1. Objective
The purpose of this test is to evaluate the ability of a loaded shipping container to withstand impact forces encountered during handling, transportation, and storage by simulating free-fall drops. This ensures that the packaging can adequately protect its contents under real-world conditions.
2. Scope
This test applies to corrugated fiberboard boxes, plastic containers, wooden crates, and other packaging systems used in shipping and logistics. The test is conducted on a fully packed container to assess structural integrity and cushioning performance.
3. Test Specimen & Preparation
- Select three representative samples of the packaging system in their final production form, including closures, labels, and internal cushioning.
- Ensure each test sample is fully loaded with the intended product to simulate real-world conditions.
- Condition the specimens per ASTM D4332 (Standard for Conditioning Containers for Testing) before testing.
4. Test Equipment & Setup
- Drop Tester Machine: A free-fall drop tester that allows precise control over drop orientation and height.
- Drop Surface: A flat, rigid, and non-resilient surface that meets the specifications outlined in ASTM D5276.
- Measuring Instruments: High-speed cameras (if needed), measuring tape, and force sensors (optional).
5. Testing Procedure (Based on ASTM D5276 Index)
5.1 Determination of Drop Heights
- The drop height is determined based on the package weight following the standard guidelines.
- Refer to Table 1 in ASTM D5276 for weight-based drop height classification.
| Package Weight (kg) | Drop Height (mm) |
|---|---|
| 0 - 9.1 | 760 |
| 9.2 - 18.1 | 610 |
| 18.2 - 45.4 | 460 |
| 45.5 - 90.7 | 300 |
| >90.7 | 150 |
5.2 Drop Orientation & Sequence
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The container will be dropped in the following orientations:
- Flat Drop – Bottom Face
- Flat Drop – Top Face
- Flat Drop – Longest Side
- Flat Drop – Shortest Side
- Corner Drop (one corner at a time)
-
The sequence of drops will be determined based on real-world shipping conditions and package handling risks.
5.3 Repetitive Drops (if required)
- If necessary, the test may include multiple drops from different heights to simulate repeated handling conditions.
5.4 Data Collection & Observations
- Visual Inspection: Document any visible damage such as tears, punctures, crushing, or broken seals.
- Structural Integrity Assessment: Check for buckling, deformation, or failure of seams.
- Internal Product Damage Assessment: Inspect whether the contents remain undamaged and properly cushioned.
- Comparison Against Acceptance Criteria: Evaluate whether the package meets the pass/fail criteria defined by the manufacturer or regulatory body.
6. Reporting & Recommendations
- Photographic evidence of each drop orientation and damage observed.
- Detailed report including measurements, observations, and pass/fail status.
- Recommendations for packaging design improvements if failure occurs (e.g., stronger materials, additional cushioning, better sealing techniques).
7. Safety Considerations
- Ensure all personnel remain at a safe distance during testing.
- Use protective gloves and eyewear if handling fragile or heavy packages.
- Ensure drop equipment is calibrated to prevent errors.
8. Undecided Factors in the Test Plan
1. Exact Drop Height for the Test Specimen
- The test plan outlines height selection based on package weight, but the actual weight category of the test specimens is not yet determined.
2. Number of Test Samples
- The standard suggests a minimum of three test specimens, but the actual sample size required for statistical validation is undecided.
3. Acceptance Criteria for Damage
- The test plan includes visual and structural assessments, but clear pass/fail criteria (e.g., allowable levels of damage) need to be defined.
4. Inclusion of Repetitive Drops
- The need for multiple consecutive drops on the same sample is not specified and depends on real-world shipping risks.
5. Testing Under Special Conditions
- If packages will be exposed to extreme temperatures or humidity, environmental pre-conditioning should be customized per ASTM D4332, but the actual conditions for this test are undecided.
Next Steps
To finalize the test plan, the above undecided factors need to be clarified based on:
✅ Actual package weight & intended shipping conditions
✅ Manufacturer-defined acceptance criteria
✅ Need for additional drop cycles or environmental testing
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