15 Quality Assurance Checks: Safety, Durability, and Final Sign-Off - Part 2

October 23, 2026

The 15 Quality Assurance Checks Every Machine Must Pass Before Shipment

7. Detergent / Suds Test for Harsh Products

For bleach, detergents, and other foaming or chemically aggressive products, a dedicated suds test is performed to simulate actual operating conditions. The internal checklist specifically calls for a “Suds Test for detergent, ammonia.”

In this QA check, a technician:

●    Runs the machine with a detergent or representative foaming solution under controlled conditions.

●    Observes foam behavior in the bowl, valves, and discharge to ensure reliable operation and level control.

●    Assesses material compatibility and surface finishes, looking for early signs of corrosion or staining in exposed iron or steel.

●    Confirms that return and overflow paths can handle foam without flooding or loss of level control.

As a manufacturer of bleach and detergent filling machinery, Laub\Hunt uses corrosion‑resistant materials, coatings, and seal designs, and they typically validate performance under realistic chemical loads before release. Laub\Hunt’s suds test ensures that machines intended for these harsh applications are evaluated under representative conditions.


8. Conveyor and Bottle Handling Performance

Reliable line performance depends on more than the filler itself; the conveyor system and its interfaces are critical. The checklist includes items on conveyor gearbox oil, ball bearings, wear strips, transfer plates, skidding adequacy, and the presence of switches on the infeed conveyor.

In this QA check:

●    Conveyor gearbox lubrication and bearing condition are confirmed.

●    Wear strips are inspected, and washers under holding bolts are checked to ensure smooth bottle travel.

●    Transfer plates between conveyor and donut plate or stars are tested with bottles to eliminate stumbling, tipping, or gaps.

●    Skidding and transport provisions are reviewed with carriers to ensure the machine and conveyor sections are adequately supported in transit.

●    Presence and basic operation of conveyor infeed switches and sensors are verified.

Laub\Hunt treats the conveyor interface as a critical part of their FAT, running customer bottles to identify interaction issues early and documenting recommended speeds and accumulation conditions. This step ensures that bottles are handled gently and predictably from the first day of installation.

 

9. Safety Features and Interlocks

Safety engineering has advanced significantly, and Laub\Hunt’s pre‑shipment checks integrate both legacy safeguards and modern safety expectations. The checklist references a limit switch at the infeed star and a switch on the infeed conveyor, both key elements of jam detection and line control.

This QA check covers:

●    Verification that all limit switches, safety interlocks, and e‑stop circuits are installed and functional.

●    Functional testing of infeed star and conveyor switches to ensure the machine responds correctly to starved or jammed conditions.

●    Confirmation that guarding provisions, access doors, and interlocked panels meet current customer and regional requirements.

Current safety standards outline formal risk assessment and safeguarding requirements for packaging machinery, including guarding of pinch points and moving parts. OSHA’s general machine guarding standard also reinforces the need to protect operators from rotating parts and nip points on packaging machines. By checking safety devices at the factory, Laub\Hunt supports faster compliance verification on site.


10. Surface Finish, Coatings, and Sanitary Design

Surface condition and coatings have a direct impact on corrosion resistance, cleanability, and operator safety. Laub\Hunt’s checklist specifies two coats of chlorinated rubber on all iron surfaces, no paint on thread surfaces, and rounding bumpable corners to a 1/8 in radius so they will not injure anyone.

In this QA check:

●    Painted and coated surfaces are inspected for full coverage, adhesion, and absence of runs or bare spots.

●    Threads and precision mounting surfaces are checked to ensure they are free of paint or coating that could interfere with assembly.

●    Edges and corners in operator reach zones are ground round to at least a 1/8 in radius to reduce injury risk.

●    Brass wearing surfaces on sliders are examined to ensure they are not being scraped or gouged.

Hygienic design guidelines for food and beverage equipment emphasize smooth, cleanable surfaces and avoidance of sharp edges in contact and non‑contact zones alike. Corrosion‑resistant coatings on iron and steel components are also widely used in detergent and bleach filling applications to extend equipment life.

 

11. Control System and Functional Logic Testing

Beyond the physical hardware, the control system must execute the correct sequence of operations. Laub\Hunt’s checklist calls for checking float switch travel (at least 4 in. between on / off), verifying plunger operation with a full tank, and ensuring correct wiring of solenoid valves.

This QA check includes:

●    Verifying float switch hysteresis and travel to maintain stable tank levels.

●    Confirming pressure regulator settings that govern plunger motion, valve actuation, and puffing cycles.

●    Testing the timing and sequencing of infeed, starwheel, valve open/close, and outfeed functions under no‑load and load conditions.

●    Documenting key control parameters as shipped, so customers can reference factory settings during commissioning.

Laub\Hunt’s FAT protocols for high‑speed filling lines dedicate substantial time to control logic verification, simulating jams, bottle absence, and other fault conditions to ensure safe and predictable response. Its Controls QA check is designed to deliver a predictable baseline that reduces on‑site debugging.

 

12. Long‑Run Reliability and Wear Observation

A brief dry run is not enough to reveal wear or rubbing issues. Laub\Hunt’s checklist calls for running the machine at least two hours and specifically watching for what wears, rubs, and squeaks.

In this QA check:

●    The machine is run for an extended period at representative speeds with bottles and water.

●    Technicians periodically inspect cams, followers, sliders, stars, guides, and conveyors for unusual wear patterns or heat.

●    Audible monitoring is used to detect squeaks or rubbing that indicate misalignment or improper lubrication.

●    Any issues are corrected and re‑tested before the machine is released for shipment.

Laub\Hunt integrates extended trial runs into FAT to validate component life, verify torque limiter settings, and observe thermal stability at full speed. This long‑run check is a key reason why customers can install and start up Laub\Hunt equipment with minimal early‑life troubleshooting.

 

13. Torque Limiter and Overload Protection Testing

Torque limiters protect both the machine and product flow when jams occur. The internal checklist specifies verifying that the torque limiter can be adjusted so the machine can be pulled back while running yet will restart from any position.

This QA check:

●    Confirms the torque limiter is installed, correctly oriented, and accessible for adjustment.

●    Tests overload behavior by simulating a mild jam and verifying that the drive slips or releases as intended.

●    Validates that the machine can be restarted from any position after an overload event without binding.

Risk‑based safety standards for packaging machinery encourage the use of torque‑limiting and overload‑protection devices to reduce injury risk and mechanical damage during foreseeable misuse and jams. Laub\Hunt explicitly validates this functionality before shipment to ensure the protection is active from day one.

 

14. Documentation, Spares, and Accessory Verification

A well‑built machine must be accompanied by complete documentation and the right accessory package. The checklist calls out the number of stars, guides, spare valves, the presence of a grease gun, and a tube of Parker O‑Lube packed with the filler, as well as a nameplate.

This QA check covers:

●    Counting and recording stars and guides shipped, including any dedicated change parts.

●    Confirming the number of spare valves and ensuring they are fully assembled with appropriate seals.

●    Packing the specified grease gun, lubricant tubes, and any special tools required for routine maintenance.

●    Verifying the machine nameplate information (model, serial, ratings) is correct and readable.

●    Ensuring that installation, operation, and maintenance documentation is included in the shipment.

Factory acceptance practices at major OEMs increasingly link spare parts lists and lubrication charts directly to equipment serial numbers, often via digital platforms or QR codes, to simplify lifecycle support. Laub\Hunt’s documentation and spares QA check aligns with this trend to support faster maintenance adoption in the field.

 

15. Final Pre‑Shipment Audit and FAT Sign‑Off

The final QA check is a structured pre‑shipment audit. At this stage, all prior checks are reviewed, any open items are closed, and the machine is evaluated against customer specifications and applicable standards.

This check includes:

●    Reviewing and signing off on all lubrication, mechanical, alignment, leak, safety, and functional test records.

●    Confirming that skidding and packaging arrangements are adequate for transport.

●    Capturing key test data (speeds, fill volumes with water, changeover times, etc.) to support the customer’s own site‑acceptance testing (SAT).

●    Ensuring alignment with current safety and hygiene guidance for the intended industry segment (household chemicals, food, beverage, or other), informed by sources such as compliance guidelines, OSHA requirements, and hygienic design guidelines.

Leading global packaging machine suppliers use structured FAT processes as a contractual milestone, often witnessed by the customer, to verify that the equipment meets performance and safety requirements before shipment. Laub\Hunt’s final pre‑shipment audit formalizes this into a repeatable, document‑backed process.


How These 15 Checks Benefit Your Operation

By formalizing our 15 QA checks and aligning them with modern industry practices, Laub\Hunt ensures machines:

●    Arrive mechanically sound, lubricated, and aligned.

●    Start up faster, with leak‑free product paths and proven controls.

●    Operate safely, with validated interlocks, torque limiters, and rounded, guarded interfaces.

●    Withstand the demands of harsh chemistries and sanitary environments.

For customers, this means less time debugging on site, fewer surprises after installation, and a more predictable path from delivery to full production.

 

Key Takeaways

●    Every machine undergoes 15 structured QA checks covering lubrication, mechanics, alignment, controls, safety, and performance.

●    Pre‑shipment validation reduces installation time and minimizes on‑site troubleshooting.

●    Wet testing and product‑simulation testing (including detergents) ensure leak‑free, real‑world readiness.

●    Alignment and bottle‑handling checks protect against jams, breakage, and inconsistent fills.

●    Safety systems, interlocks, and torque limiters are verified before shipment to support compliance and operator protection.

●    Long‑run testing identifies early wear, noise, or heat issues that short tests miss.

●    Documentation, spares, and setup parameters are delivered complete to accelerate commissioning and maintenance.

●    The final audit and FAT sign‑off create a documented, repeatable standard aligned with modern industry expectations.


You can also review Part 1 of this series.  Part 3 coming soon.   Contact us for more information.

The 15 Quality Assurance Checks Every Machine Must Pass Before Shipment

The 15 Quality Assurance Checks Every Machine Must Pass Before Shipment - Part 1

October 18, 2026
Before any liquid filler leaves our facility, it must pass a structured series of 15 quality assurance checks that cover lubrication, mechanical alignment, leak integrity, safety, hygiene, and long‑run performance.

What Happens During Factory Acceptance Testing (FAT) Stages 5 - 7

October 6, 2026
What Happens During Factory Acceptance Testing (FAT) Stages 5 - 7 Stage 5: Surface Finish, Coatings, and Safety Coatings and Finishes FAT also includes a review of protective coatings and surface finishes, important for both corrosion resistance and cleanability. Checks include: ● Confirming two coats of chlorinated rubber paint or equivalent on all iron surfaces where specified, especially for bleach and detergent applications. ● Ensuring no paint on any thread surfaces or leveling screws so adjustments remain possible. ● Verifying that brass wearing surfaces on sliders are not being scraped and are correctly aligned. These guidelines emphasize the importance of appropriate coatings and cleanable surfaces, particularly for food, beverage, and aggressive chemical products. Laub\Hunt’s attention to such details at FAT ensures long‑term durability and sanitation. Safety Devices and Nameplate As part of FAT, Laub\Hunt verifies: ● Presence and function of limit switches at the infeed star and on the infeed conveyor. ● Availability and accessibility of grease fittings and other routine‑maintenance points. ● Correct, legible nameplate data (model, serial, ratings), which customers will use for documentation and future parts orders. Best practices call for safety verification (guards, interlocks, e‑stops) and accurate identification plates as prerequisites for shipment. Laub\Hunt incorporates these checks to help customers meet safety and compliance requirements. Stage 6: Long‑Run Performance Trials Extended Run Test FAT is not limited to quick spot checks. Laub\Hunt performs extended run tests where the machine operates for a couple of hours at or near production speeds with water and bottles. During this period, technicians evaluate: ● What wears: observing cams, followers, sliders, and seals for abnormal heat, friction, or polish. ● What rubs or squeaks: diagnosing any contact or misalignment indicated by noise. ● Smooth transfer of bottles across bridge plates, transfer plates, donut plates, and conveyor chains, ensuring no stumbling or misfeeds. Longer‑duration FAT runs are essential for revealing latent issues that short trials miss—such as thermal growth, creeping misalignment, or intermittent jams. Laub\Hunt’s long‑run tests follow that logic and are documented as part of the FAT record. Torque Limiter and Overload Behavior Laub\Hunt’s checklist also calls for verifying the torque limiter: It must be adjustable so the machine can be pulled back while running and restarted from any position. During FAT, Laub\Hunt: ● Tests overload conditions to ensure the torque limiter slips or releases as designed. ● Confirms that the machine can resume operation without binding after an overload event. Tests of overload and emergency behavior ensures both equipment protection and operator safety. Including this in FAT means customers receive a machine whose protective systems have already been proven under controlled conditions. Stage 7: Special Tests for Detergent and Chemical Applications Suds and Chemical‑Behavior Tests For fillers intended for bleach, detergents, and other foaming or chemically aggressive products, Laub\Hunt performs specialized tests beyond standard water trials. These include: ● “Suds tests” using detergent or ammonia solutions to observe foam behavior in the bowl, valves, and overflow paths. ● Checks that level controls remain stable and that foam does not cause chronic false readings or spills. ● Validation that seals, coatings, and materials in contact with test solutions behave as designed. It is necessary to test performance under realistic process conditions, including foaming and temperature variations, before shipment. Laub\Hunt’s suds and chemical‑behavior tests are the result of decades’ experience in the bleach and household‑chemical markets. Stage 8: Spares, Accessories, and Documentation Counting Stars, Guides, and Spares A comprehensive FAT also ensures that everything promised in equipment order is present and accounted for. Laub\Hunt technicians: ● Count and record the number of stars and guides shipped. ● Verify the number of spare valves and confirm they are fully assembled and ready to use. ● Confirm that a grease gun and a tube of Parker O‑Lube (or equivalent) are packed with the filler. Best practices include checks that all auxiliary equipment, tools, and documentation are present, as these items are often critical to smooth commissioning. Final Documents and FAT Report Throughout the FAT, Laub\Hunt records: ● Test results, observations, and any deviations from expected performance. ● Adjustments made and final “zero settings” (e.g., fill volumes, speeds, and key alignment points). ● Outstanding minor items, if any, with a plan for resolution. Best practices call for a formal FAT report and acceptance certificate once criteria are met, with any minor punch‑list items documented separately. Laub\Hunt follows this model, ensuring that you have a shared, written record of what was tested and accepted before shipment. What FAT Means for You When Factory Acceptance Testing is complete, you receive a filler that has already: ● Been fully lubricated, aligned, and checked for mechanical integrity. ● Passed dry and wet functional checks, including leak tests, safety verifications, and extended runs. ● Demonstrated performance with your bottles under realistic conditions. ● Had its accessories, spares, and documentation verified and packed. Industry standards—and Laub\Hunt’s decades in liquid filling—show that this investment in the FAT dramatically reduces startup time, rework, and risk at your plant. By the time your machine reaches your dock, the heavy troubleshooting has already been done, allowing installation and commissioning to focus on integration and optimization rather than basic fixes. Contact us for more information. Also review stages 1-2 and stages 3-4.

What Happens During Factory Acceptance Testing (FAT) Stages 3 - 4

September 30, 2026
What Happens During Factory Acceptance Testing (FAT) Stages 3 - 4 Stage 3: Dry Functional Testing Air and Control System Checks With the mechanicals validated and lubricated, Laub\Hunt conducts dry functional tests (i.e., no product yet) to confirm pneumatic and control behavior. This includes: ● Checking the air filter by running air through water to verify proper exhaust of air and any entrained moisture. ● Wiring and testing up‑and‑down solenoids, confirming the correct hoses and motions, and ensuring there are no wiring or plumbing errors. ● Setting pressure regulators for plungers and other actuators. ● Verifying float switch travel—typically at least 4 inches between on and off positions—and ensuring switches reliably trigger overflow pumps when specified. These steps represent best practices where PLC inputs/outputs, actuators, and interlocks are checked before any wet testing. Laub\Hunt’s checklist embeds these tasks in a structured, sign‑off format. Valve and Hardware Verification Still in the dry phase, technicians verify: ● Presence and condition of all valve components: blocks, washers, O‑rings, tips, and screws, with no missing parts and all fasteners snug. ● Adjustability of valves across the full outage range: clearing the bottle top, reaching the lowest fill level, and beyond. Other FAT protocols require similar checks to ensure valves and heads are complete and adjustable before any performance measurements are made. Laub\Hunt’s detailed valve checklist minimizes the risk of assembly omissions that could create leaks or inaccurate fills. Stage 4: Wet Test and Leak‑Tightness Water‑based Wet Test The core of FAT is the wet test, where the filler is run with water to verify leak‑tightness and system behavior under realistic hydraulic conditions. Laub\Hunt technicians: ● Check for leaks at valves, hose gaskets, manifolds, and piping to any vacuum pumps. ● Inspect rotating seals by deliberately stressing them side‑to‑side to see if leakage occurs. ● Verify that O‑rings at switches are lubricated and not leaking, and that Permatex or similar thread sealant is applied on specified switch threads. Laub\Hunt prioritizes leak tests, emphasizing the need to verify seals, connections, and wetted components before shipping. Laub\Hunt’s process ensures the entire liquid path is sealed and stable. Functional checks with water and bottles Simultaneously, the team verifies system functions under wet conditions: ● Confirming float switches control overflow pumps correctly. ● Running bottles through the filler to test stars and guides in real operation. ● Checking that valves reach and maintain target levels at different settings and that the full range of fill‑level adjustment is available. ● Ensuring the cam for “puffing” or venting seals properly on the upper tip O‑ring before being withdrawn from the valve. Water trials validate filling accuracy, container handling, and control logic before committing to performance metrics. Laub\Hunt integrates these into a single wet test phase, tightly linked to its checklist items. Contact us for more information. Also Review stages 1-2 and stages 5-7 .