for setup, adjustment, a sustained run, changeover and repeat confirmation. Reserve a representative approved pack and record the settings used.

Define a good pack in measurable terms

Good-pack criteria can cover product position, seal continuity, cut position, print registration, code quality, appearance, absence of product in the seal and any agreed test appropriate to the pack. Avoid subjective acceptance such as “looks acceptable” without an approved reference.

Measure sustained accepted output

State the timed run, allowed planned interventions, reject rules and how starvation or downstream blockage will be recorded. Separate machine-generated losses from unavailable product, temporary manual loading or equipment outside the quoted boundary.

Include changeover and fault recovery

Where multiple formats are included, test the defined changeover using the supplied parts and approved instructions. Check start-up waste, first-off approval and repeatability. Simulate agreed line states such as no product, no film, downstream stop, inspection reject and restart without bypassing safety functions.

Evidence by project stage

Use each test to close the right risk

Flow-wrapper trial and acceptance scope
Stage	Primary purpose	Typical evidence
Application trial	Investigate product handling, film forming, sealing and pack concept before the final scope is fixed.	Trial materials, settings, pack samples, observations, open risks and a recommendation.
Factory acceptance test	Verify the agreed machine and factory-available interfaces before dispatch.	Checklist, timed run, good-pack count, alarms, changeover, documentation and signed open-item list.
Site acceptance test	Confirm installation, utilities, integrated transfers, line states and operator handover.	Site checklist, integrated run, interface tests, training record and outstanding-action ownership.
Production release	Transfer the accepted format into controlled routine operation.	Approved recipe, reference pack, film and product records, maintenance tasks and escalation route.

Test-material checklist

Supply enough representative material for setup and proof

Products

Minimum, nominal and maximum sizes
Normal production variation
Most fragile, sticky or unstable condition
Production temperature and presentation

Film and print

Production-grade reel, not a generic substitute
Technical data and unwind direction
Print mark, repeat and coding area
Enough reel length for every test stage

Acceptance records

Numbered protocol and revision
Defined pass/fail criteria
Recorded settings and results
Accepted packs and open-item list

Plan site conditions before factory acceptance

The site-preparation guide and line-integration guide identify interfaces that cannot be proved on the standalone machine.

Agree the protocol early

Make acceptance part of the quotation, not an argument at dispatch

Send the required test materials, run conditions, pack standards and project boundary with the enquiry so the proposed scope can include the necessary evidence.

Discuss a trial or FAT Review quotation factors

Questions buyers ask about acceptance

Make the approved result traceable and repeatable

A useful protocol identifies who accepts the pack, which materials were used, what remains open and what must be proved again after installation.

Who should approve the reference pack at factory acceptance?

The reference pack should be approved by named people who are authorised to represent the customer’s production and quality requirements, with the supplier recording the agreed result. The pack should be linked to the product, film reel, artwork revision, recipe, machine configuration and protocol version used during the test.

Retain more than appearance alone. Record the acceptance checks, code position, seal assessment and any limits that still require site confirmation.

What should be retested after the flow wrapper is moved to site?

Site acceptance should retest conditions that transport, installation and line integration can change. These include utilities, levels and alignment, product transfers, guarding interfaces, ready/run/fault signals, coding and inspection, reject handling, blocked and starved states, restart behaviour and operator handover.

Factory evidence can remain valid where the condition is unchanged, but the site protocol should state which checks are repeated and why.

How should unresolved factory-acceptance items be controlled?

Unresolved items should be placed on a controlled action list with a clear description, production impact, owner, target date, evidence required for closure and approval route. Separate items that prevent dispatch or safe use from minor documentation or optimisation actions.

Do not rely on meeting notes or verbal assurances. Link each item to the protocol and confirm whether it must be closed at the factory, before commissioning or during site acceptance.

How much product and film should be allowed for setup, sustained running and changeover?

The material allowance should cover threading and setup, adjustment, repeated starts, the agreed timed run, rejects, retained samples, each format change and confirmation after changeover. The exact quantity depends on pack length, reel format, trial duration, product variability and the number of conditions being tested.

Agree the calculation before materials are shipped. The output guide helps define the timed run, while the coding and inspection guide identifies additional test packs.

Flow-wrapper trials, FAT and SAT