Commissioning is the moment of truth. Weeks or months of planning, fabrication, and installation culminate in the instant when the plant runs under real conditions for the first time. In the food industry, a critical factor is added: time pressure is enormous because every day of delay means lost production — and with perishable products, there is no buffer.
At VLD Service, we have performed or supported the commissioning of over 50 plants in Switzerland.
What commissioning really means
Commissioning is not “connect the power and press the start button”. It is a structured process that typically takes 20–30% of the total project time:
Mechanical verification: Are all components correctly installed? Are alignment, spacing, and tolerances within specification?
Electrical verification: Insulation resistance, protective conductor continuity, motor rotation direction, functional test of all safety circuits.
Software parameterisation: Load PLC programme, configure HMI, parameterise variable frequency drives, calibrate sensors.
Dry run: The plant runs without product. All movements are checked, speeds adjusted, limit positions verified.
Wet run / Production test: The plant runs with real product. Now you see whether everything works as planned.
Optimisation: Fine-tune cycle times, adapt recipes, train operators, create documentation.
The proven 6-phase process
Phase 1: Pre-check (1–2 days before)
- Is installation fully completed?
- Are all utility connections present (power, water, compressed air, steam)?
- Is the area cleaned and accessible?
- Is documentation available (circuit diagrams, PLC programme, parameter lists)?
- Are the customer’s operators informed and available?
Phase 2: Initial electrical inspection
Systematic verification per EN 60204-1:
- Visual inspection of the entire electrical installation
- Insulation resistance measurement (≥ 1 MΩ at 500V DC)
- Protective conductor test (≤ 0.3 Ω)
- Phase rotation check
- Emergency stop functional test (each button individually)
- Verification of all safety devices
Phase 3: Individual component test
Each component is tested individually: motors, pneumatic cylinders, sensors, valves, VFDs.
Phase 4: Sequence test (dry run)
The complete plant executes the intended production cycle — without product. All operating modes are tested and fault scenarios are simulated.
Phase 5: Production test (wet run)
The plant works with real product:
- First batch at reduced speed
- Gradual increase to nominal capacity
- Quality control of produced goods
- Cycle time measurement
- Cleaning cycle test
Phase 6: Handover and documentation
- Acceptance protocol signed with customer
- Operator training
- Handover of maintenance plan
- Backup of PLC programmes and parameter lists
- Punch list for non-critical follow-up items
Common mistakes
Mistake 1: No pre-check
The installation team reports “finished”, but during commissioning it turns out: a cable is missing, a valve is incorrectly connected. Each issue costs hours.
Mistake 2: Software not prepared
The PLC programme was written in the workshop, but real parameters are not yet entered. The programmer must improvise on site.
Mistake 3: No operators present
Commissioning is complete, but nobody from the customer was present. Result: the operator doesn’t know the plant.
Mistake 4: Time pressure during optimisation
The plant runs, production must start immediately. No time left for fine-tuning.
Solution: Plan at least 2 days for optimisation after the first successful production run.
Swiss specifics
High quality expectations: Swiss food producers expect a flawless handover.
MaschV and EKAS: The Swiss Machinery Ordinance and EKAS guidelines define safety requirements. The declaration of conformity must be available at handover.
Multilingualism: HMI and documentation in DE/FR/IT depending on the region.
Cleaning validation: Many Swiss plants require proof that the installation is actually clean after the cleaning cycle — particularly in meat processing.
Our experience
VLD Service has performed over 50 commissionings in the Swiss food industry:
- Complete commissioning: From initial electrical inspection to handover
- PLC programming: Siemens S7/TIA Portal, Allen-Bradley, plant-specific
- HMI configuration: WinCC, Ignition — multilingual (DE/FR/IT)
- Post-optimisation: Even weeks after handover, until the plant stably reaches nominal capacity
Planning a plant commissioning? Contact us early — ideally during the installation phase: +41 32 552 28 88 or info@vldservice.ch.
For machinery manufacturers: Selling equipment into Switzerland and need local commissioning support? Learn how we act as your on-site installation and commissioning partner in Switzerland.
