Tube-entry challenge
Include the longest, softest or most naturally curved dip tube and the bottle opening most likely to catch it. Record tube-end condition before and after feeding.
Acceptance testing
Trigger capper FAT and SAT checklist
Define representative samples, operating conditions, quality checks and recovery tests before accepting a trigger capping machine.
Acceptance planning
Define the test conditions before the trigger capper is demonstrated
A useful factory acceptance test and site acceptance test should prove the agreed duty rather than only show that the machine moves. For trigger closures, the test plan needs to identify the bottle, trigger body, dip tube, neck finish, filled weight, feed method, operator tasks and quality rules used for every result.
The factory test can verify the built machine, controls, tooling, changeover and representative pack handling before dispatch. The site test then confirms installation, utilities, line interfaces, production materials, operator handover and recovery in the real environment. Neither stage should rely on a speed figure without stating the conditions behind it.
- Use production-intent bottles, trigger sprayers and dip tubes.
- Define accepted output, rejects, stops and normal replenishment.
- Agree cap-height, torque, thread and cosmetic checks before the run.
- Include starved, blocked, stop, restart and jam-recovery states.
- Record open actions, owners and evidence required before closure.
FAT and SAT matrix
Separate factory evidence from site evidence
The same requirement may be checked at both stages, but the operating environment and evidence are different.
| Acceptance subject | Factory acceptance evidence | Site acceptance evidence |
|---|---|---|
| Approved formats | Run the agreed reference bottle and the approved extremes that materially change tube entry, bottle support or closure handling. | Confirm the delivered tooling and settings against production bottles, triggers, product condition and normal component supply. |
| Closure feeding | Record bulk loading, orientation, recirculation, tube condition, buffer level and hand-off to the placement station. | Confirm replenishment access, operator workload, site storage, line-demand signals and response to short stops. |
| Placement and pre-threading | Check tube entry, cap centring, seating and clean thread start across representative component variation. | Repeat with site conveyors, filled-weight bottles and normal upstream bottle spacing. |
| Tightening quality | Use the agreed torque or closure-quality method, cap-height reference points and appearance standard. | Confirm the same method, instrument, sample timing and acceptance window with site quality personnel. |
| Accepted output | State run duration, feeder arrangement, operator duties, planned checks, rejected packs and treatment of stops. | Measure saleable output while the connected line performs normal filling, conveying, inspection and downstream work. |
| Fault and recovery | Demonstrate safe stops, affected-pack identification, controlled clearance and first-good-pack approval after restart. | Confirm line-wide stop logic, isolation boundaries, access, communications and the disposition of bottles held between machines. |
| Changeover | Record parts, tools, settings, recipes, checks and time to a stable approved run for the selected formats. | Repeat with the site team and confirm storage, identification, cleaning and first-off release arrangements. |
| Documentation and training | Review manuals, drawings, settings sheets, spare-parts information and outstanding actions. | Record operator, setter and maintenance handover using the installed machine and agreed safe working procedures. |
Representative samples
Build a risk-based bottle and closure test matrix
Testing every possible combination is not always practical. Select the formats that challenge different parts of the process and record which combinations were not run.
Bottle-stability challenge
Include the lightest, tallest, narrowest or most flexible filled bottle. Confirm guide and clamp contact without unacceptable distortion or marking.
Orientation challenge
Include trigger bodies with asymmetric actuators, shipping clips or nozzle direction requirements that change the feeder and hand-off rule.
Thread-engagement challenge
Include the closure and neck-finish combination most sensitive to cocking, cross-threading or incomplete seating.
Changeover challenge
Choose formats that require different guides, grippers, heights, wheels, chucks or recipes so the full change procedure is exercised.
Line-interface challenge
Use the bottle pitch and upstream/downstream conditions most likely to starve or block the capping stage.
Evidence record
Record measurements, interventions and affected packs
Video can support a witness record, but it should be linked to the approved test case and measurable result.
Before the run
Record requirement revision, machine configuration, sample identifiers, product or filled weight, operator roles, instruments, acceptance limits and planned run states.
During the run
Record start and finish times, accepted quantity, rejects by reason, stops, replenishment, adjustments, alarms, recovery actions and samples retained for review.
After the run
Confirm cap height, torque or agreed closure test, tube condition, thread engagement, cosmetic quality and disposition of every affected pack.
Close-out
List deviations and open actions with an owner, due point and evidence required. Separate items that block dispatch or production from observations that do not.
Use the trigger capping quality inspection guide to define pack checks, the controls and sensor guide to define line states, and the installation and commissioning page to prepare the site.
Buyer questions
FAT and SAT questions for trigger capping projects
Does a FAT prove the final production rate?
It can demonstrate an agreed reference duty under stated factory conditions. Final accepted site output still depends on production components, utilities, connected machinery, operator work and the agreed quality definition.
Should the test include feeder replenishment?
Yes when replenishment is part of normal production. A short run with a full buffer can hide operator workload, nesting, tube tangling or starvation risk.
Should empty or filled bottles be used?
Empty bottles can support setup checks, but filled-weight samples are normally more representative for stability, guide contact and conveyor behaviour.
What happens to untested formats?
List them explicitly and record the engineering basis for approval, the remaining risk and any site test required before release.
Can video replace measured evidence?
Video is useful for motion, sequence and witness context. It should not replace agreed output, defect, cap-height, torque or recovery records unless that has been accepted in advance.
Who should witness the SAT?
Include the people responsible for production, quality, engineering and safe operation where their acceptance responsibilities are affected.
Prepare a trigger capper acceptance plan
Send the bottle, closure, dip tube, format range, line interfaces and quality checks so the machinery scope and trial conditions can be reviewed.