What is a package drop test?

A package drop test is a simulation of the treatment that a package holding goods may experience during shipping
and handling. In a controlled environment, a full package (typically, a carton with the correct item inside) will be
dropped in various ways (on corners, edges, and faces, in a certain order) in order to find any weaknesses which can
then be addressed.
By evaluating the reliability of this packaging (from overseas to a regional distribution center in export cartons and/or
in a smaller shipper box for domestic sendings), importers will be assured that the goods will make it to them, or end-
users, in good condition!
 
How does it all work?
According to the International Safe Transit Association (ISTA), the procedure will:
 Protect products and profits with reduced damage and product loss
 Enhance customer satisfaction and continued business
A dropping robot (or quality inspector) will hold the package (which is a real unit inside the same packaging that will
be used in transit) and drop it from a set height (based on its weight, this could be between around 0.5 to 1.5m) onto
the same surface. It will be dropped 10 times, in a precise sequence.

The package drop test process

1. For each
SKU tested, select one package which must be identical to the others in its batch for a fair test (same product
inside, same interior or retail packaging, dunnage, and the same export package type).
2. Weigh the
sample package to find the correct drop height per the standard used :

3. Clean the
drop surface with a dry cloth (this happens each time between drops).
4. Drop the
box from the correct height onto the different faces ten times:
Most fragile corner (x1 drop)
3 edges coming from the most fragile corner (x3 drops)
 All 6 faces (x 6 drops):

5. After
drops are complete, inspect the package for damage. You will also inspect the product packaging and product
itself (which were inside the export packaging) for signs of damage, too.
The following will be checked:
– Unit location inside export packaging (has it shifted)?
– Cosmetic damage to outer export package and interior product retail package (if any)
– Damage to the product itself
– Product function (does it still operate perfectly?) 

Has my package passed the test?

No functional and mechanical failures should be found on product and retail packaging after test.

Therefore, you can expect a package to fail if:

 The export package is completely smashed/open
 The product’s retail box is badly damaged
 The product inside is damaged or inoperative
Seeing some small cosmetic damage is normal following a drop test, but the goal is that the product inside is totally
unharmed following the test.

Package or carton drop test standards

You may come across the following international standards. It’s helpful to know which standard your supplier is
testing to if they’re carrying out the tests as they may have slight differences. For example, ASTM’s standard is
applicable for containers weighing 110 lb (50 kg) or less, whereas the ISTA standard applies to a heavier weight:
 International Safe Transit Association (ISTA) Procedure 2A: Packaged-Products weighing 150 lb (68 kg) or
Less – please note that the drop test is one of a series of ISTA tests (along with the package vibration test) that
helps your packaging pass certification.
 ASTM D5276 – 19
Standard Test Method for Drop Test of Loaded Containers by Free Fall (for containers weighing 110 lb (50 kg) or
less)
 ISO 2206:1987
Packaging — Complete, filled transport packages — Identification of parts when testing
Also, your carrier (for example, FedEx) may be able to advise you on the standard that is applicable to them. In
which case, this is the standard for you to test to.

What is a package vibration test?

A package vibration test aims to simulate the types of vibrations that packages suffer during handling, transportation,
and shipping. If vibrations are too severe they could cause packages to become damaged by losing their integrity.
Therefore, this kind of test aims to discover if your export packaging is going to keep goods safe when being jostled
around in, say, a truck, or whether it’s going to come apart at the seams!
 
What does a vibration test look like?
The sample export page with product inside will be subjected to vibration (measured in root mean square
acceleration or Grms) created by hydraulic tables with fixed displacement (using relevant apparatus as per ASTM
D999) or random (using relevant apparatus as per ASTM D4728) vibration.
The vibrations created are equivalent to those felt during transit on a train, plane, or truck.

Do I need to run this test?

Any importer shipping products to customers should consider package reliability testing like vibration tests. Testing in
advance of shipping could save you a lot of money on recalls if the packaging is later found to be defective. It goes
without saying that FBA sellers also risk being penalized by Amazon, too.
 
The package vibration test process
Here is the process we follow for random vibration testing on packages:
1. Program the apparatus to provide the correct vibration profile.For your reference, you can see the random
vibration spectrum used here:

2. Place the test package (packed in retail packaging inside

export packaging) on the apparatus’ table. The package may be prevented from falling from the table, but
vertical movement (bouncing) may not be restricted.
3. Start the test.
4. Switch the package to rest on a different face after the allotted time has passed per face.
5. When complete, unbox all units.
Check the export packaging for damage.
Check the inner retail packaging for damage.
Check the product itself for damage and check its operation.

Note, when performing this test it is imperative that you use sample packages which are identical to those that will
be shipped in order to get accurate results. This means the same product in the same retail packaging, with the
same dunnage, and the same export packaging or carton.
 

Has my package passed the test?

Your product must pass all functional tests and cosmetic specifications after unboxing for the test to be considered a
pass.

Minor cosmetic damage to the export package or carton is to be expected, however, any damage to the product
being shipped is unacceptable.

If any damage is found, you may consider making adjustments to the packaging before shipping the whole
production and your supplier should be prepared to support you with this.

 
Common package or carton vibration test standards
 ASTM D999 – Standard Test Methods for Vibration Testing of Shipping Containers
 ASTM D3580 -Standard Test Methods for Vibration (Vertical Linear Motion) Test of Products
 ASTM D4728 – Standard Test Method for Random Vibration Testing of Shipping Containers  (truck & air)
 ASTM D5112 – Standard Test Method for Vibration (Horizontal Linear Sinusoidal Motion) Test of Products
 ASTM D7387 – Standard Test Method for Vibration Testing of Intermediate Bulk Containers (IBCs) Used for
Shipping Liquid Hazardous Materials (Dangerous Goods)
 International Safe Transit Association (ISTA) Procedure 2A: Packaged-Products weighing 150 lb (68 kg) or
Less
 ISO 2247:2000

Packaging — Complete, filled transport packages and unit loads — Vibration tests at fixed low frequency

Note, certain organisations such as carriers and Amazon, also have their own testing demands, so check with them
if applicable and then be sure to carry out the correct test.

Source :
1. https://www.sofeast.com/glossary/package-drop-test/
2. https://www.sofeast.com/glossary/package-vibration-test/