Commissioning (start-up)

Commissioning, also known as start-up, is the final stage of delivering an installation. It covers switching on all the equipment for the first time, checking that everything works together as intended, and fine-tuning the parameters until the installation consistently produces a product of the required quality.

Commissioning usually takes place in stages:

1. Pre-commissioning checks: inspection of the installation work, pipe leak tightness, motor rotation directions, and the operation of safety devices and signals.
2. Cold commissioning (water trials): the installation runs on water instead of product. Flows, operating sequences, CIP cleaning and automation responses are checked without the risk of wasting raw materials.
3. Hot commissioning (product trials): the first batches are produced from real raw materials. Process technologists and automation engineers fine-tune parameters such as temperatures, times and speeds until the product meets the quality requirements.
4. Trial run: the installation operates in normal mode for a set period to confirm that the target capacity and stability have been achieved.

During commissioning, operators and maintenance staff are also trained, and the contractor hands over the as-built documentation and operating manuals.

Water trial example: A new ketchup production line in a fruit and vegetable processing plant is first started up on water. The team checks whether the pumps deliver the correct flow, whether there are leaks at the joints and whether CIP cleaning reaches every part of the system. If something leaks, only a little water is lost, not tonnes of tomato concentrate.

Product trial example: The first batch of real ketchup turns out too runny. The process technologist and the automation engineer extend the cooking time and raise the temperature by a few degrees. The second batch is too thick, and the third has the right consistency. These settings are saved as a recipe, which operators will use day to day.