Factory Acceptance Test for Automatic Strip Packing Machine
| machine name | AUTOMATIC STRIP PACKING MACHINE |
| Client Name & Address | M/S. |
| document name | factory acceptance test |
| PROTOCOL no. | SCT/FAT/000 |
| Revision no. | 00 |
| MACHINE SR. NO. |
Table of Contents
| Sr. No. | Title | Page No. |
| 1.0 | Purpose | |
| 2.0 | Scope | |
| 3.0 | Responsibilities | |
| 4.0 | System description | |
| 5.0 | Test and inspection | |
| 6.0 | Trail report | |
| 7.0 | Fat remark |
- PURPOSE:
The Objective of this Factory acceptance test is to verify and inspection of Automatic Strip Packing Machine, by representative of ____________ at fabrication site of ____________________.
- SCOPE:
The Scope of this document is applicable to perform the factory acceptance test of Automatic Strip Packing Machine at __________________________. before deliver to ________________________________.
- RESPONSIBILITIES:
- Engineering:
- To prepare and review the factory acceptance test documents.
- To execute the FAT activity.
- Engineering:
- Manufacturing:
- To review the factory acceptance test document.
- To Co-ordinate with the engineering department during FAT activity.
- Quality Assurance:
- To review the factory acceptance test document.
- To Co-ordinate with the engineering department during FAT activity.
- Head Quality/Designee
- To approve the factory acceptance test document.
- SYSTEM DESCRIPTION :
The Strip Packing Machine is designed for packing of Tablet and Capsule within two heat sealable foil. The machine has been designed to use cellophane Film, Cellophane Lumithene, Aluminum Foil, Polythene Film Laminates and all heat sealing papers for sealing purpose.
The Tablet / Capsules are charged into the hopper. Tablets / Capsules are automatically fed to vibrating bowl. Individual Tablets passes vertically through chute provided and are enclosed between pockets formed by two plies of film. These two films are heat sealed when pass through the sealing roller. These rollers are provided with heaters.
Horizontal cutting of the strip is done by the knife and vertical cutting is done by vertical cutter.
The major component of the equipment are identified us:-
- Feeding System
- Sealing System
- Batch Coding Unit
- Cutting System
Feeding System:-Product is fed into the hopper from where it is guided into the Bowl mounted on a Vibrator. The product on the bowl is evenly distributed and guided through the Tracks on the Bowl into the Chute Channel and the feed rate of the product from the Bowl to the Chute channel is controlled by the vibrator. The Product from the chute is released onto the Sealing Roller by the Cam Operated Released Pin.
Sealing System: – The set of Sealing Rollers drawn the heat sealing Packing Material from two set of front adjustment type of friction brake system Foil holding Assembly and Foil Running Tube. The Sealing Roller is are heated to the required temperature by the Cartridge Heaters inserted into the individual Roller. Adequate pressure is applied onto the Sealing Rollers so that both the foil get sealed at the time of contact while passing through the Sealing Roller. At this stage the product which is released onto the cavity of the Roller gets packed and sealed in the foil.
Batch Coding Unit:- The left hand foil before being drawn by the Sealing Rollers passes through the Batch Coding Unit where the Batch No., Mfg. Dt., Exp. Dt. Etc is printed on the foil.
Cutting System:- The packed and sealed strip from the sealing roller passes through the Brush and Slitter Shaft which cuts the Strips vertically. These vertically cut strips then passes through the Cam operated Cutter assembly which cuts the Strip Horizontally into the desired Strip Length. The desired Strip Length can be achieved by using the appropriate Cutting Gear and Toe Cams.
The machine equipped with basic drive unit controlled by Servo Drive. Linear- Indexing servomotor is controlled by servo- drives. A freely Programmable Logic Controller, interfaced with digital display unit (Man-Machine Interface), controls the multiple functions on the machine.
The PVC, PVDC and ALU-ALU cold forming film can be used as Forming / Base film, in which blister cavities are formed by compressed air and mechanical pressure.
Draw the forming film from the forming reel feed and passes between the Forming die & blow head through forming heating platen in case of thermo-formable material and forming tool in case ALU-ALU cold forming foil (Change Part) through the dancing arm to the linear indexing station via forming, sealing Station, Perforation Station.
The movement of unwinding of forming film draw motor is controlled by proximity switch for start of the unwinding and stop of the unwinding of the foil from the reel feed.
This blister formed web moves over the web guide track and at this station the products are fed into the blisters through individual feeding devices. The formed web along with the tablet or capsules moves to the sealing station, where it is fused to the aluminium foil, which has been drawn from an aluminium reel – feed station. That printed sealed web is transferred to mechanically driven perforation station (If Applicable) through Linear Indexing. The punching tool punches out the specified pack, which is transferred to the out feed conveyor.
The waste web is then transferred to the trim winding station passing over the dancing arm and guide rollers where the trim is wound on the trim-winding roller.
All the operational controls and sequences of the machine are arrayed by Man- Machine Interface (MMI) which is conveniently located in front of the machine and rotary encoder, which determines the positional accuracy of the machine with the feedback.
All parametric changes can be done with controls through the Man-Machine- Interface, which has multiple levels of password protection.
Products to be packed on the machine are specifically pharmaceutical products such as Tablets and Capsules. Different types of product can be fed into the blister formed cavities on the formed web over the web guide track at the feeding zone.
The output capacity of the machine depends upon the product characteristics like size and shape of the products and on the type of feeding device.
TEST AND INSPECTION:
- Physical Check:
| Method | Description | Acceptance Criteria | Observation | Sign/date |
| Outer Surface finish verification | Check Outer surface of machine | -Matt finish
-Curved corner -No dent -No visible spot of welding |
||
| AC/DC panel checking | Visual check | -Should be available
-Proper wiring |
||
| Document verification | Verification of calibration certificate of RPM meter ,Timer | -Calibration certificated should be available | ||
| Document verification | Verification of MOC certificate | -MOC certificated should be available |
Basic Component Verification :
| Test Description | Acceptance
Criteria |
Test
Method |
Observation | Acceptance
Criteria fulfilled |
Checked
by |
Verified
by |
| Machine
Dimensions |
3870 (L) X 1182 (W) X 1965 (H) mm + 2% mm | Machine
Dimensions |
□ Yes
□ No |
|||
| G.A. Drawing | Machine construction should meet with G.A. drawing. | □ Visually
□ Via Tag |
□ Yes
□ No |
|||
| Main switch (ON/OFF) | ON/ OFF function
Qty.: 01 no. |
□ Visually
□ Via Tag |
□ Yes
□ No |
|||
| Emergency switch (ON/OFF) | Make: Banner
Qty.: 1 No. |
□ Visually
□ Via Tag |
□ Yes
□ No |
|||
| Hopper | 40 + 1 | □ Visually
□ Via Tag |
□ Yes
□ No |
|||
| Vibrator plate | 1.25 + 0.025 | □ Visually
□ Via Tag |
□ Yes
□ No |
| Model Name | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| Serial Number | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| Wiring reference | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| Type of forming | Flat, Intermittent | □ Visually
□ Via Tag |
□ Yes
□ No |
| Base material reel feeds | One Number | □ Visually
□ Via Tag |
□ Yes
□ No |
| Reel change over | Manual | □ Visually
□ Via Tag |
□ Yes
□ No |
| Base Foil unwinding | Pneumatically operated brake belt for reel feed and loop control by driven motor | □ Visually
□ Via Tag |
□ Yes
□ No |
| Test Description | Acceptance
Criteria |
Test
Method |
Observation | Acceptance
Criteria fulfilled |
| Method of forming | Mechanical compressive plug assisted cold Forming.
Compressed air Thermo forming. (For Thermo-formable material) |
□ Visually
□ Via Tag |
□ Yes
□ No |
|
| Type of feeding | Automatic feeding system.
Product specific – Feeder can be changed. Consisting of Product Hopper, Linear Vibrator, Rotary Vibrator, Bowl dish, Feeding track sector, Vertical Feeding channel with Release pin mechanism. |
□ Visually
□ Via Tag |
□ Yes
□ No |
|
| Lidding material unwind
|
With brake belt.
|
□ Visually
□ Via Tag |
□ Yes
□ No |
|
| Type of sealing | Flat, Intermittent.
|
□ Visually
□ Via Tag |
□ Yes
□ No |
| Password protection | There are levels of user authorization to Control the accessibility of parameters. | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| Jog mode / inch mode | Inch/Jog mode for machine setting adjustments | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| Run Mode | For Indication of ready Inputs.
For Indication of Safety interlocks. For starting of main motor in smooth mode. For building up of speed up to set speed. |
□ Visually
□ Via Tag |
□ Yes
□ No |
|
| Cyclic operation | To define cyclic operation:
Stamping Base foil draw Indexing Punching |
□ Visually
□ Via Tag |
□ Yes
□ No |
|
| Emergency | For stopping machine immediately.
For indication on tower lamp. |
□ Visually
□ Via Tag |
□ Yes
□ No |
| Print registration control (If Applicable) |
To detect and correct Eye mark position.
|
□ Visually
□ Via Tag |
□ Yes
□ No |
|
| Sealing Heater temperature control | For On-Off control for heater temperature control.
For Interlock with machine operation. |
□ Visually
□ Via Tag |
□ Yes
□ No |
|
| Control of individual motor for sub-drives | In-feed motor control.
Conveyor motor control. Vibrator controller. |
□ Visually
□ Via Tag |
□ Yes
□ No |
|
| Feeding control. | To control the level of product in Bowl dish
To control the vibrator. |
□ Visually
□ Via Tag |
□ Yes
□ No |
| Sr. No. | Test Description | Acceptance
Criteria |
Test
Method |
Observation | Acceptance
Criteria fulfilled |
| PLC INTERLOCKS VERIFICATION | |||||
| l | Low temperature of sealing heater | Inter locked with Machine working in ‘RUN‘ mode | Sealing temperature Low
|
□ Yes
□ No |
|
| l | High temperature of sealing heater | Interlocked with Machine working in ‘RUN’ mode | Sealing
temperature high |
□ Yes
□ No |
|
| l | Emergency switch | Inter locked with Machine working in ‘RUN’ mode and
Inch mode. |
1.Emergency
Pressed –Press Reset 2. Index servo error No. Press Reset 3. Main servo error No. Press Reset |
□ Yes
□ No |
|
| l | Lid foil presence | Inter locked with Machine working in ‘RUN‘ mode | Lidding foil over | □ Yes
□ No |
|
| l | Base foil presence | Inter locked with Machine working in ‘RUN‘ mode | Base foil over
|
□ Yes
□ No |
|
| PLC INPUT/OUTPUT DETAILS | |||||
| l | PLC make | B&R Industrial Automation | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| l | Serial number | A1590180513 | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| l | Model | 4PP420.0571-75 | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| l | Display | Graphical Colour (tft) | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| l | Supply voltage | 24 V DC | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| l | Memory | 64/128 MB DRAM | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| MOC (Material of Construction) | |||||
| · | Machine body cladding | SS 304 | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| · | Basic machine body | SS 304 | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| · | Hopper | SS 316L | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| · | Vibrator | SS 316L | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| · | Conveyor Belt | Polyvinyl Chloride | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| · | Feeding unit rubber roller | Silicon Rubber | □ Visually
□ Via Tag |
□ Yes
□ No |
|
| · | Machine Front Cover Guard | Polycarbonate | □ Visually
□ Via Tag |
□ Yes
□ No |
|
Performed by: ____________erified by:_____________________________
TRAIL REPORT:
Machine Operational & Performance Verification (Trial- I):
Effect of machine speed:
| S. No. | Machine Speed
(Cuts / Min.) |
Sealing Temp.
(°C) |
Vibrator Speed | Description | |||
| Knurling Impression of Strips | Leak test failure % | Pocket integrity failure % | Batch Coding | ||||
| 1. | |||||||
| 2. | |||||||
| 3. | |||||||
Performed by: ______________ Verified by:_______________________
Machine Operational & Performance Verification (Trial- II):
Effect of Sealing Temperature:
| S. No. | Sealing Temp. (°C) | Machine Speed
(Cuts / Min.) |
Vibrator Speed | Description | |||
| Knurling Impression of Strips | Leak test failure % | Pocket integrity failure % | Batch Coding | ||||
| 1. | |||||||
| 2. | |||||||
| 3. | |||||||
Performed by: _______________ Verified by:___________
Machine Operational & Performance Verification (Trial- III):
Effect of Vibration:
| S. No. | Sealing Temp. (°C) | Machine Speed
(Cuts / Min.) |
Vibrator Speed | Description | |||
| Knurling Impression of Strips | Leak test failure % | Pocket integrity failure % | Batch Coding | ||||
| 1. | |||||||
| 2. | |||||||
| 3. | |||||||
Performed by: ______________ Verified by:___________________
FAT REMARK:
Vendor Remark : Client Remarks :
