Requirement trace
Every critical specification item maps to inspection, document review, calculation, alarm or interlock test, or product test.
From order to stable operation
Plan chili sauce line installation, FAT, and maintenance before delivery.
A successful start-up depends on documents, site readiness, representative trials, defined responsibilities, trained operators, maintainable access, spares, and recorded closure of deviations.
Project sequence
- 01
Design review
Approve product and packaging basis, scope, documents, process narrative, materials, layout, utilities, controls, safety, hygiene, trials, and acceptance protocol.
- 02
Pre-FAT readiness
Close document comments, confirm test product or justified simulant, instruments, utilities, data sheets, software revision, open deviations, and witness plan.
- 03
Factory acceptance
Inspect build and records; test sequences, safety, alarms, controls, product behavior, capacity basis, samples, cleaning steps, and deviation handling against the signed protocol.
- 04
Site installation & SAT
Verify shipping condition, installation, utilities, field wiring, interfaces, calibration, safety, hygiene, real product, packaging, performance, and records in the actual facility.
- 05
Handover & sustain
Deliver as-built documents, source and backups as agreed, training, spares, maintenance tasks, warranties, deviations, baselines, and escalation paths.
FAT evidence
Test conditions
Product or simulant, temperature, recipe, particle load, pack, duration, instruments, sampling, calculations, and tolerances are recorded.
Deviation control
Failed or deferred items name the owner, disposition, due date, retest evidence, and effect on shipment or acceptance.
Product & filling FAT
A useful run covers transitions as well as the steady state.
| Test phase | Conditions to record | Acceptance evidence |
|---|---|---|
| Startup and product arrival | Initial product state, heat-up or conditioning, priming, air removal, buffer control, first containers and rejects | Approved sequence, sample disposition, stable-state entry criteria and recorded deviations |
| Sustained line run | Representative sauce, pack, speed basis, utilities, operating states, samples, fill results, closures, stops and losses | Balanced saleable output calculation, quality results and traceable instrument data |
| Interruption and recovery | Starvation, blocking, hold, restart, diversion or reject, power/utility recovery and product disposition | Cause-and-effect response, safe state, record continuity and approved recovery evidence |
| Change and cleaning | Recipe or pack change, residual product, recovery, disassembly, CIP/COP/manual steps, inspection and release | Changeover time basis, loss record, cleanability observations, exceptions and retest owner |
Maintainability
Access, inspection, and recovery are design inputs.
Review safe isolation, access platforms, lifting points, wear components, seal changes, instrument removal, valve service, clean inspection, lubrication segregation, diagnostic visibility, backups, and recovery after power or utility loss.
Ask for task-based maintenance intervals tied to actual components and duty. Stock critical spares using lead time, failure consequence, commonality, shelf life, and local availability—not an unexplained percentage of equipment price.