Commissioning:
arriving on-site with the plant ready to go
Proper planning is the first step towards ensuring a fast, safe and efficient commissioning process. Before commissioning shredders, mills and separation lines, our team supports you at every stage of the pre-installation process: analysing the operational, logistical and digital requirements of the production site.
Zato’s commissioning service includes pre-installation planning, machine installation and set-up, technical training for operators, and a dedicated team of contacts to manage every stage. This approach allows us to arrive on-site with a plant that is already ready to go, reducing downtime and speeding up the start of production from day one.
PLANNING & PRE-INSTALLATION
Arriving on-site with the system ready to go requires careful preparation. The Zato team analyses in advance all the factors that may affect commissioning: system layout, manoeuvring space, connectivity, logistics and coordination of the personnel involved.
What we do during the planning phase:
- Analysis of the plant layout and installation areas
- Organisation of equipment, manoeuvring space and safety
- Checking internet connections and digital communication systems
- Submission of the list of required oils and greases
- Coordination of access, timelines and personnel involved
This commissioning checklist ensures that the system is ready for initial setup, functional testing and the actual start-up.
THE BENEFITS FOR THE COSTUMER
A structured planning process translates into tangible and measurable benefits for the customer:
- Faster installation with no unexpected issues
- Better integration between the plant, site and infrastructure
- Reduced start-up costs
- Fewer plant shutdowns during the initial phase
- A machine already optimised for the desired performance
Unlike other manufacturers, Zato does not simply manage the installation: it plans, designs and optimises it in collaboration with the customer.
INSTALLATION & SET-UP
When installing a shredder, a mill or an entire separation line, the set-up phase makes all the difference.
The Zato team oversees every step of the installation, wherever in the world.
What we actually do:
- Correct alignment of rotors, shafts, pushers and critical components
- Inspection of the electrical system and safety systems
- No-load and load tests to assess how the machine performs
- Adjustment of speed, pressure and parameters according to the material being processed
- Synchronisation of the shredder, mill and separation line to prevent bottlenecks
The aim is to avoid the most common problems: vibrations, premature wear, high fuel consumption, blocked flow, and frequent downtime.
TECHNICAL TRAINING KNOWLEDGE TRANSFER
Every mistake — an incorrect load, a signalled warning ignored, a procedure skipped — can lead to unplanned downtime, premature wear and tear, and costs running over budget.
Zato training is an integral part of the commissioning process, carried out directly on the customer’s machine, using their materials and within their actual operating cycles.
What we cover in practice:
- Basic checks and key machine adjustments
- Correct material loading to avoid stress on the shredder or grinder
- Immediate recognition of abnormal signals during the cycle
- Safety procedures, emergency stop and restart
- Management of the most common faults without the need for external intervention
The results are clear: fewer operational errors, fewer avoidable downtimes, and more uptime. A trained operator reduces day-to-day operational risks and safeguards the value of the investment over time.
FAQ
How long does the commissioning phase take?
The duration depends on the complexity of the installation and the preparation of the site. Thanks to pre-installation planning, Zato minimises commissioning times, arriving on-site with everything ready to go.
Does commissioning include training for operators?
Yes. Technical training is an integral part of Zato’s commissioning process and is carried out directly on the customer’s machine, using the actual materials and following the site’s actual operating cycles.
Does Zato carry out commissioning work worldwide?
Yes. Zato’s technicians operate in around 60 countries. The commissioning service is available worldwide, with multilingual support and international coordination managed directly by Zato.
What happens if problems arise during installation?
The Zato team handles any unforeseen issues thanks to the experience gained from similar installations around the world. The aim is to resolve any problems directly on site, ensuring the system starts up correctly.
Why is pre-installation planning so important?
Proper planning reduces downtime, avoids costly unforeseen issues and ensures that the machine is already optimised for the desired performance from the very first day of production.
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