CHAPTER 10

SECONDARY PACKAGING AND TESTING

Secondary packaging is an important consideration regarding product protection within the

distribution environment. Ultimately, secondary packaging is vital to the life cycle of the primary
packaging. This chapter provides useful information on secondary packaging development and
testing.

Copyright © 2006 The Association for Dressings & Sauces 10-1

A. GENERAL INFORMATION

To provide the maximum protection for the pouched product, special attention and consideration
must go into the design of the secondary package. The most commonly used material for
secondary packaging is the corrugated box. The corrugated box is the most efficient,
economical container, which provides superior support and protection for its contents. In
addition to protection, secondary packaging can identify the product and promote brand identity
at the end of the distribution chain.

Secondary packaging must be engineered to provide containment and strength to withstand

your distribution environment. Criteria for the secondary package design should include:

1. Establishing the appropriate case design(s).

2. Maximizing the utilization of the pallet surface.
3. Maximizing the pallet cube efficiency.
4. When determining the paperboard weight and construction that should be used in the
case design, the following items need to be considered:

• Arrangement of cases on pallet

• Total shipping time - even after pallet is broken down
• Duration of case palletization
• Maximize abuse resistance needed to protect contents
• Allow case, not pouch, to support weight of other cases
• If the pallets are single, double or triple stacked

B. CORRUGATED

Figure 10-1 - Component Structure

Corrugated containers are the most frequently used shipping medium. For shipping purposes,
single wall and double wall corrugated boxes are used. A single wall consists of a liner board
on either side of a fluted medium (see Figure 10-2). Double wall corrugate is created by
bonding another single face layer to the single wall combination (see Figure 10-3).

Copyright © 2006 The Association for Dressings & Sauces 10-2

 Figure 10-2 - Single Wall Corrugate

Figure 10-3 - Double Wall Corrugate

The corrugate is attached to the liner board with an adhesive, which is generally starch-based.
Technology allows liner board and corrugate to be made to almost any basis weight and
thickness. Basis weight is the weight of the material in pounds per 1,000 square feet. The liner
board is made of virgin and recycled kraft. The corrugate is made of hardwood and recycled
fiber.

Flute Selection

When considering corrugated walls, flute size must be addressed. There are four standard flute
sizes. Larger flute sizes provide vertical compression strength and cushioning, where as
smaller sizes provide increased graphic capabilities. “C” flute is the most common choice for
secondary packaging for portion control products. It provides excellent protection as well as
top-to-bottom compression strength.

Figure 10-4 - Corrugated Flutes

Strength Determination

Strength is determined by the Mullen Burst Test or the Edgewise Compression Test (ECT). The
Mullen Burst Test determines a material’s resistance to bursting. ECT measures the stiffness or
compression strength of a corrugated material. ECT is an excellent test for determining
stacking strength.

Copyright © 2006 The Association for Dressings & Sauces 10-3

Liner boards have historically been selected because of the Mullen burst values. However, ECT
values are now more commonly used when specifying container strength. Table 10-1 below
identifies standard liner boards and corresponding Mullen burst values. Tables 10-2 and 10-3
below detail available grades of (ECT) for single wall and double wall containers.

Table 10-1 - Liner Boards/Mullen Burst Values

Grammage Basis Weight Mullen Burst Test Score

(grams) (pounds) (psi)
127 26 125
161 33 150
186 38 175
205 42 200
337 69 275

Table 10-2 - Available ECT Grades (Single Wall)

ECT Size Weight

Lbs/inch Limit Limit
23 40 20
26 50 35
29 60 50
32 75 65
40 85 80
44 95 95
55 105 120

Table 10-3 - Available ECT Grades (Double Wall)

Copyright © 2006 The Association for Dressings & Sauces 10-4

 ECT Size Weight
Lbs/inch Limit Limit
42 85 80
48 95 100
51 105 120
61 110 140
71 115 160
82 120 180

Figure 10-5 - Edge Crush Test

Specimen

Crush Tester

Copyright © 2006 The Association for Dressings & Sauces 10-5

Figure 10-5 shows an instrument used to determine the ECT value of liner boards.

Table 10-4 identifies standard flutes by basis weight and the corresponding flute flat crush
values.

Table 10-4 - Flute Basis Weight/Crush Values

Flute
Grammage Basis Weight A B C
(grams) (pounds)
127 26 0.70 1.00 1.15
161 33 0.90 1.25 1.45
195 40 1.10 1.50 N/A

Corrugated boxes can be custom designed to fit the primary packaging needs and many styles
can be used. The cartons should be engineered based on the product it must protect and
weight it must bear. Working closely with the corrugated supplier will assure the proper
materials are used in the design.

If the corrugated containers are going to be in areas of high humidity, inform the corrugated
supplier. Fifty percent of the compression strength of a corrugated board diminishes between
fifty percent (50%) and ninety percent (90%) relative humidity (RH). The liner board should be
made of virgin kraft in high humidity areas because recycled liner board absorbs water faster.
Additionally, additives to the starch adhesive may be necessary to improve its water resistance.

Additional information on corrugated is available from the following organizations:

Corrugated Packaging Council - www.corrugated.org

Fibre Box Association - www.fibrebox.org

Carton Styles

• Regular Slotted Carton (RSC) - The RSC is the most commonly used style of
shipping container. It can be hand erected or machine formed, hand filled or
machine filled, and closed by hand or machine.

Figure 10-6 - RSC

Copyright © 2006 The Association for Dressings & Sauces 10-6

 Figure 10-7 - Automatic Carton Erector

The automatic carton erector opens the carton, folds and seals the
bottom flaps in preparation for filling.

Figure 10-8 - Case Sealer

The case sealer closes and seals the top flaps using
either tape or adhesive (cold-set or hot-melt).

Copyright © 2006 The Association for Dressings & Sauces 10-7

 • Wrapper Style Carton, Figure 10-9 - The product is collated and placed on the
blank in a predetermined orientation. The blank is then folded and sealed around
the product. The wrap carton is ideal for self-supporting primary packages, such
as glass or plastic containers.

Figure 10-9 - Wrapper Style Carton

Figure 10-10 - Carton Wrapper

The equipment in Figure 10-10 folds the blank to accept

the collated primary packages, then wraps and seals the
blank around the product.

Copyright © 2006 The Association for Dressings & Sauces 10-8

 • Bliss Style Carton - A Bliss box (Figure 10-11) is made from three pieces of
corrugated. Different board grades and flutes may be used for the body/outer
and the ends. An example would be using a single wall body and double wall
end panels. This carton style requires machine setup, which is represented in
Figure 10-12.

Figure 10-11 - Bliss Style Carton Figure 10-12 - Bliss Carton Machine

Dividers

Dividers serve two functions: (1) they add to case strength and (2) they offer protection from
puncture and abrasion.

In refrigerated and shelf stable products, the case must protect the product. The case has to
bear a great deal of weight, and thus have a good stacking strength.

When considering corrugated box cost, it is cheaper to have a single wall corrugated box than a
double wall corrugated box. Unfortunately, the strength of the single wall case may not be
sufficient, therefore; the double wall strength is needed. Luckily, a less expensive option is
available, a single wall case with a divider. Frequently, a Z divider in a single wall case is not
only cheaper, but is stronger than a double wall corrugated case (see Figures 10-13 and 10-14).
However, labor costs for setup and insertion of the dividers must be taken into consideration.

Copyright © 2006 The Association for Dressings & Sauces 10-9

 Figure 10-13 - Z Divider

Figure 10-14 - Case with Z Divider

C. CASE DESIGN

When determining the dimensions of a secondary carton, the first step is to establish the
number of packages each carton will contain (primarily determined by maximum acceptable
case weight for handling ease) and the arrangement of the packages within the carton.

For example, a carton containing six #10 pouches could utilize two practical package stacking
arrangements. The first arrangement would be a single stack container in which all six
packages are column stacked on top of another (see Figure 10-15). The second option would
be to design a container with two cells. Each cell or compartment contains a stack of three
packages each (see Figure 10-16). Designing a six count #10 box to contain three stacks of

Copyright © 2006 The Association for Dressings & Sauces 10-10

two packages would not be a practical solution. A carton with three stacks of two #10 packages
would be awkward and lack sufficient height to assure a proper glue joint (See Figure 10-17).

Figure 10-15 - Single Stack of Six Packages

Figure 10-16 - Two Stacks of Three Packages

Figure 10-17 - Three Stacks of Two Packages

Triple Stack of 2 (3x2)

In some cases, there is only one practical stacking arrangement. For example, a carton
containing eight 64 oz. packages would have only one arrangement; two stacks of four
packages (see Figure 10-18). One stack of eight packages would result in a tall, narrow
alignment, and the carton would easily topple over (see Figure 10-19). A carton containing four
stacks of two packages would not have the required height to make the carton joints strong
enough to handle the load. Therefore, the only acceptable arrangement would be two stacks of
four packages each.

Figure 10-18 - Two Stacks of Four Packages

Copyright © 2006 The Association for Dressings & Sauces 10-11

 Double Stack of 4
(2 x 4)

Figure 10-19 - One Stack of Eight Packages

Single Stack of 8
(1 x 8)

D. DIMENSION CONSIDERATIONS

Calculating Secondary Packaging Dimensions for Pouches

Once the carton contents and package arrangements have been determined, the carton’s
physical dimensions must be calculated. When working with Vertical Form Fill and Seal (VFFS)
packages, always obtain the internal dimensions (ID) first. If the ID of the box container is
known, the outer dimensions can be determined by the type of corrugated board used. The
corrugated supplier can design the case once supplied with the ID. The internal dimension (ID)
is important in guaranteeing the survivability of packages under abusive conditions. To
correctly determine the ID of the case, the cell length, width and depth must be calculated.
Carefully read the measurement directions. Failure to accurately read these instructions will
result in an improperly sized case and an inadequately protected pouch.

Dimensions are given in the sequence of length, width (breadth) and depth (height). The
opening of a box is a rectangle; that is, it has two sets of parallel sides. The longer of the two
sides is considered its length, the shorter of the two sides is considered its width. The side
perpendicular to the length and width is considered the depth of the box.

Figure 10-20 – Calculating Secondary Packaging Dimensions

Copyright © 2006 The Association for Dressings & Sauces 10-12

 1. Length Calculation - Take the measurement from the center of a full finished
pouch. For accuracy, the pouch must be full and filled at normal production
temperatures. Do not use the cutoff length or an empty package. Do not
include the seals in the measurement. Subtract 1” from the filled pouch length
measurement and consider it to be the inner cell length for packages up to a #10
can equivalent (100 oz.). Two inches should be subtracted from a filled pouch
length when the pouch holds more.

2. Width Calculation - Generally, the narrowest section of the package is slightly 1”

below the horizontal seal area. For accuracy, the package must be full and have
been filled at the same product temperatures as normal. Do not use an empty
package, half of the width of the film or half of the width of the film minus the
side seal, lap or fin seal. This will result in an inaccurate measurement. Once
the narrowest package width is known, subtract 0.5” and the resulting number
will be the inner cell width. It may help to refer to Figure 10-21 on page 10-14.
Half of an inch is subtracted from the pouch width in order for the case to
support the side wall of the pouch. If the case is dropped, the case side wall
receives the shock, not the pouch.

Similar to the width measurement, 1” or 2” is subtracted from the pouch length to protect the
horizontal end seals. Studies prove that on a two foot drop, the shock of the drop goes to the
extremities of the pouches, which is the side walls and end seals. This shock causes the side
walls and end seals to tear open or stretch.

By subtracting 0.5” and 1”, respectively, from the width and length the cell becomes
“undersized.” This undersizing allows the end seals and side walls to be tucked inwards. Now,
when the case is dropped, the shock energy transfers from the pouch side walls and end seals
to the sides of the case. The case is stoutly made, so it can withstand these shock waves. The
pouches can thus survive a drop and still be intact.

Copyright © 2006 The Association for Dressings & Sauces 10-13

 Figure 10-21 - Length and Width Measurements for Case Design

To obtain the inner diameter cell length:

Measure the distance between point A and point B. Subtract 1”.

To obtain the inner diameter cell width:

Measure the distance between point C and point D and subtract 0.5”. Alternately, measure the
distance between point E and point F and subtract 0.5”.

3. Depth Calculation - Construct a cell according to the length and width

dimensions calculated. Stack the correct number of pouches in the cell (use
pouches that are slightly heavier than the target weight, but within the upper
weight specification). Insert a ruler down the side of the cell to the bottom.
Balance another ruler or flat piece on the top pouch (see Figure 10-22). Read at
the intersection. Add 0.25”. This is the cell depth with a slight “headspace.”

Copyright © 2006 The Association for Dressings & Sauces 10-14

 Figure 10-22 - Depth

Ruler
Measure HERE
HEA D SPA C E
at Intersection
POUCH
POUCH
POUCH Ruler or Flat Piece
POUCH Balanced on Pouches POUCH
POUCH

During transportation, the packages in a case and the cases on a pallet start moving in
harmonic motion (sine wave). The force of the downward motion must go someplace. The
bottom pouch within a case receives all the shock energy from pouches in the case. The force
from other cases may also be transferred to that case. Luckily, the case(s) have 0.25” of
“headspace.” This allows the energy to act as a spring. The shock wave acts as a downward
force. The energy hits the bottom pouch and deflects causing the pouches to move upward. If
the 0.25” headspace were not there, the pouches and the energy would not deflect. The energy
would be exerted on the bottom pouches, particularly the end seals, side seals and adjacent
corrugation walls of the secondary container. The pouch side walls and end seals, as well as
the case side walls, may give way. Thus, for refrigerated and shelf stable product, this 0.25” of
headspace in the case is important.

Figure 10-23 - Headspace

As shown in Figure 10-23, too much headspace can be as disastrous as too

little movement and settling can occur

Inner dimension calculations of a cell are the most critical calculation of the case design. With
canned and bottled products, the product can support the weight of other cases. However, a
pouch cannot depend on the strength of the case itself for protection and stacking strength.

Copyright © 2006 The Association for Dressings & Sauces 10-15

Pouch packaging is in its infancy compared to other food packaging methods. Corrugated
suppliers are well versed on can and bottle case design. Few have been involved in the
research of pouch case design. To ensure product integrity, it is recommended that either the
product manufacturer or the film supplier provide the corrugated supplier with the ID.

Calculating Secondary Packaging Dimensions for Rigid Containers

Calculating the inside dimensions for rigid packaging such as portion control cups is much less
complicated compared to flexible pouches. First, determine the optimum stacking arrangement
for the product inside the case. Figures 10-24 and 10-25 show carton dimensions and product
configurations for the same portion control cups.

Figure 10-24 - Calculating a Cup Package

Arrange 6 x 6 x 10 layers = 360 per carton

Copyright © 2006 The Association for Dressings & Sauces 10-16

 Figure 10-25 - Alternate Case Arrangement

Arrange 5 x 4 x 18 = 360 per carton

As previously discussed with pouch containers, avoid arrangements with small footprints or that
would be awkward to handle (see Figures 10-16 and 10-18 on pages 10-11 and 10-12). Once
the most practical arrangement is determined, measure the length, width and depth. Provide
these dimensions to the corrugated supplier to complete the carton design. The corrugated
supplier will determine allowances and proper headspace. Software, such as Computer
Assisted Packaging Evaluation (CAPE) or TOPS, is also available for case design and pallet
pattern configurations. To obtain more information on these programs contact the following:

CAPE Systems, Inc.

Corp. Headquarters & Supply Chain Solutions Center
3619 Kennedy Road
South Plainfield, NJ 07080
Phone: 908-756-2000
[email protected]
www.capesystems.com

TOPS ENGINEERING
World Headquarters
275 W. Campbell Road, Suite 600
Richardson, TX 75080
Phone: 800-889-2441
[email protected]
www.topseng.com

Copyright © 2006 The Association for Dressings & Sauces 10-17

Pallet Pattern Calculation

When calculating pallet patterns for secondary packaging, it is recommended that software be
used. The software will calculate the optimum pattern to maximize utilization of the pallet
surface and cube efficiency.

Figure 10-26 - Calculating a Pallet Pattern

50 cases per pallet x 360 = 18,000 per unit load

Figure 10-27 - Alternate Pallet Pattern

54 cases per pallet x 360 = 19,400 per unit load

In Figure 10-26, the cartons are stacked 5 high requiring the bottom carton to support the
weight of 4 cartons on top. The alternate pallet pattern shown in Figure 10-27 yields more
packages per pallet, and the cartons are only stacked 3 high.

Copyright © 2006 The Association for Dressings & Sauces 10-18

Pallet patterns can either be Interlocked (see Figure 10-28), Column stacked (see Figure 10-29)
or a combination of the two (see Figure 10-30). Interlocking provides a stable unit, but up to
45% of stacking strength is lost. Column stacking is the desired option to maximum stacking
strength. If stacking strength is critical, but the unit is unstable with a full column stack, consider
interlocking the top one or two layers of the unit. Tier/tie sheets may also be used to help
stabilize units.

Figure 10-28 - Interlocked Pattern

Figure 10-29 - Column Pattern

Copyright © 2006 The Association for Dressings & Sauces 10-19

 Figure 10-30 - Combination Pattern: Interlock Upper Layers

E. SECONDARY PACKAGING TESTING

In order to determine if the secondary package will provide the necessary protection for the
product, testing may be required. Consider the distribution environment from the time the
product is packaged in the case until it reaches the end user. The following testing procedures
will enable you to simulate this environment and insure adequate protection for the product.

Environmental Testing: Distribution shipping and handling

• Drop/shock testing (cases)
• Vibration (handling/shipping)
• Compression (stacking)

Time, temperature and humidity need to be taken into consideration when developing
secondary packaging and conducting testing.

Drop Testing

Secondary Packaging
Per ASTM D4169 – Standard Practice
for Performance Testing of Shipping Containers
and Systems

Drop testing is an effective way to determine if packaging materials can withstand impacts
caused by dropping during manual handling. The most effective drop test is one that has a
clear objective and is repeatable and reproducible. A repeatable and reproducible drop test can
be designed according to the ASTM D4169 standard.

Copyright © 2006 The Association for Dressings & Sauces 10-20

Step 1: Define the objective
- Why drop test?
- What will be verified?
- Where will the results lead?

Forming a clear objective is a must for an efficient and effective drop test. Here is one
example:

EXAMPLE 1 OBJECTIVE - To verify that the corrugated box can protect its product from
dropping during manual handling at the production line and down stream. Verification of
protection may lead to qualifying the box design.

This objective focuses on the box design and places emphasis on its ability to protect product
from one distinct hazard.

Step 2: Procedure
The ASTM D4169 standard can be followed as a procedural guideline to develop a drop test
plan that will satisfy the objective.

• DEFINE THE PACKAGING TO BE TESTED.

The ASTM D4169 standard supports pouches/bags, corrugated boxes and cylindrical
containers.

Typically, the actual shipping unit (the smallest complete unit that will be subjected to
the distribution cycle) is tested. For example, a corrugated box and its product.
However, depending on the objective of the drop test, individual components of a
shipping unit may also be tested.

• ESTABLISH THE ASSURANCE LEVEL.

This should be based on the product value, the desired level of anticipated damage
that can be tolerated, the number of units to be shipped, knowledge of the shipping
environment or other criteria. There are three pre-determined levels:

LEVEL I – Highest intensity.

LEVEL II – Intermediate intensity (recommended).
LEVEL III – Lowest intensity.

Drop Height, in. (mm) Assurance Level

Shipping Weight, lb. (kg) I II III
0 to 20 (0 to 9.1) 24 (610) 15 (381) 9 (229)
20 to 40 (9.1 to 18.1) 21 (533) 13 (330) 8 (203)
40 to 60 (18.1 to 27.2) 18 (457) 12 (305) 7 (178)
60 to 80 (27.2 to 36.3) 15 (381) 10 (254) 6 (152)
80 to 100 (36.3 to 45.4) 12 (305) 9 (229) 5 (127)
100 to 200 (45.4 to 90.7) 10 (254) 7 (178) 4 (102)

Copyright © 2006 The Association for Dressings & Sauces 10-21

• DETERMINE THE ACCEPTANCE CRITERIA.
What is the desired condition of the product and packaging at the end of the test?

In many cases, the acceptance criteria can be the following:

Criterion I - Product is damage-free.

Criterion II - Packaging is intact.
Criterion III - Both criteria I and II.

This typically means that the packaging and/or its contents are suitable for sale upon
completion of the test. More detailed criteria may be used. Methods may range from
simple pass-fail judgments to highly quantitative scoring or analysis systems.

• WRITE A TEST PLAN.

Follow the ASTM D4169 standard. Assure that the plan will satisfy the objective. At
the minimum, a test plan should include:

- Description of the packaging and its contents.

- Assurance levels and rationale.
- Acceptance criteria.
- Processing parameters and set points.
- Sample collecting and conditioning.
- Number of samples to be tested.
- Party to perform test.
- Testing facility.
- Finished product identification and controls.

Below is a sample test plan for a box:

Copyright © 2006 The Association for Dressings & Sauces 10-22

 DROP TEST PLAN Designer: John Lute
for BOX 205080 Date: 10/2/2002
modeled after ASTM D 4169 Pages: 1

DESCRIPTION:
1. Test Unit: Resource# 205080 Pillow Pack Carton 10/.5, OD (L)18.875 x (W)9.5 x (H)9.875, Flute BC, ECT51, TixHi = 10x5.
2. Assurance Level: Level I, based on absence of Schedules B, C, D, E, and F.
3. Acceptance Criteria: Criterion III--Packaging is intact and product damage-free.
4. Test Schedule: DC-2 User Specified.
5. Test Plan:
Sequence Test Schedule Test Method Level Procedure
1 A Handling-- D 5276 Box w ith product (approx. 41 lbs.): Refer to the photos
Manual one drop on top, one drop on each below . Cradle box in
bottom edge, one drop on tw o both hands at the
diagonally opposite bottom corners, recommended height
one drop on bottom, height for each (see lines on photos)
drop 18 in. (457 mm). over a clean, flat
surface. With elbow s
bent at 90°,
simultaneously separate
both hands to permit the
box to free fall.

TOP DROP BOTTOM EDGE DROP BOTTOM CORNER DROP

BOTTOM DROP

6. Samples: 1 sample shall be taken directly from the bottom, middle, and top layers of one pallet at start-up, middle, and end o
production run.
7. Condition Samples: No conditioning needed. Ambient temperatures and relative humidities.
8. Execute Test: Perform test in accordance to the above
9. Evaluate Results: Examine boxes and pouches to determine if the acceptance criteria has been
10. Document Test Results: Use the attached data sheet to record all steps in detail.
11. HOLD all product. Release if test objective is met.

Copyright © 2006 The Association for Dressings & Sauces 10-23

Step 3: Evaluation
• REPORT THE TEST RESULTS, but at a minimum, a report should include:

- Reference to ASTM D4169 – Standard Practice for Performance Testing of

Shipping Containers and Systems.
- Description of the packaging and its contents.
- Assurance levels and rationale.
- Acceptance criteria.
- Processing parameter set points and actual output.
- Sample conditioning used.
- Number of samples tested.
- Variation from recommended procedures.
- Condition of samples after test.
- Name of person that performed test.
- Testing facility used.
- Finished product disposition.

• DETERMINE IF THE ACCEPTANCE CRITERIA WAS MET.

• DETERMINE IF THE OBJECTIVE WAS MET.

Copyright © 2006 The Association for Dressings & Sauces 10-24

Vibration Testing Equipment

ASTM D999 – Standard Method for Vibration Testing of Shipping Containers

Figure 10-31 Figure 10-32

Repetitive Shock Resonance Rotary Motion
Vertical Linear

Figures 10-31 and 10-32 show two types of machines used for vibration testing. Refer to test
procedure ASTM D999 for additional information. ASTM D4728 – Standard Test Method for
Random Vibration Testing of Shipping Containers describes the procedure for random vibration
testing.

Copyright © 2006 The Association for Dressings & Sauces 10-25

Shock/Drop Testing Equipment

Figure 10-33 Figure 10-34

Drop
Incline

ASTM D5276 – Standard ASTM D880 – Standard Test Method for

Test Method for Drop Test Impact Testing for Shipping Containers and
of Loaded Containers Systems

The procedure for shock/drop will vary by machine. The use of a drop tester (Figure 10-33) is
usually limited to packages up to 150 pounds. It is used to determine if a certain weight
dropped from a predetermined height can survive.

The incline (Figure 10-34) provides similar results on a larger scale. An incline tester is
generally for unit loads including the pallets. Velocity of impact is regulated by distance for both
the drop and incline testers.

Refer to ASTM methods ASTM D5276 and ASTM D880 for drop testing and incline testing
procedures, respectively.

Copyright © 2006 The Association for Dressings & Sauces 10-26

 Figure 10-35

Shock

ASTM D3332 – Standard Test Methods

for Mechanical-Shock Fragility of Products
Using Shock Machines

A shock machine (Figure 10-35) is used for the primary package and uses velocity and
acceleration to determine a damage boundary. Again, this test is performed at standard
conditions. Any special conditions to be considered could be written into the test plan. Test
procedure ASTM D3332 is application for this test.

Copyright © 2006 The Association for Dressings & Sauces 10-27

Compression Testing

Compression testing provides data on maximum strength of the shipping container. The
container is compressed and deformation at various loads is recorded. ASTM D642 describes
the procedure for compression testing.

Figure 10-36

ASTM D642 – Standard Test for Determining

Compressive Resistance of Shipping Containers,
Components and Unit Loads

Copyright © 2006 The Association for Dressings & Sauces 10-28

Alternative Testing

The International Safe Transit Association (ISTA) has pre-written test plan procedures. Figure
10-37 shows alternative test methods for shock testing.

Figure 10-37

With proper design considerations, primary and secondary packaging can withstand distribution
hazards with reduced damage or loss. Benefits include launch confidence, economic
distribution costs and consumer satisfaction.

ASTM International test methods are available for purchase at www.astm.org.

Copyright © 2006 The Association for Dressings & Sauces 10-29