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Pre-shipment Tests

Pre-shipment tests can be a useful tool when used properly. The most effective time to utilize a pre-shipment test is before actually shipping the product or when design changes are made to any packaging or product component. This way, any potential problems can be identified and solved that may occur during shipment. There are many choices when it comes to pre-shipment tests today. The most important thing to remember is that the test results are only as good as the test procedure performed. Some results of performing the wrong test include, inaccurate test findings, over-packaging (thus overspending), and damage in shipment which leads to customer dissatisfaction which translates to lost sales.

Common pre-shipment tests are Carton Box Drop, Carton Box Vibration, Compression on Carton Box, Atmospheric Preconditioning…etc.

International Safe Transit Association (ISTA) – ISTA Test Procedures

ISTA 1 Series: Non-Simulation Integrity Performance Tests. Challenge the strength and robustness of the product and package combination. Not designed to simulate environmental occurrences. Useful as screening tests, particularly when used as a consistent benchmark over time.

• Procedure 1A: Packaged-Products weighing 150 lb (68 kg) or Less
Basic Requirements: fixed displacement vibration and shock testing.

• Procedure 1B: Packaged-Products weighing Over 150 lb (68 kg)
Basic Requirements: fixed displacement vibration and shock testing.

• Procedure 1C: Extended Testing for Individual Packaged-Products weighing 150 lb (68 kg) or Less
Basic Requirements: fixed displacement or random vibration, shock testing and compression.

• Procedure 1D: Extended Testing for Individual Packaged-Products weighing Over 150 lb (68 kg)
Basic Requirements: fixed displacement or random vibration, shock testing and compression.

• Procedure 1E: Unitized Loads
Basic Requirements: vertical linear or random vibration and shock testing.

• Procedure 1G: Packaged-Products weighing 150 lb (68 kg) or Less (Random Vibration)
Basic Requirements: random vibration and shock testing.

• Procedure 1H: Packaged-Products weighing Over 150 lb (68 kg) (Random Vibration)
Basic Requirements: random vibration and shock testing.

ISTA 2 Series: Partial Simulation Performance Tests. Tests with at least one element of a 3 Series type General Simulation performance test, such as atmospheric conditioning or mode-shaped random vibration, in addition to basic elements of a 1 Series type Non-Simulation Integrity test.

• Procedure 2A: Packaged-Products weighing 150 lb (68 kg) or Less
Basic Requirements: atmospheric conditioning, compression, fixed displacement or random vibration and shock testing.

• Procedure 2B: Packaged-Products weighing over 150 lb (68 kg)
Basic Requirements: atmospheric conditioning, compression, fixed displacement or random vibration and shock testing.

• Procedure 2C: Furniture Packages
Basic Requirements: atmospheric conditioning, compression and shock testing.

• Procedure 2D: Packaged-Products Considered Flat
Basic Requirements: fixed displacement vibration and shock testing.

• Procedure 2E: Packaged-Products Considered Elongated
Basic Requirements: fixed displacement vibration and shock testing.

ISTA 3 Series: General Simulation Performance Tests. Designed to provide a laboratory simulation of the damage-producing motions, forces, conditions, and sequences of transport environments. Applicable across broad sets of circumstances, such as a variety of vehicle types and routes, or a varying number of handling exposures. Characteristics will include simple shaped random vibration, different drop heights applied to the sample package, and/or atmospheric conditioning such as tropical wet or winter/frozen.

• Procedure 3A: Packaged-Products for Parcel Delivery System Shipments 70kg (150 lb) or Less (standard, small, flat or elongated)
Test Procedure 3A is a general simulation test for individual packaged-products shipped through a parcel delivery system.  The test is appropriate for four different package types commonly distributed as individual packages, either by air or ground.  The types include standard, small, flat and elongated packages.  Basic Requirements: atmospheric pre-conditioning, random vibration with and without top load, and shock testing.

NOTE:  Effective 2006, Procedure 3A has superseded Procedures 3C (Packaged Products... for Parcel Delivery System Shipments) and 3D (Small Packaged-Products Bagged for Parcel Delivery System Shipment).  3A encompases and updates both of these previous Procedures.  Former users of 3C and 3D are now encouraged to use 3A.

• Procedure 3E: Unitized Loads of Same Product
Basic Requirements: atmospheric conditioning, compression, random vibration and shock testing.

• Procedure 3F: Packaged Products for Distribution Center to Retail Outlet Shipment 100 lb (45 kg)
Basic Requirements: atmospheric conditioning, compression, random vibration and shock testing.
• Procedure 3H: Performance Test for Products or Packaged-Products in Mechanically Handled Bulk Transport Containers
Basic Requirements: atmospheric conditioning, random vibration and shock testing.

ISTA 4 Series: Enhanced Simulation Performance Tests. General Simulation test with at least one element of focused simulation, such as test sequence or condition linked to actual known distribution. Project 4AB, an Enhanced Simulation Performance Test, is currently under development by ISTA. It will closely tie the tests and sequence to a user-defined pattern of distribution, and will include a broad range of current and quantitative information on distribution environment hazards.  So the Focused Simulation elements are test-tailoring to individual situations, and usage of up-to-date and specific hazard profiles and parameters. Project 4AB will be a web-based application to generate customized test plans; most of the complexity will be handled "behind the scenes" without burdening the user.

ISTA 5 Series: Focused Simulation Performance Tests. Designed to provide a laboratory simulation based on actual field-measured and observed hazards and levels. Measured hazards will typically include complex shaped random vibration, multi-tiered drop height distribution, temperature and humidity extremes and/or cycling, and dynamic or static compressive loads. 5 Series are not performance tests per se, but Guides to the creation of Focused Simulation user-defined tests.

• Guide 5B: Focused Simulation Guide for Thermal Performance Testing of Temperature Controlled Transport Packaging

ISTA 7 Series: Development Tests. These tests are used in the development of transport packages. They can be used to compare relative performance of two or more container designs, but are not intended to evaluate the protection afforded packaged-products.

• Project 7A: Open Reusable Transport Containers for Loads of 60 lb (27 kg) or Less and Unitized for Shipment on a Pallet
Basic Requirements: compression and shock testing.

• Procedure 7B: Closed Reusable Transport Containers for Loads of 150 lb (68 kg) or Less
Basic Requirements: fixed displacement or random vibration, shock testing, compression and atmospheric pre-conditioning.

• Procedure 7C: Reusable Intermediate Bulk Containers
Basic Requirements: atmospheric conditioning, compression, random vibration and shock testing.

• Procedure 7D: Thermal Controlled Transport Packaging for Parcel Delivery System Shipment
Basic Requirements: atmospheric conditioning, vibration and shock testing. 

The classification of ISTA test procedures

Test procedures sorted by Distribution Mode or Type:

 
Any distribution mode
Individual packages weighing 150 lb (68 kg) or less: ISTA 1A, 1C, 1G, 2A

Any distribution mode
Individual packages weighing over 150 lb (68 kg): ISTA 1B, 1D, 1H, 2B

Individual packages, small parcel delivery mode: ISTA 3A, 3C, 3D, 2D, 2E

Unitized load, any distribution mode: ISTA 1E, 3E

Reusable systems, any distribution mode: ISTA 3H

Furniture packages: ISTA 2C

Non-unitized DC to retail: ISTA 3F

Thermal performance: ISTA 5B

Development tests:
Open container: ISTA 7A
Closed container: ISTA 7B
Intermediate Bulk Container (IBC): ISTA 7C
Thermal performance: ISTA 7D

More Explanation on the ISTA test procedures

ISTA Series 1 are Non-Simulation Integrity tests that evaluate the ruggedness of product and package but don't necessarily simulate what happens in actual distribution. The tests require relatively simple and inexpensive equipment, simple procedures, and minimal operator skills.

ISTA Series 3 are General Simulations that are based on broad definitions of the hazards of distribution. There are individual specific Procedures, covering a number of packaged-products and distribution systems.

ISTA Series 5 are Focused Simulations, based on user-measured or observed hazards, sequences, intensities, etc. This series is intended for the highest-value products, and/or the most demanding situations. Equipment and operator requirements are much like the 3 Series, but test design requires thorough knowledge and complete information.

ISTA Series 2 and 4 are combinations of the Series above and below, with elements of each.

Question to be investigated

1. Are tests product specific?

In general, ISTA tests are not specific to the product or type of product being packaged and shipped. The one exception to this is ISTA 2C, for individually packaged furniture products.

A number of ISTA tests are specific to the type of package, and several are specific to particular means or modes of transport.

2. Does ISTA testing ensure no damage?

The distribution environment is large in scope, diverse, and extremely complex. It would be impossible to design a product or package, or packaged-product pre-shipment test, which would always ensure perfect performance.

Further, packaged-products and pre-shipment tests are typically designed for normal environments (perhaps with a reasonable safety factor), yet occasionally very abnormal circumstances can arise. It would usually be impractical and uneconomical, for instance, to design and test for a 3-story drop height, a train derailment, or a package being run over by a lift truck, yet occasionally these things do happen.

However, properly-applied ISTA tests will greatly increase the probability of damage-free shipments. The basic (1 Series) ISTA tests are most useful as screening tools, to used to avoid major problems in shipment. The more sophisticated ISTA tests (especially the 3 Series and higher) are able to uncover more subtle effects, and allow fine-tuning of costs and environmental impacts as well as reasonable avoidance of damage of all types.

3. Why not use VERY demanding test methods?

Not unless your only or overriding concern is prevention of damage. For some products (extremely expensive, critical, dangerous, etc.) this might make sense, but for most products the objective is probably good overall balance. In other words, a good combination of low damage, low package cost, low distribution costs, low environmental impact, etc.

4. What's the difference between ISTA & UN/DOT?

UN/DOT tests apply to the packaging of Hazardous Materials (Dangerous Goods). These are different tests, with different purposes, than ISTA.

ISTA tests are primarily used to evaluate or compare the effectiveness of packaging in protecting the product. UN/DOT tests are intended to ensure that people and the environment are protected from the product. The emphasis in UN/DOT testing is on safely containing the material, not necessarily preventing damage to it. UN/DOT tests have strict legal and environmental ramifications.

UN/DOT
The companies which are engaged in the transportation of hazardous material are obligated to comply with the requirements set forth in the Hazardous Material Regulations (HMR) published by the Department of Transportation (DOT), Title 49 CFR. These regulations include information on package classification, markings, labeling, documentation, specifications, testing procedures and training requirements for the company’s personnel, and conform to the principles established by the United Nations (UN) Model Regulations, Thirteenth Edition.

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