Plastic Extrusion Line Factory Acceptance Test Checklist

A factory acceptance test, often called a FAT, gives the buyer and supplier a structured way to check a plastic extrusion line before shipment. A useful FAT connects the trial material, tooling, product size, operating conditions, measurements and records to the technical agreement.

The checklist below can be adapted for pipe, profile, sheet, board, hose, strap and pelletizing equipment. It is a planning aid. The signed contract, product standard, machine manuals and applicable local requirements remain the project-specific basis.

1. Freeze the FAT scope before the trial

Start with the latest agreed equipment list and technical specification. Identify the machines, moulds, dies, calibrators, change parts, controls and optional functions included in the test. Mark any item that cannot be demonstrated until installation at the buyer’s factory.

Name the product to be made during the test. Record its material, size, wall or thickness, structure, colour or surface requirement, applicable drawing or standard and the target output basis. If the final product range includes many sizes, agree which representative size or sizes will be tested and how the remaining range will be verified.

2. Confirm materials, tooling and measuring equipment

Item	What to record before testing
Raw material	Polymer or formulation, grade where relevant, moisture or preparation condition, colour and quantity available
Tooling	Die, mould, calibrator, sizing parts, inserts and change parts used for the selected product
Utilities	Voltage, frequency, cooling-water condition, compressed air and other services available for the trial
Measurement	Instrument name, range or resolution where needed, calibration status and responsible person
Test record	Drawing or standard revision, data sheet, sample identification and photo or video naming method

Material differences can change processing behaviour and product results. The record should make clear whether the trial uses the buyer’s intended material, a supplier-provided substitute or a limited quantity. Do not compare output figures without recording the material and product size behind them.

3. Inspect the complete line before running material

• Match machine names, quantities and main identification details to the agreed scope.
• Check that guards, access points, emergency stops and warning labels are present for the trial configuration.
• Review visible piping, cables, connectors, lubrication points and utility interfaces.
• Confirm the installed tooling and the direction of product flow through each downstream unit.
• Record optional equipment, buyer-supplied items and parts that will ship separately.

The inspection should be performed by competent people using the supplier’s procedure. A FAT does not replace commissioning, site risk assessment or checks required after transport and installation.

4. Record start-up and stable operating conditions

Record the agreed start-up sequence and the settings used once the line reaches a stable condition. Depending on the process, the record may include temperature zones, screw speed, line speed, vacuum or pressure, cooling conditions, haul-off settings, cutting or winding settings and the time used to reach stable production.

Define the observation period before the trial begins. Short demonstration runs can confirm functions, but they may not be enough to evaluate sustained output, temperature stability, winding consistency or repeated cutting. The report should state the actual duration rather than implying a longer test.

5. Measure the product against agreed criteria

Use the product drawing, sample agreement or applicable standard to define the measurements. Examples may include outside dimensions, wall or thickness, weight per length or area, profile geometry, layer structure, surface appearance, cut length, coil format or pellet form. The relevant checks differ by product, so list them before the trial.

Identify each retained sample and connect it to the recorded settings and measurement sheet. If a property needs laboratory conditioning or testing that cannot be completed during the FAT, record who will test it, the method, the sample set and how the result affects acceptance.

6. Verify the output basis and material balance

An output statement is meaningful only with a named material, product size, product quality condition and measurement period. Agree whether output will be calculated from weighed acceptable product, line speed and product weight, or another written method. Separate start-up scrap, rejected product and acceptable product where the test plan requires it.

Also record the settings and utilities used to obtain the result. A single peak reading should not be presented as a sustained production result unless the agreed method defines it that way.

7. Test controls, alarms and change functions

Operate the controls that are part of the agreed line. Check normal start and stop functions, speed coordination, displayed process values, counters, recipes where included, alarms and interlocks that can be tested safely. Record functions that require site utilities, connected equipment or production conditions that are unavailable at the supplier’s factory.

If product changeover is important, define the part of the change that will be demonstrated. Record the tooling, settings, time boundary and additional parts involved instead of relying on a general statement that the line can make several products.

8. Close the FAT with documents and an open-item list

1. Attach the signed test sheet, measured results, settings and identified sample list.
2. List photographs and videos by machine, product and test stage.
3. Check the agreed document list, spare-parts list and tooling list.
4. Record every deviation or unfinished item with an owner, action and completion evidence.
5. State which checks must be repeated during site commissioning.
6. Have authorized representatives record the result against the agreed acceptance procedure.

Frequently asked questions

Does a FAT prove every product size in the range?

Usually a project selects representative products because changing every tool and running every size may be impractical. The agreement should state which sizes are tested and what evidence supports the remaining range.

Can video replace an in-person FAT?

Video can document agreed steps when remote participation is accepted, but the plan still needs material identity, product measurements, operating records and clear sample traceability. The buyer and supplier should agree the remote procedure in writing.

What happens when an item does not pass?

Record the observation, the related acceptance criterion, the corrective action, the responsible party and the evidence required for closure. The contract should define whether the item needs a repeated test before shipment or can be closed by another agreed method.