Bottle washer factory acceptance testing.
A factory acceptance test should show what the machine did with agreed bottles under recorded conditions. It should not rely on a short demonstration or undefined idea of “clean”.
Agree the protocol before the test.
The buyer and supplier should identify the machine configuration, bottle sample set, operating conditions, observations, acceptance criteria and treatment of exceptions in advance. The FAT then becomes evidence against an agreed brief rather than a negotiation after the machine runs.
Where bottle washing forms part of a site’s food-safety or quality-control system, the site remains responsible for determining the validation and verification approach appropriate to its hazards and process. The UK Food Standards Agency’s MyHACCP validation and verification guidance explains the general distinction between proving a control can work and checking that it continues to operate as intended.
Build a representative test matrix.
| Test element | Define before FAT | Evidence captured |
|---|---|---|
| Machine configuration | Nozzles/heads, guides, change parts, wash/dry stages and controls included | Configuration record, photographs and software/version reference where applicable |
| Bottle set | Minimum, maximum, unstable and difficult bottle; quantity for repeats | Sample IDs, dimensions, incoming photos and pre-existing damage |
| Residue/label set | Typical and worst-case contamination, age and preparation method | Traceable preparation record and pre-test observations |
| Utilities | Water quality/pressure/flow, power, air and drainage condition | Actual test readings or controlled condition statement |
| Operating cycle | Start-up, steady running, stops, restarts and changeover | Run duration, counted throughput, interruptions and operator interventions |
| Acceptance | Residue, label, moisture, damage, reject and transfer criteria | Results by sample and agreed pass/conditional/fail decision |
Include normal and difficult operation.
- Cold start and normal start-up sequence
- Steady operation for long enough to expose accumulation or operator constraints
- Controlled stop and restart with bottles in the system
- Upstream starvation and downstream blockage response where the line interface is included
- Format change for a representative second bottle
- Cleaning, drain-down and inspection access
Record exceptions without hiding them.
- Adjustment made during the run and its reason
- Rejected bottle and reject category
- Operator intervention or manual rework
- Utility deviation
- Unrepresentative sample or changed test condition
- Open action, owner and closure evidence
Differentiate FAT, SAT and process validation.
FAT demonstrates the agreed machine configuration under factory test conditions. Site acceptance testing confirms installation, services, interfaces and operation in the buyer’s environment. Process validation or qualification may require additional evidence under production conditions. The project documents should state which decisions each stage can and cannot close.
Documents to leave with the test
- Signed protocol and results
- Sample identification and preparation record
- Machine settings and utility conditions
- Photographs or video where authorised
- Measured observations and reject record
- Deviation/action list and agreed closure route
- Confirmed scope for site installation and commissioning
Continue with the post-wash inspection guide and line integration checklist.
Prepare a representative bottle trial.
Send the bottle set, residue/label description and proposed acceptance criteria so the trial scope can be reviewed before quotation.
Request an FAT-ready review