Package Testing
Methods

Appendix B compatibility testing evaluates the chemical compatibility and permeability of plastic packaging when in contact with liquid hazardous materials. The test determines whether the packaging material is appropriate for the intended chemical contents. Three test methods are specified under Title 49 CFR: 180 days at 18°C or above, 28 days at 50°C or above, and 14 days at 60°C or above. Results confirm compatibility for Title 49 CFR compliance and are also used in packaging consulting engagements for product-package compatibility analysis.

Basis weight testing measures the mass per unit area of paper and paperboard, expressed in grams per square meter (gsm) or pounds per thousand square feet. Basis weight is a fundamental material specification for paper-based packaging and is used in quality control, material acceptance testing, and freight classification.

Box compression testing measures the maximum compressive load a corrugated box can sustain before failure. A continuous compressive force applied to the top of the box records the peak load at which the structure collapses. BCT is the primary measure of corrugated box structural integrity and is used to establish stack load ratings, validate packaging specifications for distribution, and classify freight under LTL motor carrier standards.

Bubble emission testing submerges a sealed package in water and applies internal pressure or vacuum to identify gross leaks. Escaping air bubbles indicate a breach in the seal or packaging material. The method detects leak paths large enough to compromise sterile barrier integrity and is used as a pass/fail screening test for medical device and pharmaceutical packaging.

Bulk packaging performance testing applies to dangerous goods packaging designs above the bulk threshold: intermediate bulk containers (IBCs), large packagings, and bulk containers. Test sequences vary by container type and include bottom lift, top lift, stacking, drop, leakproofness, and vibration testing as applicable. IBCs must also pass hydraulic pressure and internal pressure tests. Results support UN certification marks for bulk dangerous goods packaging.

Burst strength testing evaluates the resistance of a sealed package to internal pressure, confirming that the seal and packaging material can withstand the pressure differentials that occur during distribution. Increasing internal pressure is applied until the package fails, characterizing whether failure occurs at the seal or in the packaging material.

Cobb water absorption testing measures the mass of water absorbed by a paper or paperboard surface over a defined contact period. The test quantifies moisture resistance for corrugated packaging that must perform in humid environments, cold chain storage, or refrigerated transport. Cobb values are a standard specification for corrugated packaging used in food and beverage, cold chain, and outdoor distribution applications.

Concentrated impact testing applies a focused point load to a package surface to simulate the localized damage that occurs when packages are struck by sharp corners, conveyor mechanisms, or adjacent packages during handling. The test evaluates a package's resistance to puncture and localized structural failure.

Drop testing subjects packaged products to free-fall impacts from specified heights and orientations, simulating the drops that occur during warehouse handling, conveyor transfer, and last-mile delivery. The test evaluates whether the packaging absorbs impact energy sufficiently to protect the product inside. Drop height, orientation, and number of drops are defined by the governing standard and the product’s weight class.

Dye penetration testing applies a colored dye solution to the seal area of a package and observes whether the dye penetrates through any breach in the seal. The method reveals small seal defects, including incomplete seals, channels, and contamination, that visual inspection alone cannot detect. Dye penetration is a destructive test used to characterize seal quality and validate sealing processes.

Dye penetration testing applies a colored dye solution to the seal area of a package and observes whether the dye penetrates through any breach in the seal. The method reveals small seal defects, including incomplete seals, channels, and contamination, that visual inspection alone cannot detect. Dye penetration is a destructive test used to characterize seal quality and validate sealing processes.

Edgewise crush testing measures the compressive strength of a corrugated board specimen loaded on its edge, in the direction in which the fluted medium runs. ECT is the primary measure of corrugated board column strength and correlates directly with the box compression strength of finished boxes. ECT values are used in box specification, freight classification, and packaging design.

ESCR testing evaluates the resistance of plastic packaging materials to cracking under stress when in contact with chemical agents. Stress cracking is a failure mode in plastic containers where the combination of internal stress from the manufacturing process and chemical exposure from the contents initiates crack propagation. Three ASTM methods cover different plastic container types: ASTM D5571 (tight-head drums), ASTM D1975 (injection-molded open-head pails), and ASTM D2561 (blow-molded polyethylene containers).

Hydrostatic pressure testing applies internal water pressure to a packaging system to evaluate the strength of the container walls and closure under hydraulic forces generated by liquid fill. For dangerous goods packaging, hydrostatic pressure testing is a required performance test for packaging intended to contain liquids, confirming the container will hold under the pressure of its contents during transport.

Infectious substance packaging testing validates packaging designs for Category A and Category B infectious substances under the UN packaging requirements for biological materials capable of causing disease in humans or animals. Category A packaging must survive a drop sequence designed to test both the primary receptacle and secondary packaging containment under worst-case conditions. TEN-E performs testing for both Category A (capable of causing life-threatening disease) and Category B (lower risk) infectious substance packaging.

Insulated shipper validation confirms that a complete insulated shipping system, including shipper, insulation, refrigerant, and payload configuration, maintains the required temperature range through a defined transit profile. Validation testing establishes the performance envelope of the system: the maximum transit duration, ambient temperature conditions, and payload mass for which the shipper is qualified. Results support pharmaceutical and medical device cold chain documentation requirements under FDA and GDP frameworks.

Leakproofness testing verifies that a closed packaging system does not leak under test conditions. For dangerous goods packaging, leakproofness testing involves submerging the filled or representative package in water and applying internal air pressure; the absence of air bubbles confirms the closure system is leakproof. Leakproofness is a mandatory performance test under Title 49 CFR for liquid dangerous goods packaging designs.

Lighter testing and certification evaluates lighter packaging designs under the performance requirements of 49 CFR 173.308(b) and Part 178. TEN-E holds Lighter Certification Agency status, a DOT-authorized designation that allows TEN-E to test lighter packaging to the applicable performance standards and issue LAA (Lighter Authorization Approval) numbers for compliant designs. An LAA number is the documentation required for companies that ship lighters as dangerous goods under Title 49 CFR.

Low pressure testing simulates the reduced atmospheric pressure that packaged products experience during air transport. At altitude, pressure differentials can cause flexible packaging to expand, seal integrity to fail, aerosol containers to vent, and liquid products to leak. The test applies a sustained vacuum representative of cruising altitude conditions to confirm that packaging maintains integrity under air transport pressure conditions.

Non-bulk packaging performance testing is the required test sequence for dangerous goods packaging designs with a liquid capacity below 450 liters (119 gallons) or a solid net mass below 400 kilograms (882 pounds). The test sequence includes drop, stacking, leakproofness, hydrostatic pressure, and vibration testing, applied at performance levels corresponding to the packaging’s assigned Packing Group (I, II, or III). Results support the UN certification mark and DOT compliance documentation for packaging used in ground, air, and sea transport of hazardous materials.

Puncture testing measures the force required to pierce a packaging material with a defined probe or needle, characterizing resistance to puncture from sharp objects encountered in distribution, handling, and storage. Puncture resistance is relevant for both protective packaging materials and sterile barrier packaging where a breach would compromise sterility.

Righting testing restores a toppled dangerous goods package to its upright orientation and evaluates the package after restoration. The test is paired with topple testing to confirm that a package that has tipped during transport can be righted without leakage, structural failure, or loss of closure integrity.

Rotational edge drop testing pivots a package about its bottom edge and releases it to simulate the tip-over and edge impacts that occur during manual handling and conveyor transfer. The test concentrates impact energy on package edges and corners, which are the most common failure points in corrugated and rigid packaging.

Seal strength testing measures the force required to separate a heat seal in flexible packaging or thermoform materials. The test quantifies both the strength of the seal and its failure mode, specifically whether the seal peels cleanly or fails adhesively, providing a complete picture of whether the seal meets the integrity requirements for its application. For sterile barrier packaging, seal strength results are a required component of ISO 11607 validation documentation.

Conditioning testing exposes packaging to controlled temperature and humidity conditions for a defined period before performance testing. Conditioning ensures that materials have reached equilibrium with the test environment, which is a required step in many distribution and medical device testing sequences. Standard conditioning protocols include ISO 2233 (packaging conditioning) and ASTM D4332 (container conditioning).

Shock testing applies high-amplitude, short-duration impact pulses to simulate the sudden mechanical shocks that occur during transport events such as rail car coupling, conveyor drops, and rough handling. Unlike drop testing, which evaluates free-fall impact, shock testing applies defined pulse shapes to characterize packaging response to specific impact profiles. Shock testing is relevant to electronics, industrial equipment, and sensitive instruments.

Compression testing measures the load a package can sustain before the structure fails, relevant to corrugated and rigid packaging that must support the weight of stacked units in warehouse storage and transport. Stacking tests evaluate the performance of multiple packages under sustained compressive load, simulating actual distribution stack heights and dwell times. Results establish safe stack height limits and validate corrugated packaging structural specifications.

Tear testing evaluates a dangerous goods package’s resistance to tear propagation. The 100 mm tear at a 45-degree angle cannot expand by more than 25% when subjected to a top load of twice the maximum net mass.

Temperature cycling testing exposes packaging to repeated transitions between high and low temperature extremes, simulating the thermal stresses that occur during transport through different climate zones, aircraft cargo holds, and cold storage and ambient transitions. The test evaluates whether packaging materials expand and contract without losing seal integrity, and whether closure systems remain functional through repeated temperature cycles.

Tensile testing measures the force required to stretch or pull apart a material specimen until it fails, characterizing the tensile strength and elongation at break of packaging films, foils, laminates, and flexible materials. Tensile data is used in material specification, quality control acceptance testing, and failure analysis when packaging film or laminate has failed in distribution or in use.

ISTA 7E combines the thermal transport evaluation of ISTA 7D with parcel delivery distribution simulation, including the drop, vibration, and compression sequences from ISTA 3A, to validate insulated shippers intended for parcel delivery systems. The test confirms that a thermal transport package maintains its required temperature range and physical integrity through the complete cycle of parcel delivery conditions, addressing both thermal and mechanical performance in a single test sequence.

ISTA 7D is a development test protocol for temperature-controlled transport packaging. The test subjects an insulated shipping system carrying a representative payload to a defined external temperature profile, simulating warm, cold, or ambient summer and winter distribution conditions, and monitors internal temperature throughout. Results validate whether the packaging maintains the required temperature range for the specified payload and transit time, and support documentation for pharmaceutical GDP compliance and cold chain qualification.

Topple testing tips a filled or representative dangerous goods package onto its side from a defined height to simulate the sideways falls that occur during transport handling. The test evaluates whether the package maintains its structural integrity and closure system when subjected to the lateral impact, and is required for specific dangerous goods packaging types under Title 49 CFR.

UV exposure testing subjects packaging materials to controlled ultraviolet radiation to simulate the degradation effects of sunlight and fluorescent light exposure over time. The test evaluates whether packaging materials, including labels, films, coatings, and substrates, maintain their physical and functional properties under UV exposure. UV testing is relevant to outdoor storage, display packaging, and packaging that must meet specific light resistance specifications.

Vacuum testing applies external vacuum to a sealed package to simulate the reduced pressure conditions of air transport and evaluate seal integrity under pressure differential. The test applies to flexible packaging, pouches, and trays where seal failure under reduced pressure is a risk. For dangerous goods packaging, vacuum testing forms part of the performance test sequence for specific packaging types under Title 49 CFR.

Vibration testing replicates the sustained oscillation a packaged product experiences during ground transport on trucks and rail cars. Fixed displacement vibration applies a single-frequency sinusoidal input. Random vibration applies a power spectral density profile that more accurately simulates real-world road and rail conditions. The test reveals whether packaging fatigues, loosens, or fails under sustained transport vibration before the product reaches its destination.