FAQ/Glossary

Acceptance (technical)

Acceptance is the formal confirmation that a beverage filling line or individual machine essentially meets the contractually agreed requirements. A functional or acceptance test should be carried out before acceptance and as a basis for assessment. In most cases, the performance test is carried out in accordance with DIN 8782, 8743 or EN415-11.

Acceptance criteria

Predefined technical, hygienic and functional requirements that must be met for the system to be approved.

Acceptance report

Document that records the results of the tests, deviations, rectifications and finally the confirmation of acceptance

CIP-System (Cleaning in Place)

Automated cleaning system within the filling line – is also tested for effectiveness and safety as part of the acceptance process.

Leak test

Check that packaging units do not leak after sealing.

Labeling accuracy

Measure of how precisely labels are applied in accordance with the specifications – is checked as part of the quality inspection.

FAT (Factory Acceptance Test)

Preliminary inspection of the system at the manufacturer’s premises before dispatch. The customer and manufacturer test functionality and quality based on defined specifications.

Format parts

Interchangeable system components that are used for different packaging formats – their functionality is also tested during acceptance.

Format changeover

Process of converting the filling line to a different container format – A test checks whether this can be completed within the specified time and without errors.

Foreign body detection

Systems that check for unwanted particles in the beverage or packaging – particularly relevant for sensitive products (e.g. baby drinks, organic juices).

Fill level control

Sensor-based, camera-based or X-ray-based systems for monitoring the correct fill level in each bottle – this check is already required for compliance with the legal proof in accordance with the Finished Packaging Ordinance (FertigPackV). Proof of compliance with the specified tolerances should be provided as part of a performance test.

Commissioning

The process that takes the beverage filling line or packaging machine from pure installation to production readiness is referred to as commissioning. This also includes functional tests, calibration and instruction of the operating personnel.

IQ/OQ/PQ 

Validation stages, especially for sensitive products (e.g. in the pharmaceutical or food industry):

• IQ (Installation Qualification): Check whether the system has been installed correctly
• OQ (Operational Qualification): Test of functions according to specification
• PQ (Performance Qualification): Testing under real production conditions

KPI (key performance indicators)

Key Performance Indicators (KPIs) are metrics that, ideally, have been contractually agreed upon and are assessed during performance and quality reviews.

Empties management

Function of a system for detecting, cleaning and checking returnable containers – an important component of returnable filling systems.

Acceptance testing

The performance acceptance includes the determination of productive and non-productive times and their technical assessment within a defined period. Loss quantities are also assessed and work quality is checked. The agreed KPIs are calculated from all times and quantities. This allows the actual performance status of the machine/system to be represented during the period under review. The longer the acceptance period is selected and agreed, the more reliable the results are for normal day-to-day operations.

Performance analyses according to DIN 8782

The performance factors (KPIs) are usually calculated in accordance with DIN 8782 and DIN 8743 when analyzing performance and sources of interference. This allows a direct comparison to be made with standard business performance indicators. In deviating cases, the calculation is carried out on request according to the existing, deviating calculation models of the respective operating site.

Scope of analysis according to DIN 8782

The analysis covers the entirety of the production system. The interfaces of this system are clearly defined in advance. In this way, adjacent systems and their impact on the effectiveness of the production line (logistics, product preparation, shift and product changes, etc.) can also be included on a case-by-case basis. The duration of the analysis is determined by the client; however, it has been found that 3 production days are often sufficient to carry out a meaningful analysis.

Power losses according to DIN 8782

A comprehensive fault profile of the filling line can be created by precisely allocating performance losses, which result in downtime or reduced speed due to defects or backlogs on the filling machine. In addition to direct faults in the machine system, organizational weaknesses can also be identified. The condition of the machine system is also assessed: to what extent is the system’s positive wear reserve available or used up? This is an important parameter for investment planning.

As the analysis always represents the image of current production, additional interviews are conducted with the operators and shift leaders so that all areas and further suggestions for improvement can be included.

Production losses according to DIN 8782, 8743, EN415-11

DIN8782 does not take sufficient account of the loss quantities. Therefore, supplements from the DIN8743 and EN415-11 standards are used for this area.

It is very important to record all loss quantities that occur during the analysis period. As every unit of unsaleable or unprocessable goods represents a direct loss of efficiency, these must be precisely determined and accounted for.

Often, losses in normal production are given little or no consideration. It is only when an exact balance sheet is drawn up that the often high losses resulting from this become apparent. These include underfilled containers, mislabeling, inadequate packaging and pallets that are not suitable for transport or high-bay storage.

Analysis report / expert opinion in accordance with DIN 8782

A report or expert opinion is prepared for each analysis. This is usually available at the latest on the 5th working day after completion of the on-site work.

In addition to a comprehensive fault profile, the performance parameters and the loss quantity calculation, optimization measures are named and described. Furthermore, the expected positive effects are determined by iterative calculations and illustrated in clear figures. This allows direct business forecasts and investment plans to be drawn up.

Performance evaluation of individual machines

Various characteristic values are available for assessing the performance of individual machines. The reproduction of these in the current standards DIN 8782, DIN 8743 and EN415-11 is incomplete and can therefore only be presented in conjunction with the generally recognized rules of technology.
The MTBT in particular is calculated differently in practice, often as a mixed value with the MTBF included. However, in order to be able to make important statements about the running behavior of a machine, there should be one value each for planned and self-disturbance-related interventions. The MTBI can be used to determine the overall operating intensity. This can also be used for further calculations on the required number of operators in a higher-level area.

Performance evaluation of individual machines:
1. Machine technical availability

This characteristic value is to be used for machines that are constant in terms of their rated power, but have dynamic power control. This value shows the ratio of running time to operating time, adjusted for unplanned downtime not caused by the system. The calculation is purely temporal. Output losses and scrap quantities are not taken into account. However, regular, quality-compliant production is assumed.

Performance evaluation of individual machines:
2. Machine technical delivery rate

This characteristic value is to be used for machines that are constant in terms of their rated output and are not, or only in defined steps, output-controlled. Machines operating in this way are often master machines in the machine system (filling machine, stretch blow molder). The delivery rate corresponds to the ratio of the effective output (average number of items produced without problems during the general running time) to the nominal output. Times with reduced output and quantities that do not meet quality requirements are determined as lost quantity.

Performance evaluation of individual machines:
3. MTBX (T/F/I) (mean time between touch/failure/intervention)

The MTBX values reflect the average time between events. They are a characteristic value for the error frequency or operating intensity of a machine. Observation times for MTBX determination should not be less than 8 hours.
The MTBF and MTBT values are now well-known quantities, but the MTBT is often understood as a composite value of the intermediate time between fault rectification and supply intervention.
According to the generally recognized rules of technology, MTBF and MTBT must be clearly separated from each other, as two different and meaningful characteristic values can be determined in a separate calculation with machine-related interventions to rectify faults and planned interventions to supply the machine. Accordingly, the MTBF reflects the error frequency, the MTBT is the characteristic value for the planned intervention frequency, i.e. the capacity of consumables.
The MTBI can be used to make a statement about the overall operating intensity of a machine. This is formed by combining MTBF and MTBT.
This provides a characteristic value which, through further calculation, allows conclusions to be drawn about the quantitative personnel deployment, even in higher-level machine areas/groups.

Performance evaluation of individual machines:
4. MTBT (mean time between touch)

This value describes the capacity of a machine in terms of its supply of consumables, disposal of waste and planned cleaning times. The machine’s precisely designed storage for consumables and containers for waste ensure that the general intervention time by an operator is reduced.
The MTBT indicates the average time between operator interventions. The interventions recorded here are exclusively for loading and disposal. If the machine is running smoothly at nominal capacity, they maintain production without downtime. Planned cleaning times are also taken into account here.
Interventions that occur due to machine malfunctions must be precisely defined here (and, if necessary, contractually agreed), as these can then be recorded and described using the MTBF parameter.

Performance evaluation of individual machines:
5. MTBF (mean time between failure)

The MTBF is a parameter for the frequency of machine-related faults and the resulting operating intensity of a machine. This value quantifies the susceptibility to faults. It indicates the average time between machine-related operator interventions. The interventions included here are only those that are carried out to rectify machine faults. Interventions for reloading and troubleshooting, e.g. due to defective supply material, are not recorded here. In order to obtain representative values, the observation period should be at least 8 hours.

Performance evaluation of individual machines:
6. MTBI (mean time between intervention)

In order to be able to make a statement about the overall operating intensity of a machine, the MTBI is used as a composite value of MTBT and MTBF.

Performance curves

Diagrams or tables that show how the performance of the system changes under different conditions (e.g. bottle size, beverage type, temperature).

Defect log

List of defects or deviations identified during acceptance. Basis for subsequent improvements by the supplier.

OEE (Overall Equipment Effectiveness)

Overall equipment effectiveness is a key figure that is determined as part of a performance test. This key performance indicator is used to make statements about the performance of the entire production process, including machines and non-machine faults.

SAT (Site Acceptance Test)

Acceptance test of the beverage filling line or individual machine at the final installation site after installation and commissioning. Includes tests under production conditions and acceptance reporting.

Safety acceptance

Checking compliance with safety regulations, e.g. CE marking, emergency stop functions, access protection.

Interface check

Test whether the system communicates correctly with adjacent systems – such as labeling, packaging, conveyor technology or IT systems.

Cycle time

Time required for the production of a unit – a key parameter in performance acceptance.

Handover protocol

Confirmation of the official handover of the system from the supplier to the operator after successful acceptance.

Closure test

Ensuring that closures (e.g. crown caps, screw caps) are correctly seated and properly sealed – including torque testing for screw caps.

HACCP-compliant acceptance

Consideration of the HACCP guidelines (Hazard Analysis and Critical Control Points) – hygienically critical points must be identified and controlled.

Sampling

Sampling of beverage samples during test production for microbiological, chemical and sensory analysis.

Initial sensory release

First taste test of a bottled beverage to ensure that there is no interference from machine parts or cleaning agents.

Rinse pattern inspection/Spray shadow test

Check that all nozzles of the device for cleaning the outside of the machine are working correctly and effectively – this is done visually or with special test bottles.

Batch tracing

Ability of the system to fully trace every batch produced – relevant for recall and quality assurance processes.

Error reporting system

System that automatically detects, reports and, if necessary, documents faults – is tested for response time and accuracy during acceptance.

HMI (Human Machine Interface)

User interface for operating the filling system – must be intuitive, error-free and functional.

PLC (Programmable logic controller)

Central control unit of the system. Acceptance includes the control of all programmed processes, emergency routines and interfaces.

Guaranteed minimum benefit

Contractually guaranteed lower limit of production output that must be proven upon acceptance.

Residual defects report

List of minor, non-critical defects that still need to be rectified but do not prevent acceptance.

CE marking

Legally required declaration by the manufacturer that the system complies with all relevant EU directives – a prerequisite for commissioning.

Handover training

Training of operating personnel by the system manufacturer – usually part of the acceptance phase.

Maintenance schedule

Plan for regular maintenance, which is handed over to the operating team after acceptance.