A beverage filling line SAT checklist should prove that the installed equipment meets defined site-acceptance requirements under agreed utilities, materials and operating conditions. Powering up the machines and producing a few containers is a startup milestone, not a complete site acceptance test.
Write the SAT protocol before shipment. Link every test to the purchase agreement, technical specification, approved drawings, product and package data, FAT record and site responsibilities.
Quick answer: Release the site, verify delivered scope and installation, close safety and utility checks, prepare approved materials, define the performance-run boundary, measure good finished output and package quality, test faults and changeover where required, record deviations, then close documents, training and the punch list.
Keep FAT, SAT and commissioning separate
The factory acceptance test checks equipment before shipment within the supplier’s available conditions. SAT repeats and extends agreed tests after the equipment is installed at the buyer’s site. It can prove site utilities, installed interfaces and functions that could not be demonstrated at the factory.
Commissioning is broader. It brings the system from mechanical completion into controlled operation. The International Society of Automation’s ISA-105 overview identifies commissioning, loop checks, FAT, SAT and site integration as related but distinct automation activities.
1. Freeze the SAT basis
List the machines, software, interfaces, product formats and documents in the test. State exclusions and owner-supplied equipment. Define acceptance limits, measurement methods, instruments, samples, run conditions, stop treatment and signatories before results are known.
The protocol should also state which FAT open items must be closed before SAT and which tests are intentionally repeated. An approved change after FAT must appear in the SAT configuration record.
2. Confirm site readiness
Release the building and work area against the installation plan. Confirm drainage, lighting, ventilation, safe access, finished surfaces where required and removal of construction debris.
Verify the line utilities at the agreed connection points. Record voltage, air, water, cooling, heat, gas and drainage conditions that apply to the test. If the utility condition is outside the approved range, resolve it or record the test limitation before continuing.
3. Reconcile delivered and installed scope
Compare nameplates, quantities, options, change parts, guards, instruments, conveyors, loose parts and supplied spares with the contract and packing list. Check the installation against the latest layout, piping and electrical drawings.
Record alignment, anchoring, leveling, conveyor transfers, pipe supports, flow direction, cable identification and accessible service points. Link each deviation to a numbered punch-list item rather than leaving it in meeting notes.
4. Verify safety and control functions
Test guards, access switches, emergency stops, reset behavior and approved isolation points within the SAT scope. Work on machinery must follow the site’s energy-control procedure. OSHA’s lockout/tagout guidance describes requirements for controlling hazardous energy in U.S. workplaces.
Complete point-to-point and loop checks as required. Challenge sensors, actuators, drives, valves, alarms, interlocks and operator-interface messages. Simulate defined starved, blocked and fault conditions so the line response can be observed and recorded.
5. Prepare representative product and packaging materials
Use approved containers or preforms, closures, labels, coding consumables, film, cartons, trays and product. Identify each material batch. Supply enough for setup, sampling, the performance run, controlled stops and repeat tests.
If water or another substitute is used, record what it can prove and what remains open. Water may demonstrate flow and basic filling motion, but it does not automatically prove behavior with carbonation, pulp, viscosity, product temperature or the validated cleaning process.
6. Release product-contact systems
Confirm that cleaning, sanitation and QA release are complete before the commercial product enters the line. The Codex General Principles of Food Hygiene provide recognized guidance on good hygiene practices and HACCP. The plant must apply the regulations and food-safety plan relevant to its product and market.
7. Define and run the performance test
State the starting condition, product and format, measurement point, elapsed-time boundary and treatment of planned and unplanned stops. Measure acceptable finished units at the agreed downstream point. A filler-cycle counter can hide rejects, missing closures, label faults and incomplete packs.
Record material input, good output, rejects, samples and stop causes according to the agreed method. Check fill, closure, label, code and secondary pack against the product and contract criteria. Use identified measurement tools with a defined status.
8. Test line interfaces and recovery
Create controlled shortages and blockages at agreed points. Observe whether accumulation works, upstream equipment responds correctly and the line returns to stable operation without uncontrolled surges. Verify communication with owner-supplied processing, inspection, warehouse or coding systems where included.
Record the fault, expected behavior, actual response and recovery step. Avoid clearing the fault informally before evidence is captured.
9. Demonstrate changeover where required
For a multi-format line, use named starting and destination SKUs. Check change parts, tools, recipes, adjustments, cleaning, material replacement and first-good-pack release. The changeover checklist provides a station-by-station structure.
If changeover time is contractual, define the start and finish boundary and which activities are included. A result has little value when the parties time different work.
10. Close documents, training and punch-list items
Review the agreed manuals, drawings, electrical documents, software backups, recipes, spare-parts lists, maintenance information and supplied certificates. Training records should identify the equipment, topics, attendees and any competency check required by the contract.
Classify open items by their effect on safety, food safety, legal compliance, performance and reliable operation. Critical items should block release. For accepted minor items, name the owner, due date, corrective action and evidence needed for closure.
SAT evidence table
| Test area | Define before testing | Keep as evidence |
|---|---|---|
| Configuration | Equipment, software, recipes and materials | Signed configuration record and photos |
| Utilities | Connection points and acceptable conditions | Readings and load condition |
| Output | Good-unit point, timing and stop rules | Counters, calculations and stop log |
| Quality | Sampling and acceptance criteria | Results, retained samples or photos |
| Deviations | Classification and release authority | Punch list, owners and closure evidence |
Paima lists installation and training among its project services. Confirm the exact SAT scope, materials, travel responsibilities, acceptance criteria and handover records in the commercial agreement. Project information can be sent through the contact page.
Frequently Asked Questions
Does passing FAT remove the need for SAT?
No. FAT and SAT occur in different locations and prove different conditions. The contract should state which tests are repeated and which site interfaces remain for SAT.
Who should sign the SAT report?
Name authorized representatives for the buyer, supplier and relevant contractors before testing. QA, production, engineering or safety representatives may sign specific sections according to the project.
How long should a SAT run last?
There is no universal duration. It must be long enough to prove the defined output, quality, material supply, utilities and operating behavior for the project risk.
Can training happen after SAT?
The sequence depends on the contract, but operators participating in trials need enough training for their assigned tasks. Final training and competency records may remain part of handover.
Can minor punch-list items remain open?
Only when authorized parties accept the risk and record the owner, due date and closure evidence. Safety, food-safety or fundamental performance failures should not be treated as minor.
