Services for start-up and testing of extrusion lines

FAT, SAT, technical training and specialized support for every stage of the plant cycle

Factory Acceptance Test (FAT): full testing before delivery

Bausano performs a Factory Acceptance Test (FAT) on every line produced, reproducing actual operating conditions before shipment. The client can attend in person and schedule test sessions on the dedicated plant, verifying parameters, performance and functionality. The test facility was recently expanded to accommodate large-scale lines as well, such as those for extruding pipes up to 1200 mm in diameter, an uncommon requirement in the industry. Unlike many manufacturers that perform partial or out-of-cycle tests, Bausano carries out complete operational FATs, including flow simulation, temperature control, software integration and output verification – the full set of tests that validate the line before delivery. The presence of an in-house mechanical workshop also makes it possible to immediately modify the plant at the client's request, without having to suspend the test or postpone the intervention. This level of flexibility and direct customization during testing is a distinctive advantage compared to other manufacturers, which often rely on external subcontractors or static testing.

FAT included in the plant cost:

Bausano is among the very few manufacturers to include a full-scale FAT in the plant cost, executable with the client on-site and immediately modifiable, significantly reducing the risk of non-conformity during installation.

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Virtual FAT: remote control with real-time supervision

Bausano also offers the option of performing a virtual FAT, connecting remotely with its technical team. The client watches the plant tests live, with access to process data, checklists and technical documentation. The virtual FAT makes it possible to monitor all testing phases without the need for travel, maintaining transparency, traceability and operational continuity. The connection is managed by the Bausano team, with mechanical, electrical and software technicians present in the test room.

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Site Acceptance Test (SAT): installation and final verification at the client's site

The Site Acceptance Test (SAT) represents the final stage of the supply process. After delivery and plant installation, Bausano carries out testing directly at the client's facility, verifying the operation of the entire line under actual operating conditions. This step makes it possible to validate not only correct installation, but also full integration with existing infrastructure and compliance with the performance specified in the contract. The SAT ensures continuity between factory testing and on-site start-up, confirming production parameter stability, finished product quality and compliance with safety standards. The intervention is carried out by specialized Bausano technicians, in collaboration with the client's staff. Installation and start-up timelines are defined and agreed with the client from the moment the contract is signed, based on line complexity, the number of modules to be integrated and the readiness of the production site, with a planned intervention schedule designed to minimize downtime.

Installation and commissioning

Bausano technicians handle assembly, connection to existing systems and initial configuration. This includes positioning and aligning mechanical components, electrical and pneumatic connections, process parameter configuration, and no-load and load start-up of the line. Operating parameters, power absorption, machine safety and performance consistency against design data are checked.

Technical verification and final acceptance

The SAT includes functional tests and finished product trials, which include verification of the main process parameters, checking of the performance specified in the contract, and qualitative assessment of the extruded material. Results are recorded in a technical acceptance report, which formally closes the delivery phase. If requested, operating staff receive direct support during the initial stages of production.

Technical training for operators and maintenance staff

Bausano provides a technical training service dedicated to the client's operators, maintenance staff and process technicians. The goal is to transfer the knowledge needed to manage the plant independently, reducing intervention times and increasing operational stability. Courses include modules on mechanics, automation, operation and diagnostics. Training can take place at Bausano's premises or at the client's facility, including during testing or start-up. Sessions combine theory, hands-on practice and documentation support. To request technical assistance, schedule a FAT, a SAT or a training course, clients can contact the Bausano team directly through the dedicated technical assistance service, available to define the timing, format and content best suited to each plant.

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If you want to know more about Bausano Extrusion Lines, our Testing & Training procedures or if you have any other questions fill out the form. One of our representatives will get back to you as soon as possible.