Carefully read the equipment operation manual, electrical schematic diagram, and pneumatic diagram.
Ensure that operators and maintenance personnel have received on-site training from the supplier to understand emergency stop, basic operation, and cleaning procedures.
Installation and connection inspection:
Horizontal calibration: Use a spirit level to check if the equipment base is completely level, which is the basis for ensuring filling accuracy.
Public works connection:
Power supply: Confirm that the voltage, frequency, and phase meet the equipment requirements, and that the grounding is reliable.
Air source: Provide clean and dry compressed air with a stable pressure within the required range of the equipment (such as 0.6-0.8MPa), and install triple components (filter, pressure reducing valve, oil mist device).
Water/oil source: Connect the pipeline to ensure sufficient liquid supply and no leakage. Do not use edible oil directly for the first time.
Mechanical inspection: tighten all screws and pipe joints; Check if the conveyor belt and chain plate are smooth; Confirm that there is no interference from moving parts such as the filling head and capping head.
Cleaning and disinfection:
Thoroughly clean, disinfect, and dry all parts of the equipment that come into contact with materials (such as material boxes, pipelines, pumps, filling valves, etc.) to prevent contamination from impurities and moisture.
Confirmation of Safety Environment:
Clear away debris around the equipment to ensure a smooth safety passage.
Check if all safety shields, emergency stop buttons, and photoelectric protection devices are installed properly and functioning effectively.
2、 No load test machine (running without material)
Purpose: To check the coordination of mechanical motion, electrical control, and pneumatic systems of the equipment.
Steps and precautions:
In manual mode, test the actions of each unit one by one: start and stop of the conveyor belt, lifting and lowering of the bottle clamp/bottle support cylinder, opening and closing of the filling valve, rotation of the capping head, etc., and observe whether the actions are smooth, in place, and without abnormal noise.
Switch to automatic mode, do not put in the bottle, let the device run in a loop. Check if the PLC program logic is normal and if the signal sensing at each workstation is accurate.
Key observation: whether the cylinder movement speed is adjustable and stable; Is the speed and torque of the motor (such as the screw cap motor) normal; Check for any abnormal friction, collision, or looseness.
3、 Load Test Machine - "Water Test" (Key Accuracy Test)
This is the most important step, it is strictly prohibited to use oil directly!
Purpose: To test the filling accuracy, sealing performance, and overall coordination of equipment by replacing oil with water.
Steps and precautions:
Use a liquid with a viscosity similar to edible oil: usually water is used directly, but for high viscosity oils (such as sesame oil), a dilute glycerol aqueous solution can be considered for simulation.
Bottle type and container: Use empty bottles that are identical to the actual production (including material, weight, and bottle type).
Parameter setting: Set parameters such as target filling volume, filling speed, and lead time on the operation interface.
Operation and testing:
Start at low speed and observe whether the bottle is stable and accurately aligned during transportation and lifting.
Filling accuracy testing: Fill at least 30-50 bottles continuously, weigh them one by one using an electronic scale ("gross weight tare weight=net weight"), and calculate the average error and standard deviation. The target accuracy is usually required to reach ≤± 0.5% (high-end equipment can reach ± 0.1%).
Check for leaks: Observe whether there is any dripping when the filling valve is opened or closed; Check for leaks at all pipeline interfaces and pump seals.
Full bottle transportation: Observe whether the filled bottles are stable during transportation and subsequent workstations (such as capping), and whether there is any bottle tipping or splashing.
4、 Production trial machine - "oil test" (final verification)
Objective: To conduct final validation using actual edible oil after achieving full compliance in the "water test".
Steps and precautions:
Small batch trial production: First, use a small amount of edible oil (such as tens of liters) for a short-term trial run.
Parameter tuning: Due to the different density, viscosity, and foaming properties of oil compared to water, it may be necessary to fine tune the filling time, advance amount, or pump speed to achieve optimal accuracy.
Quality inspection:
Recheck the filling accuracy and sealing.
Observe foam: whether the foam generated in the filling process is within the controllable range, whether it will overflow or affect the accuracy.
Check for contamination: After stopping the machine, check for any wire drawing or oil dripping on the filling valve and bottle mouth. The first batch of products should be isolated and checked for equipment contamination (such as moisture, cleaning agent residue, metal shavings) in the oil.
5、 Test machine completion and recording
Data recording: Detailed record of all parameter settings, accuracy test data, encountered problems, and solutions for no-load, water test, and oil test.
Final cleaning: After the trial run is completed, immediately thoroughly clean and drain the equipment according to the regulations to prevent edible oil from solidifying in the pipeline.
Acceptance confirmation: Sign a trial machine acceptance report with the equipment supplier to confirm that the equipment performance meets the technical indicators specified in the contract (such as speed, accuracy, and qualification rate).