Startup Readiness
Bottling Line Spare Parts and Commissioning Checklist
Prepare site utilities, installation, test materials, software backups, training, critical spares, issue records, and site acceptance before startup.
A bottling line can pass a factory test and still start poorly at the buyer’s site if utilities, installation, format parts, test materials, software, training, spares, and issue ownership are not ready. Commissioning and spare-parts planning should begin during quotation review, not after the containers arrive.
1. Divide parts into useful groups
Ask for separate lists for startup consumables, routine wear parts, critical breakdown spares, electrical and control spares, product-contact seals, format parts, special tools, and recommended stock for the first operating period. Each line should identify machine, part number, drawing reference, quantity, unit, supplier, lead time, storage needs, and replacement guidance.
| Part group | Examples to discuss | Buyer decision |
|---|---|---|
| Wear and consumable | Seals, belts, guides, filters, lubricants and routine service items | Expected life and stocking quantity |
| Critical breakdown | Parts whose failure can stop the line | Lead time, redundancy and local availability |
| Controls | Sensors, power supplies, drives, HMI or PLC-related items | Exact model, backup and replacement procedure |
| Format parts | Stars, guides, screws, molds, heads or pack change parts | Included formats, labels and storage |
| Special tools | Setup, maintenance, calibration or lifting tools | Included quantity and training |
2. Confirm software and document backups
Request final electrical drawings, input/output lists, alarm list, parameter record, PLC and HMI backup, drive settings, recipes, network addresses, passwords or access-control procedure, and restore instructions as contractually appropriate. Record the delivered version and storage location.
3. Make site readiness measurable
- Equipment foundations, floor, drainage, access, platforms, lifting, lighting, ventilation, and clean working area.
- Power, grounding, compressed air, high-pressure air, process water, cooling, steam, chemicals, drainage, and network at agreed quality and capacity.
- Representative product, bottles, caps, labels, film, cartons, pallets, cleaning media, lubricants, and laboratory tools.
- Buyer operators, maintenance staff, translators where needed, supplier technicians, safety controls, permits, and shift schedule.
4. Define commissioning stages
Separate mechanical completion, utility checks, dry testing, cleaning, water or product trials, individual-machine tests, integrated line tests, format changeovers, training, performance runs, issue correction, and site acceptance. Each stage should have prerequisites, responsible parties, records, and a clear release decision.
5. Keep one issue and punch-list record
For each issue, record machine, date, symptom, evidence, production effect, temporary action, responsible party, target date, parts or software needed, verification method, and closure approval. Distinguish installation damage, missing scope, adjustment, operator training, utility instability, packaging-material variation, and design nonconformity.
6. Plan support after the technicians leave
Confirm support hours, response channel, remote-access method, language, escalation path, warranty reporting, parts ordering, software-change control, and who can authorize adjustments. Photograph nameplates and connect each machine serial number to the final manual and parts list.
Do not accept a generic spare-parts box without a reconciled list. Before shipment and again after installation, verify quantities, labels, machine references, preservation, and missing items.
Questions buyers ask
When should spare parts be discussed?
Before the order, then reconciled during FAT, packing, delivery, and site startup.
What belongs in a commissioning plan?
Site readiness, utilities, installation, test materials, technicians, tools, training, startup stages, output checks, issue logging, and acceptance.
Why is a parts list not enough?
Each item should connect to a machine, part number, drawing, quantity, stock recommendation, replacement method, source, and lead time.