Packaging line solutions

Installation & Commissioning

Installation and commissioning convert the approved design into a safe, repeatable operating process. A structured plan confirms utilities, access, materials, acceptance criteria and operator readiness before arrival.

Talk to us about this line Use the specification checklist

UK project supportProduct and pack trialsIntegration to handover

A coordinated production route

Specify the line as one operating process

The engineering brief should describe the required good packs at the end of the line, not only the cycle rate of individual machines. Product behaviour, component quality, replenishment, changeovers, inspection and short stops all affect the sustainable result. The line should therefore be balanced around the real production calendar and a defined operating margin.

Start with evidence

Provide representative product, containers, closures, labels and secondary packaging from the approved range. Include the most difficult combinations, dimensional tolerances and any temperature or storage conditions that change behaviour.

Typical line stages

Pre-installation readiness and site coordinationDefine the incoming condition, operator activity and transfer requirements before equipment is selected.
Positioning, levelling, connections and line interfacesMatch the process technology to representative product and packaging samples across the full approved range.
Dry testing, wet trials, recipes and format setupCoordinate the mechanical and control interfaces so upstream and downstream stages recover predictably.
Training, documentation and acceptance handoverConfirm inspection, rejection, documentation and handover requirements against measurable acceptance criteria.

What shapes the final specification

These subjects should be resolved with values, samples and named responsibilities. Where uncertainty remains, the proposal should state the assumption and the test or design review that will close it.

Specification point 1

Floor loading, access routes and installation equipment

Record the operating range, difficult extremes and any allowable variation rather than supplying only a nominal value.

Specification point 2

Electrical, compressed air, extraction and network readiness

Include controlled samples, drawings or test evidence so the design basis can be verified before manufacture.

Specification point 3

Production materials and representative samples

State the required result and how it will be checked during factory and site acceptance testing.

Specification point 4

FAT, SAT and performance acceptance criteria

Assign the interface owner and document the utilities, access, safety and maintenance implications.

Performance and acceptance

Acceptance criteria should define the tested format, material quantities, operating duration, good output, quality checks, allowable interruptions and action-closeout process. A factory acceptance test demonstrates the line before dispatch; site acceptance confirms installation, utilities, interfaces and agreed production performance in the operating environment.

Faster route to stable productionBuilt into the project brief and verified at the agreed handover stage.

Documented settings and approved formatsBuilt into the project brief and verified at the agreed handover stage.

Operators trained on normal running and changeoverBuilt into the project brief and verified at the agreed handover stage.

Open actions recorded through final handoverBuilt into the project brief and verified at the agreed handover stage.

Information to send with an enquiry

Product description, safety information and representative samples
Container, closure, label and case drawings or physical samples
Fill or pack range, target good output, batch size and shift pattern
Available layout, access, working heights and utility details
Required checks, reject handling, coding and production data
Installation window, training, spares and support expectations

Clear project answers

Installation & Commissioning FAQs

What is the difference between FAT and SAT?

Factory acceptance testing checks the equipment before dispatch; site acceptance testing verifies the installed system against the agreed site criteria.

Who supplies trial materials?

The project plan should identify quantities of product, containers, closures, labels, cases and consumables needed at each test stage.

Is operator training included?

It can be included and should cover safe operation, startup, shutdown, changeover, cleaning, routine checks and basic fault response.

Plan your next step

Turn installation and commissioning into a documented handover sequence

A successful site phase depends on work completed before equipment arrives: access, utilities, floor and layout, production materials, people, permits, safety interfaces and acceptance methods. The project plan should state what Lancing, the customer and any third party must provide at each gate.

Packaging line site-interface schedule

The exact responsibilities vary by project. Record the named owner and required date for every row rather than relying on standard assumptions.

Installation, commissioning and SAT responsibility schedule
Site interface	Information or preparation required	Completion evidence
Access and handling	Delivery vehicle, doorway and route dimensions, floor capacity, lifting equipment, unloading and secure storage.	Route survey, handling plan and confirmed equipment or competent contractor.
Position and floor	Approved line datum, levels, anchoring or mobility, drainage, service clearances and marked work area.	Signed layout, site measurement and readiness inspection.
Electrical and controls	Supply, isolators, earthing, cable routes, network, upstream and downstream signals and IT access where needed.	Utility schedule, completed site work and connection test.
Process services	Compressed air, extraction, water, vacuum, product feed, drainage, ventilation or other specified services.	Connection points labelled and available at the agreed condition.
Materials and people	Products, packs, closures, labels, film, cases, operators, maintenance and quality representatives.	Correct quantities and approved versions available for the commissioning and SAT programme.
Safety and permits	Site induction, work permits, isolation, guarding interfaces, temporary controls and access restrictions.	Approved method and competent attendance for the planned work.
Acceptance and release	SAT protocol, quality checks, action ownership, training, documents and authority to release production.	Signed results, controlled actions and formal handover record.

A controlled site sequence

The order may overlap, but each stage should have a clear completion condition.

Receive and position

Inspect delivered equipment, confirm location, levels, access and any transport or storage issues before connection.

Connect and inspect

Complete mechanical, electrical, utility, data and safety interfaces and record checks before energisation.

Commission functions

Prove individual movements, devices, modes, sequences, faults and safety functions using controlled materials.

Prove production

Run approved formats and product, complete SAT and quality evidence, close actions and hand over training and documents.

Materials planning for commissioning

Insufficient or unrepresentative material can delay acceptance or produce evidence that does not match normal production.

Separate setup, engineering trial, performance run, quality sampling, training and contingency quantities.
Use approved production-intent components and record batch, supplier and storage or conditioning where these affect behaviour.
Include the difficult approved formats and products, not only the easiest reference pack.
Provide safe product supply, collection, rework, disposal and cleaning arrangements for all trial material.
Confirm instruments, standards, sampling and people authorised to accept the product or finished pack.
Protect enough material and time to repeat an agreed test after corrective action where necessary.

Buyer questions

Installation and commissioning questions

What is the difference between commissioning and SAT?

Commissioning makes the installed equipment operate correctly and safely in its site environment. SAT is the agreed witnessed evidence that the specified site acceptance criteria have been met. The project documents should define both.

Who should attend packaging line commissioning?

Attendance depends on scope, but production, engineering, quality, safety and IT or facilities representatives may each own critical decisions. Name the required people and their authority before the site programme starts.

Why can a line pass FAT but require site work before SAT?

FAT uses the agreed factory setup and utilities. Site product supply, services, retained machinery, layout, environment, data systems and operator practices can introduce different interfaces that must be commissioned and accepted on site.

Turn the guidance into a project brief

Use the related pages to document the product, pack, output, layout and acceptance evidence before requesting a detailed proposal.

Use the site-readiness guide Review FAT and SAT