A dairy facility completes a $600K CIP system upgrade on schedule and budget. The equipment is installed. Controls are programmed. Electrical connections are tested.
The project team declares success and moves on.
Six weeks later, operators report: Cycle times are inconsistent. Chemical consumption is 15% higher than expected. Downtime occurs weekly when the control system doesn't achieve setpoint.
The root cause: Commissioning was inadequate. The equipment was installed and functional, but not optimized for actual production conditions.
The Three Commissioning Phases
Phase 1: Factory Acceptance Testing (FAT)
Happens: At equipment manufacturer's facility BEFORE delivery
What it tests: Equipment works as specified in controlled conditions
Example: Separator achieves 10,000 gallons/hour throughput at lab conditions (ideal temperature, composition, flow)
Cost: $15K-$30K
Timeline: 2-4 days
Duration: 1-2 weeks to schedule and execute
Problem: FAT doesn't replicate your facility's conditions. Lab conditions rarely match production reality.
Phase 2: Site Acceptance Testing (SAT)
Happens: At your facility with your equipment, your utilities, your water quality, YOUR conditions
What it tests: Equipment works as specified at YOUR facility
Example: Same separator achieves 9,200 gallons/hour at actual facility (real water hardness, temperature variability, actual operator proficiency)
Cost: $30K-$60K
Timeline: 2-4 weeks
Duration: 3-6 weeks to schedule, execute, troubleshoot, retest
Value: Identifies performance gaps BEFORE going live
Phase 3: Production Ramp-Up
Happens: Full production with new equipment
What it accomplishes: Operator training, process refinement, performance documentation
Cost: Embedded (production team time)
Duration: 2-6 weeks depending on complexity
Value: Validates that equipment meets production targets at sustained rates
Why Commissioning Gets Skipped
Budget pressure: "We're at budget limit. Commissioning seems optional." Schedule pressure: "We need production to start immediately." False confidence: "Equipment passed FAT. It should work fine."
The result: Equipment that technically works but underperforms operationally. Hidden costs emerge over months: higher energy use, more downtime, lower capacity realization.
The Cost of Inadequate Commissioning
Poor commissioning typically results in:
- 10-20% lower throughput than expected
- 15-25% higher operating costs (energy, chemical, labor)
- 5-10% more downtime due to control instability
- 3-6 months to optimize performance (if pursued at all)
Adequate commissioning cost: $50K-$100K Value recovered from optimization: $150K-$300K annually
ROI: 150-300% in first year, then ongoing savings.
The Commissioning Roadmap
Adequate commissioning requires:
- Detailed performance requirements documented (before project starts)
- FAT at manufacturer validating specs
- SAT at your facility with your conditions (4-6 weeks)
- Production ramp-up with dedicated support (4-6 weeks)
- Performance documentation proving targets achieved
- Operator training and optimization
For food manufacturing companies, budgeting and scheduling adequate commissioning—especially SAT—is foundational to achieving expected project ROI and operational performance.
