GUIDELINES FOR SELECTING AND USING ISTA®

TEST PROCEDURES & PROJECTS

Getting Started 2

Testing Rationale 2

Testing Expectations and Objectives 2-3

Testing as a Demonstration of
Guidelines for Selecting and
Minimum Use of Packaging 3
Using ISTA® Test Procedures
Laboratory Tests and Distribution Hazards 3 and Projects
Types of ISTA Tests 4
PREFACE
Specialized Test Protocols The International Safe Transit Association (ISTA) is a global
Developed by ISTA 5 alliance of shippers, carriers, suppliers, testing laboratories,
and educational and research institutions focused on the
Member Performance Tests 5 specific concerns of transport packaging. We help our
members control costs, damage, and resources during the
Special Considerations for ISTA distribution of packaged-products by:
Procedures and Projects 5-6
1. Creating and publishing laboratory preshipment
Know Your Distribution Environment 6 Testing Procedures

Product Damage Tolerance and Package 2. Certifying Packaging Laboratories

Degradation Allowance 6
3. Certifying Packaging Laboratory Professionals
Face, Edge and Corner 4. Certifying packaged-products
Identification 6
5. Providing education, training, and support.
Samples 6-7
OUR MISSION is to provide economic and environmental
Retesting 7 benefits by helping our members prevent product damage
and over-packaging during the physical distribution of goods.
Repeated Testing 7
OUR VISION is "Just Right Transport Packaging" -
Line Extension Policy 8 packaging which meets the protective needs of the product,
as well as meeting the economical and environmental needs
Identification of Product and of the product's shipper and user. This Just Right Packaging
Package Tested 8 is designed and certified against Just Right preshipment
testing which adequately simulates the hazards of actual
Test Parameter Tolerances 8 transportation/distribution.

Additional Considerations 8-9

These Guidelines are intended to provide the user of
ISTA® Test Procedures and Projects and other ISTA
Suggested Steps for Selecting
a Test Protocol 9 documents with insight and information on the
protocols, and what factors to consider in selection,
Reminders for Use of ISTA® Test Protocols 9-10 use, and results interpretation.

Documentation of Tests 11
©January 2009 International Safe Transit Association.
Communication with ISTA 12 All rights reserved.

ISTA Test Report Testing 12

ISTA Tests Quick Reference 13-15

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TEST PROCEDURES & PROJECTS
GETTING STARTED policy (corporate specification, for example), by regulatory
Following are four straightforward suggestions to improve application (testing of packaging for hazardous materials and
protective packaging effectiveness and move toward Just dangerous goods, for example), or by customer
Right Transport Packaging. requirements (purchase specification, for example). While
these situations usually have little flexibility in test selection,
1. Test the Package. they are still in the broad category of supporting decisions on
If you are not regularly using a laboratory package packaging suitability.
performance test, start now. Even a simple lab test used
wisely is preferable to trial and error or total reliance on field Other types of tests are available but a detailed treatment is
experience. outside of the scope of this document. Material tests seek to
characterize material performance for the use in design and
2. Know Your Distribution Environment. development, such as cushion curves. Engineering tests
Find out more about how products move, including the seek to find a specific performance quantity, such as the
variety of channels used to move your goods. If you are a deceleration experienced by a product in a package when
supplier to shippers, help them explore this information. Use dropped from some height, as in an instrumented drop test.
this knowledge to identify sources of distribution hazards and
observe or measure them. Use this knowledge to reduce TESTING EXPECTATIONS AND OBJECTIVES
exposure to hazards of distribution, to help specify the An important consideration in the selection of a test protocol
performance of packages, and to select an appropriate is the objective of running the test, i.e., what information is
laboratory test protocol. needed to make the decision associated with this test.
Broadly put, these specific objectives for each test might be
3. Continuously Review and Improve. categorized simply as screening or prediction.
Distribution hazards change, as do packaging materials.
Review and retest even the most successful designs A screening test would be used to avoid serious problems in
periodically. Rapid situation changes, such as new markets shipment, usually damage to the product. This test objective
or distribution strategies, require immediate attention. category is a common one, and can adequately fill the needs
of many users. Screening tests give the user confidence that
4. Stay Up to Date. the chances of serious transport damage have been
Take every opportunity to learn more about your products minimized. Screening tests have the following general
and distribution, learn about new technologies and characteristics:
procedures, and exchange knowledge with others who have
similar concerns. Educational opportunities, such as ISTA's • simple and inexpensive to perform
annual Transport Packaging Forum, are a good source of • widely available and accepted
update. The ISTA® Certified Packaging Laboratory
Professional (CPLP) program is another excellent • utilize simple equipment
educational and recognition tool. Find out more from ISTA • accommodate known and suspected severe hazards
Headquarters or visit www.ista.org.
• are not necessarily a simulation of the hazards of
TESTING RATIONALE distribution
The need for testing comes from the difficulty of predicting • achieve damage resistance by challenging the strength
what will happen in large-scale operations, coupled with the and robustness of the product and package (a strong
requirement to make decisions prior to implementation. product/package resists damage).
Essentially, every test comes from the need to make a
Prediction is a more difficult expectation for a preshipment
decision. The test results provide the decision-maker with
performance test. While screening seeks to avoid serious
information to help maximize correct decisions. The
problems, prediction must allow the user to foresee more
decisions supported by preshipment performance testing of
subtle effects, such as minor damage, occasional damage,
transport packaging are typically about how well the package
or non-functional problems with the package. In an ideal
will protect the contents during distribution.
prediction situation, the tested samples and representative
samples of distributed products would be indistinguishable.
Testing can also be a mandated activity as part of a package
This is not always entirely possible given the technology mix
development, new product release, or engineering
available today, but it is approachable.
modification. This testing may be driven by organizational

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Prediction allows the user to fine-tune cost and LABORATORY TESTS AND DISTRIBUTION
environmental impact as well as helping to avoid damage of HAZARDS
all types. By testing incrementally reduced cost and Four basic categories of hazards exist in distribution: Shock,
material-content designs, the near-optimum configuration Vibration, Compression, and Atmospheric. Each hazard
could be achieved. Prediction might also allow the user to category is reflected in an ISTA laboratory test type, although
design a package for a repeatable low level of damage, not all ISTA® Procedures and Projects include all test types.
consistent with an objective of lowest overall system cost. Within each test type are sub-types of more specific tests
Without a good prediction test to represent field that are used to simulate specific hazards in distribution. The
performance, this trade-off of package cost and damage cost following table summarizes these relationships.
would be largely guesswork.
Distribution Major Test Associated
Hazard Category Test Types
TESTING AS A DEMONSTRATION OF
MINIMUM USE OF PACKAGING Handling Drop Shock Drop
ISTA tests establish lower limits for packaged-product and Impact • free-fall
• rotational
performance, but in general do not set upper limits.
• on hazard
Therefore, used in their most straightforward pass/fail • hazard impact
fashion, ISTA tests do little to detect over-packaging Incline Impact
situations. However, with the addition of a "reduce to Horizontal Impact
Vertical Impact
damage" or "pass with minimum margin" approach, ISTA
testing can be used for the demonstration of minimum use of Transportation Vibration Fixed Displacement
Vibration • rotary
packaging. "Reduce to damage" means that if a packaged-
• vertical linear
product passes the test it must be redesigned with less Variable Displacement
packaging and tested again until an optimum level is • vertical
reached. "Pass with minimum margin" might involve • horizontal
Random
subjecting a packaged-product which has passed the test to • vertical
increased severity levels, determining when damage does • horizontal
occur, and then verifying that those levels are not overly • multi-axis

excessive. Stacking Load Compression Static (dead load)

Machine
• apply & release
A "reduce to damage" or "pass with minimum margin"
• apply & hold
protocol employing screening tests should be used with Dynamic Load Under Vibration
extreme caution. Since screening tests may not well
Atmospheric Atmospheric Temperature
represent actual field exposure in either intensity or type, the Conditions • soak
tests cannot be readily shown or proven to have a good • cycle
relationship to the field damage. Using screening tests can Humidity
perhaps be effective if coupled with a program of field • soak
• cycle
monitoring and feedback after package redesign. But the far Pressure
better approach is to use tests which provide a good actual • soak
simulation of the distribution hazards. • cycle

Table 1 Hazard Categories and Test Types

It is important to note that test protocols can evaluate the

effectiveness of packaging only for hazards represented in
the protocol. For example, a test procedure that does not
include a compression test is unable to evaluate a packaged
product's resistance to warehouse stacking loads. By
knowing the distribution environment in detail (see Getting
Started, above), users can select an appropriate test to
evaluate the performance of packaging in light of all known
hazards. Without this selection process, real hazards may
not be addressed as part of a package's protective ability,
and significant damage could result in spite of a test being
passed.

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TEST PROCEDURES & PROJECTS
TYPES OF ISTA TESTS
ISTA test protocols are approved by Test Series Groups and ISTA members may cause the package to carry the ISTA®
by the ISTA Technical Council. New protocols are initially Certification Mark (ISTA arrows, also referred to as the Seal)
given the designation "Project" during their implementation and the package is considered as Certified. Displaying the
phase. After a minimum one-year period, a "Project" is ISTA® Transit Tested Seal on a distribution package
evaluated and will either be adopted as an established indicates that the packaged-product has passed the
"Procedure", revised and kept as a "Project" for another particular ISTA protocol. It does not necessarily have a
period of time, or be dropped. Member labs may use either connection to damage claim payments, but shippers that
Procedures or Projects for Package Certification by display the Seal are certainly in a better negotiating position.
performing the test protocol with the package passing, and
forwarding a completed Report to ISTA Headquarters, ISTA has organized its test protocols into Series, as
except in the case of non-certification procedures that are follows:
clearly delineated in their introductions. Shippers who are

1 Series: 4 Series:
Non-Simulation Integrity Performance Tests. Enhanced Simulation Performance Tests.
Challenge the strength and robustness of the product and General Simulation tests with at least one element of Focused
package combination. Not designed to simulate environmental Simulation, such as test sequence or test conditions linked to
occurrences. Useful as screening tests, particularly when used actual known distribution. Project 4AB is currently the only
as a consistent benchmark over time. protocol in this Series. 4AB is a web-based Enhanced Simulation
Test Plan generator, with on-line access available at no charge to
2 Series: all ISTA members. Project 4AB closely ties the tests and
Partial Simulation Performance Tests. sequence to a user-defined pattern of distribution, and includes a
Tests with at least one element of 3 Series type General broad range of current and quantitative information on distribution
Simulation performance tests, such as atmospheric conditioning environment hazards. See the Project 4AB section of the ISTA®
or mode-shaped random vibration, in addition to basic elements website (www.ista.org) for more details.
of a 1 Series type Non-Simulation Integrity test.
5 Series:
3 Series: Focused Simulation Guides.
General Simulation Performance Tests. Guides for the creation of laboratory simulations based on actual
Designed to provide a laboratory simulation of the general field-measured and observed hazards and levels. The 5-Series
damage-producing motions, forces, conditions, and sequences are not performance tests per se, but information and instructions
of transport environments. Applicable across broad sets of related to establishment of user-defined Focused Simulation
circumstances, such as a variety of vehicle types and routes, or tests. Guide 5B for Temperature Controlled Packaging is
a varying number of handling exposures. Characteristics will currently the only document in this Series.
include simple shaped random vibration, different drop heights
applied to the sample package, and/or atmospheric conditioning. 6 Series:
Member Performance Tests.
Test protocols created by ISTA members to meet their particular
purposes and applications. The tests may be completely original,
1 Series protocols can reasonably be expected to be
or may be modifications or variations of ISTA Procedures or
screening tests, with an increasing expectation of
Projects or other published and accepted tests. ISTA reviews and
predictability through Series 5. Whether this is true in any
accepts these tests, but primary responsibility rests with the
specific case needs to be evaluated by comparing lab and
originating members.
distribution results. This important validation process
should be a part of each user's normal operations.
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.

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SPECIALIZED TEST PROTOCOLS MEMBER PERFORMANCE TESTS
DEVELOPED BY ISTA The ISTA 6-Series, Member Performance Tests, are
While a packaged-product weight range identifies many protocols created by ISTA members to suit their own
protocols, several ISTA® Projects and Procedures have particular purposes and applications. The tests may be
been developed in response to specific needs of members completely original, or may be modifications or variations of
and the larger packaging community. These include tests for ISTA Procedures or Projects or other published and
specific distribution modes, such as parcel and LTL delivery accepted tests. They are reviewed, approved, and formally
and bulk shipments, for package types, such as unitized accepted by ISTA, and are made available either on a limited
loads and reusable containers, and for specific product basis or generally, as determined by the originators.
types, such as furniture. All of these are criteria for selection
of a test. Test protocols are continuously being worked on The primary responsibility for creation, validation, and
and developed by ISTA members and staff, so it is important maintenance of 6-Series tests rests with the originating
to keep informed. The latest versions of all tests are members.
available on the ISTA® website, and may supersede those
printed in the Resource Book. Table 2 shows one way of Typical uses for Member Performance Tests might be by
organizing and describing current Projects and Procedures. large retailers to establish unique performance-based
packaging requirements for their suppliers and vendors, or
Procedure 3A for Parcel Delivery System Shipment uses by carriers to reflect their particular conditions of distribution.
latest information and data to configure the drop, random
vibration, top load, and other tests and conditions. 3A SPECIAL CONSIDERATIONS FOR ISTA®
overlaps with Procedures 2D (Flat Packaged-Products for PROCEDURES AND PROJECTS
Parcel Delivery System Shipment) and 2E (Elongated Safety
Packaged-Products for Parcel Delivery System Shipment), Safety of personnel is a serious and all-important
although the 3A requirements reflect General Simulation requirement when running ISTA® Test Procedures. Many of
rather than the 2-Series Partial Simulation approaches. the test types used in ISTA procedures are inherently
dangerous, involving massive moving
Package Type objects and test system components.
Distribution Each laboratory must have a well-
Type Individual Packages
Unitized Bulk Reusable designed safety program and monitor
up to 150 lbs. (68 kg) over 150 lbs. (68 kg)
tests and conditions to insure safety
1A, 1C, 1G 1B, 1D, 1H 1E 3H 7A from injury. Extra care must be taken
Any
2A 2B 3E 7C 7B when testing heavy items, when
2C (Furniture) 2C (Furniture)
4AB 4AB handling dry ice or any chemical, and
when load stability may become an
Specialized 2C 2C Not Not Not issue.
Furniture Applicable Applicable Applicable

Instrument Calibration
Parcel Not Not Not
Instrumentation used to control
2D (Flat Packages) Not
Delivery 2E (Elongated Applicable Applicable Applicable Applicable laboratory testing equipment or to
Packages) record data from tests must be properly
3A
5B (Thermal) calibrated, traceable to national or
7D (Thermal) international standards, to ensure
LTL 2F, 3B 2F, 3B 3B Not Not
accuracy. Calibration intervals should
(Less-Than- Applicable Applicable be established with consideration of:
Truckload)
Delivery
• Manufacturer’s recommendations
Distribution 3F Not Not Not Not • The laboratory’s overall Quality
Center Applicable Applicable Applicable Applicable
to Retail Program
• Customer requirements.
Various 6-Series 6-Series See Series See Series See Series
as appropriate as appropriate

Table 2 Test Protocols

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ISTA recommends instrument calibration intervals of not among all entities concerned with safe arrival of the
greater than one (1) year. shipment, low damage rates, cost effective packaging, etc.

If there is the possibility that an instrumentation component FACE, EDGE AND CORNER
has been damaged (e.g. if an accelerometer is accidentally IDENTIFICATION
dropped or impacted), it should be checked and/or re- ISTA® Procedures and Projects use a system of
calibrated before being put back into use. identification for parts of a test specimen package in order to
simplify the test sequence and documentation process.
KNOW YOUR DISTRIBUTION Occasionally, users may face the challenge of testing a
ENVIRONMENT packaged product that does not fit an identification scheme
An important step in the selection and use of ISTA® easily. For example, a package with a hexagonal cross
Procedures and Projects is the user's familiarity with the section could have six vertical faces, a top and a bottom. In
actual distribution environment for the packaged products these situations, the user is advised to develop a logical
under test. Understanding the flow of packages, how they identification system that fits the test specimen in question,
are shipped and handled and stored, is critical to test and to document both the identification system and the
selection and results interpretation. Users should regularly orientations for all tests conducted. The specified number of
observe package distribution, both in the manufacturer's drops and drop heights shall be maintained as well as other
facility and in warehouses, transportation facilities, vehicles test levels, and how these tests were applied to the test
and customer locations. In some cases, users may use specimen shall be documented.
measurement instruments and techniques to determine
vibration, drop, compression, and temperature/humidity SAMPLES
levels during distribution. This detailed knowledge, Most ISTA® Procedures and Projects require a minimum of
observation, or measurement may be very useful in test one packaged-product to be tested. A single "pass",
selection, for example, the use of an individual package test however, does not provide high confidence that other
protocol instead of or in addition to a unitized load test seemingly identical packaged-products will also pass the
protocol when loads are broken down during distribution. same test. This is due to inherent variation in packaging
materials, package components, and the package contents
PRODUCT DAMAGE TOLERANCE AND as well as other statistical considerations. ISTA generally
PACKAGE DEGRADATION ALLOWANCE recommends replicate testing, using new samples each
Before testing begins, a determination must be made as to time. Having three successful tests of identical packaged
the definition of damage to products and packages. This products helps improve the assurance; five or more are
determination must include any allowable damage to the recommended when possible. Even ten successful replicate
product and any allowable change in package condition. tests, however, do not guarantee that all future tests will also
These determinations are made to allow the evaluation of be successful.
packaged-product specimens after performance of all tests,
and assignment of pass or fail results. When possible, these There is no definite rule about appropriate sample size; it
determinations should be quantitative in nature to minimize may depend on the purposes of testing, the desired
results interpretation. Use of product quality standards, user confidence level, and the availability of samples. ISTA®
acceptability information, and other data is encouraged. Procedures and Projects specify a minimum number of
samples required to run the test and achieve package
ISTA intentionally does not specify what constitutes product Certification. In addition, a recommendation for replicate
damage and package degradation. These determinations testing is generally made. ISTA's policy is that if any sample
are dependent upon the particular product, package, fails any of the tests, then the entire test is considered failed.
distribution system, market, customers, and other factors
and can vary widely. Therefore product damage and The additional testing time for larger sample sizes need not
allowable package degradation must be defined by the be a barrier to better test technique. For example, most
shipper, manufacturer, damage claim group, and/or other vibration test systems will allow the user to test many
stakeholders and interested parties. In most cases, the packages simultaneously, thus saving considerable time. In
shipper/manufacturer is in the best position to define product this way, a sample size of five would have essentially the
damage due to detailed familiarity with the product. same elapsed time for vibration testing as a sample size of
Sometimes others may contribute to these determinations, one.
including carriers and test lab personnel. But in any case,
definition and agreement should be reached cooperatively

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Occasionally, proper samples are not available to meet When there is any doubt as to whether a change will
minimum requirements for a test protocol. The use of non- potentially affect performance, retesting should be done.
functional dummy products is not allowed in most cases, but Determining when retesting is required may involve knowing
samples with minor, identifiable damage, such as minor and tracking specification details of both the package and the
surface scratches, may be acceptable. The key is: when the product, such as new or changed components, materials,
test is complete, can we determine if the product was interior packaging, closure methods, etc.
damaged according to the Product Damage Allowance
statement developed before testing began? Changing the grade of the corrugated board in the box
definitely requires retest, even in those situations where
Another technique is to re-use a product for several test carrier regulations imply the "equivalence" of two grades of
sequences with appropriate inspection to insure that the corrugated (such as 200 psi burst and 32 lb/in ECT grades).
product has not been damaged. The user must be cautious In many instances, corrugated from these two grading
to not re-use a product that has become more susceptible to systems will be different in construction and performance
damage due to prior testing. In this way, one product and and thus must be retested on a grade change. Basis
three packages could be used to achieve a sample size of weights (weight per unit area) of corrugated board
three. The test would be run three times, re-packaging the constituents have been shown to be good indicators of box
single available product each time. equivalence or change. If the basis weights change, even if
the board is rated for the same performance, a retest is
RETESTING appropriate. It is therefore strongly recommended that the
ISTA test protocols should be repeated periodically or as measurement and documentation of basis weights in
necessary to maintain the quality characteristics of the accordance with TAPPI (Technical Association for the Pulp
packaged product on arrival. In addition, tests must be and Paper Industry) T410 and TIP 0308-01, FEFCO
repeated whenever there is a change in the product, the (European Federation of Corrugated Board Manufacturers)
package, or the process. Some changes are not included in Testing Method No. 10, ISO (International Organization for
this requirement, but only if the change is not associated with Standardization) EN 536, ASTM D646, or other accepted
potential performance in any way. industry standards accompany every packaged-product test
where corrugated packaging is involved.
Changes in the product can include changes in:
• Design (configuration, components, accessories, etc.) Retesting is also strongly recommended when distribution
• Size / weight (dimensions, shape, mass, center channels change, as this may mean a different test protocol.
of gravity, etc.) An example is the opening of an e-commerce business (to
replace or supplement traditional retail distribution) that
• Materials (type, construction, fabrication, gage, etc.) involves significant shipments direct to customer by small
parcel carriers.
Changes in the package can include changes in:
• Configuration (individual package or unit load, REPEATED TESTING
container type and sub-type, style, design, The issue of product returns, especially in specialized
interior packaging, etc.) channels such as e-commerce, catalog sales, TV sales and
• Size / weight (dimensions, shape, mass, caliper, similar distribution, is an important one. Return rates for non-
gage etc.) traditional retailing have been shown to often be much higher
• Materials (corrugated, plastic, metal, glass, etc.) than traditional retailing distribution. Returns happen for
many reasons and are not all damage related. Accordingly,
• Components (closures, labels, straps, pallets,
a package must be capable of both initial distribution (source
skids, wraps, etc.)
to customer) and return distribution (customer to source) in
these cases. Consider requiring a sample product and
Changes in the process can include changes in:
package to be subjected to additional testing when expected
• Manufacturing / assembly (vendor, location,
return rates are high or other marketing and distribution
automation, etc.)
factors indicate increasing significance of returns.
• Filling (equipment, speed, automation, etc.)
• Distribution system (parcel delivery, LTL,
intermodal, etc.)

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LINE EXTENSION POLICY ADDITIONAL CONSIDERATIONS
In some cases, and for ISTA members only, ISTA approves The following items are specific to certain Procedures,
a limited amount of testing to represent more extensive Projects, or tests:
testing. For example, a line of products with 30 models may
be able to be certified by testing less than 30 packaged- Incline Shock and Horizontal Shock. Note that when
products. This technique applies when the models and conducting an incline shock test, the parameter measured
packages are very similar. Use of this technique for and controlled is the impact velocity. When conducting a
certification requires prior approval by ISTA staff, and is horizontal shock test, the parameter to monitor and control is
considered on a case-by-case basis. Contact ISTA velocity change. Horizontal shock should be programmed to
Headquarters for additional information and to discuss your short duration nominal half-sine pulses unless otherwise
specific needs. instructed in the Procedure. Durations around 10
milliseconds are desirable if practical.
IDENTIFICATION OF PRODUCT AND
PACKAGE TESTED Conditioning. If controlled temperature and humidity
Whether reporting test results to ISTA for Certification or conditions are required or are to be used in any test
approval, or documenting the test for future reference or a Procedure, the best approach is to perform all tests directly
customer report, identifying the test sample is vitally in the conditioned atmosphere. If this is not possible, then
important. Product description should include product name, tests should be performed quickly after removal of test items
brand, model number, serial number, place and date of from the conditioned atmosphere, and test items should be
manufacture, and similar information. It is strongly returned periodically to conditioning as necessary to
recommended that photographs, detailed drawings, and/or maintain the required control.
complete specifications of the product and any included
accessories accompany the report. The temperature and humidity conditioning times specified in
the Procedures are dwell times at the specified conditions,
Package description must also be detailed and specific and and do not include any time which may be required to
should include type, style and material of packaging; transition from one condition to another. Some Procedures
corrugated board composition; cushion details including (i.e. 7D) specify the transition times (ramp times), and those
performance; film gage and composition; application or should be followed.
package forming details; mold numbers; any pallet or skid;
unitization method for unit loads; methods of closure, etc. It In certain situations longer temperature and humidity
is strongly recommended that photographs, detailed conditioning dwell times may be required. There are
drawings, and/or complete specifications of both exterior and packaged-product configurations which may equilibrate
interior packaging accompany the report. extremely slowly with their surrounding atmospheres. For
example, hot-filled containers in the interior of dense unitized
TEST PARAMETER TOLERANCES loads may require a week or more to reach room
ISTA test protocols generally do not include tolerances on temperature. If necessary, make measurements or
test parameters such as drop height, compression force, calculations and extend the conditioning times accordingly.
vibration time and intensity, etc. In all cases the
requirements given are considered minimums; i.e., no The strength of corrugated board is affected by its moisture
variation or tolerance below the stated values is allowed. If content, not directly by the surrounding atmospheric
any particular test in a test sequence is below the required humidity. It may be helpful to measure levels and changes
minimum, that test does not count and must be repeated. in board moisture content during atmospheric conditioning.

Although "conditioning" usually refers to atmospheric

conditioning (temperature/humidity), in ISTA® Procedures
other hazard types may be used as conditioning as well. For
example Procedure 1C where compression conditioning is
used, or Procedure 7D where drop conditioning is used.
When using any hazard type to condition a specimen, the
objective is not to see how the specimen performs during
that conditioning, but rather, to prepare the specimen for a
subsequent test which will be used for performance

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evaluation. Conditioning situations are appropriately SUGGESTED STEPS FOR SELECTING A
identified in ISTA® Procedures. TEST PROTOCOL
ISTA suggests consideration of the following items when
Compression Loads/Forces and Vibration Top Loads. selecting a test protocol.
Compression loads/forces in the Procedures and Projects
are generally calculated from the weight and number of • Test rationale: required, experimental, decision
identical packages which could be stacked on the test supported.
package in actual distribution, or a stacking density of
nominally 200 kg/m3 (12 lb/ft3) for mixed loads. These • Test objective and expectation: screening, prediction,
values are then multiplied by Compensating Factors to cost and environmental reduction, comparison to an
account for effects not tested, such as temperature/humidity, alternative, or demonstration of a minimum use of
stacking patterns, long-duration loading, etc. If compression packaging.
testing is performed in conjunction with atmospheric
conditioning which reduces container strength (e.g. • Test Series: Non-Simulation Integrity, General
corrugated containers under high humidity, plastic containers Simulation, Focused Simulation, Developmental, or
under high temperature), these Compensating Factors can combinations.
be reduced. If ISTA recommendations for Compensating
Factors and/or Compensating Factor ranges are not
• Resources: equipment, budget, time frame,
followed, sufficient justification must be included in the Test
expertise, experience, past history.
Report.

• Package type: weight, configuration, application.

For the application of compression forces with a
compression testing machine, all ISTA Procedures require
• Distribution type: unspecified or varied, special.
the use of a fixed (not swiveling) platen arrangement in
Know your distribution environment.
accordance with the “Fixed Platen Testing Machine”
paragraph of the “Apparatus” section of ASTM D642. For
corrugated boxes and cases, swivel platen testing machines REMINDERS FOR USE OF ISTA TEST
generally cause failure at the specimen’s weakest point, PROTOCOLS
whereas fixed platen machines generally cause failure to • Use care in selecting the right test for the situation. In
occur at the specimen’s strongest point. Any such item some cases, more than one test should be run and
which passes a swiveling platen test at a specified force results compared. Field testing (trial shipments) may
would therefore pass the same test force requirement using be used as an adjunct to lab testing.
a fixed platen. Use of a swiveling platen may result in test
failures at the specified force which might not have occurred • Use the current test. ISTA® Projects and
using a fixed platen. Procedures are continuously being reviewed,
updated and expanded. New and revised tests
For Procedure 3A, the vibration top loads were determined are available on the ISTA website at www.ista.org and
by empirical testing that resulted in correlation between may supersede those in the Resource Book.
damage in the test lab and damage in the field. It was found
that top loads representing average load densities of • Use representative samples. Both products
nominally 200 kg/m3 (12 lb/ft3) caused unrealistic failures and packages should be as close as possible to
during lab testing. By experiment, proper correlation was actual production items. In some cases this may
found at 100 kg/m3 (6 lb/ft3). mean testing a product and package early in the
development cycle and then later when production
Non-Equivalent Alternatives. In many ISTA Procedures, products are available. Samples should not have
alternative methods are permitted for performance of some been previously tested, or shipped to a test lab
tests. Examples: Drop, Incline Impact, and Horizontal without over-packaging or other consideration.
Impact for Shock tests; Fixed Displacement and Random for
Vibration tests. It must be recognized that in many cases • Review the test before performing it.
these alternative methods are not equivalent; i.e., they will Check for new sections, order of tests,
not necessarily produce the same results. The alternatives documentation requirements.
chosen for a particular Procedure should be carefully
documented in the Test Report.

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GUIDELINES FOR SELECTING AND USING ISTA®
TEST PROCEDURES & PROJECTS
• Damage/Degradation determination. Most • Determine results. Most procedures require a
ISTA protocols call for determining the Product pass/fail determination. This determination must be
Damage Tolerance and Package Degradation made in light of the package and product
Allowance before the test begins. damage/degradation criteria determined before the
test began. Details on how the evaluation was made
• Check lab status. If the package is to be Certified by should be included in the test documentation.
ISTA, the performing lab must have a current
laboratory certification, renewable every two years. • Review the test. Was it the right test? Was it
done correctly? Is the documentation complete?
• Perform all tests, at the correct levels and Would you understand it and be able to reproduce it
in the correct order. ISTA® Procedures and two years from now?
Projects do not allow test levels, times, etc.
below the stated values, flexibility in the order of • Finalize. Distribute documentation. Send report to
performance, nor the elimination of any tests. Over- ISTA for Certification or approval. Make decisions.
tests are permitted if desired, however. For example,
certification to an ISTA test may be obtained if all • Monitor Actual Shipments. If possible, obtain
requirements of that test were met and in addition, information on performance in actual distribution of the
more or higher drops were conducted, the vibration packaged-product tested. This performance, when
test was run longer or at a higher level, the compared to results from the laboratory tests, can be
compression force used was greater, etc. used to evaluate the effectiveness of tests and guide
future testing decisions.
If the purpose of a test does not include ISTA
Certification of the packaged-product, then ISTA
has no official involvement or responsibility and
therefore the test can be modified at the user's
discretion. In such situations it is not necessary or
desirable to send a Test Report to ISTA.

• Document results as tests are performed.

Record intermediate results, options selected,
calculations made and any deviations. Photo,
video and drawings are good documentation tools.

• Do not alter package condition.

Interior inspection of the product or package (by
opening the package) is not allowed during the
conduct of an ISTA Test Procedure where packaged-
product certification is desired. Doing so may alter the
package condition and thereby invalidate the test
results. If intermediate inspection is desired, the
recommended approach is to perform separate tests
for investigation and certification. First test one or
more packaged-products, inspecting them as desired
to determine intermediate damage. When any issues
or problems have been corrected, separately
subject one or more new packaged-products to
the complete test, without intermediate inspections, to
determine pass/fail or for certification.

10 Version 2009
 GUIDELINES FOR SELECTING AND USING ISTA®
TEST PROCEDURES & PROJECTS
DOCUMENTATION OF TESTS Package Description
The following general information, in addition to specific • Description of entire shipping unit
testing details, is required when completing a Certified
• Type or style of package
Laboratory Test Report:
• List and details of packaging materials used
• Pallet or skid and unitization method, if applicable
ISTA Certified Testing Laboratory Information
• Method(s) of closure, if applicable
• Complete laboratory name and address
• Photographs, detailed drawings, and/or complete
• Test Laboratory ID number
specifications as appropriate
• Test Technician who performed the test
• Test Report submitted by: name and signature
Packaged-Product Tested
• Gross weight of packaged-product
Product Manufacturer/Shipper Information
• External container size in inches (mm or m):
• Manufacturer/Shipper company name and address Length x Width x Depth (L x W x D)
• Test requested by: individual's name • A picture or pictures should be included
• Manufacturer/Shipper ISTA License Number, if
applicable and known
Product Damage Tolerance Criteria
• Definition of product damage tolerance
Third-Party Test Request Information
• Name of person who determined definition of
• Test conducted for: company name and address product damage tolerance
• Test requested by: individual's name • Description of the method of determining
• Relationship to the product manufacturer/shipper product damage

Test Information Package Degradation Allowance Criteria

• Test Procedure or Project performed • Definition of package degradation allowance
• Date tested • Name of person who determined definition of
package degradation allowance
• Number of samples tested
• Description of the method of determining
• Number of replicate tests performed
package degradation
• Test Number(s) assigned by test laboratory, if
applicable
ISTA Test Report Forms may be downloaded from
• Appropriate details of tests and findings
www.ista.org. Custom forms with additional information are
acceptable, but data on the ISTA Forms are considered to be
Product Description the minimum.
• Product name, brand, model number, and serial
number as appropriate
• Place and date of manufacture
• Photographs, detailed drawings, and/or complete
specifications as appropriate

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GUIDELINES FOR SELECTING AND USING ISTA®
TEST PROCEDURES & PROJECTS
COMMUNICATION WITH ISTA ISTA Distributing Confidence, Worldwide TM
ISTA is very interested in your preshipment performance 1400 Abbot Road
testing needs and experience. Please let the organization
Suite 160
know when you have suggestions, observations or
questions. East Lansing, MI 48823-1900 USA
Telephone: [+1] 517-333-3437 Fax: [+1] 517-333-3813
E-mail: [email protected]
Website: http://www.ista.org

Version date: January 2009

ISTA TEST REPORT PROCESSING

Test Laboratory Test Laboratory Test Laboratory ISTA Headquarters

Conducts an ISTA Procedure All samples tested, including all The results of the test (pass Examines the report to ensure
or Project. replicate tests if conducted, or fail) are submitted to ISTA that the test was conducted in
must meet the criteria from the Headquarters using an accordance with the test
Product Damage Tolerance accepted Test Report Form procedure and for
and Package Degradation (available in Word format at completeness. Upon
Allowance Block to report the www.ista.org). acceptance of the report, ISTA
test results as a pass. If any processes the report by
sample fails any of the test performing the appropriate
methods then the test is action.
considered a failed test.

Packaged-Product PASSED Packaged-Product

FAILED

Shipper IS an ISTA Member: Shipper is NOT an ISTA Shipper IS an ISTA Member: Shipper is NOT an ISTA
Member: Member:

ISTA Headquarters ISTA Headquarters ISTA Headquarters ISTA Headquarters

Certifies the packaged-product; Assigns a database reference Retains a copy of the report Retains a copy of the report
assigns a database reference number to the report form; form on file for a minimum form on file for a minimum
number to the report form; retains a copy of the report amount of time. amount of time.
retains a copy of the report form on file for a minimum
form and certification details on
amount of time.
file.

Shipper Shipper Shipper Shipper

Receives a Certification Notice. May NOT use the ISTA® Receives no correspondence. Receives no correspondence.
Transit Tested Certification
May use the ISTA® Transit Mark on the packaged-product. May NOT use the ISTA®
Tested Certification Mark on the Transit Tested Certification
packaged-product according to
No correspondence is received Mark on a failed packaged-
the license agreement and
ISTA policy. from ISTA. product.

Test Laboratory Test Laboratory Test Laboratory Test Laboratory

Receives a copy of the Receives an Acknowledge- Receives no correspondence. Receives no correspondence.

Certification Notice. ment of Testing from ISTA.

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 ISTA® TESTS QUICK REFERENCE

TEST ARE ORGANIZED BY SERIES:

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.

2 SERIES: PARTIAL SIMULATION PERFORMANCE TESTS

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

3 SERIES: GENERAL SIMULATION PERFORMANCE TESTS

Designed to provide a laboratory simulation of the general 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.

4 SERIES: ENHANCED SIMULATION PERFORMANCE TESTS

General Simulation tests with at least one element of Focused Simulation, such as test sequence or test conditions linked to
actual known distribution. Project 4AB is currently the only protocol in this Series. 4AB is a web-based Enhanced Simulation
Test Plan generator, with on-line access available at no charge to all ISTA members. Project 4AB closely ties the tests and
sequence to a user-defined pattern of distribution, and includes a broad range of current and quantitative information on
distribution environment hazards. See the Project 4AB section of the ISTA® website (www.ista.org) for more details.

5 SERIES: FOCUSED SIMULATION GUIDES

Guides for the creation of laboratory simulations based on actual field-measured and observed hazards and levels. The 5-
Series are not performance tests per se, but information and instructions related to establishment of user-defined Focused
Simulation tests. Guide 5B for Temperature Controlled Packaging is currently the only document in this Series.

6 SERIES: MEMBER PERFORMANCE TESTS

Test protocols created by ISTA members to meet their particular purposes and applications. The tests may be completely
original, or may be modifications or variations of ISTA Procedures or Projects or other published and accepted tests. ISTA
reviews and accepts these tests, but primary responsibility rests with the originating members.

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.

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ISTA® TESTS QUICK REFERENCE

IMPORTANT
Procedures periodically receive corrections or revisions before the publish date of the next Resource Book. Please visit the
ISTA® website at www.ista.org for the most up-to-date procedures and projects. Members receive free and complete online
access to all Test Procedures.

ISTA® PROCEDURES AND PROJECTS:

1A Packaged-Products weighing 150 lb (68 kg) or Less
1B Packaged-Products weighing Over 150 lb (68 kg)
1C Extended Testing for Individual Packaged-Products weighing 150 lb (68 kg) or Less
1D Extended Testing for Individual Packaged-Products weighing Over 150 lb (68 kg)
1E Unitized Loads
1G Packaged-Products weighing 150 lb (68 kg) or Less (Random Vibration)
1H Packaged-Products weighing Over 150 lb (68 kg) (Random Vibration)
2A Packaged-Products weighing 150 lb (68 kg) or Less
2B Packaged-Products weighing Over 150 lb (68 kg)
2C Furniture Packages
2D Packaged-Products Considered Flat
2E Packaged-Products Considered Elongated
2F Performance Testing of Shipping Containers for LTL Shipment National Motor Freight
Classification Item 180 NCC/LTL
3A Packaged-Products for Parcel Delivery System Shipment weighing 70kg (150 lb) or Less
3B Project: Packaged-Products for Less-Than-Truckload (LTL) Shipment
3E Unitized Loads of Same Product
3F Packaged Products for Distribution Center to Retail Outlet Shipment, 100 lb (45 kg) or Less
3H Performance Test for Products or Packaged-Products in Mechanically Handled Bulk Transport
Containers
4AB Project: Packaged-Products for Shipment in Known Distribution Channels
5B Focused Simulation Guide for Thermal Performance Testing of Temperature Controlled
Transport Packaging
6 Member Performace Tests - details in 6-Series section.
7A Project: Open Reusable Transport Containers for Loads of 60 lbs (27 kg) or Less and Unitized
for Shipment on a Pallet
7B Closed Reusable Transport Containers for Loads of 150 lb (68 kg) or Less
7C Reusable Intermediate Bulk Containers
7D Thermal Controlled Transport Packaging for Parcel Delivery System Shipment

14 Version 2009
 ISTA® TESTS ORGANIZED BY DISTRIBUTION MODE OR TYPE
QUICK REFERENCE
Any Distribution Mode and Individual Packages Weighing…
150 lb (68 kg) or Less Over 150 lb (68 kg) Basic Requirements

1A 1B fixed displacement vibration & shock testing

1C 1D fixed displacement or random vibration, shock testing and compression
conditioning (optional atmospheric conditioning)
1G 1H random vibration and shock testing
2A 2B atmospheric conditioning, compression, fixed displacement or random vibration,
and shock testing

Small Parcel Delivery Mode and Individual Packages

Test Package Type Basic Requirements

3A 70 kg (150 lb) or Less Small, atmospheric conditioning, shock, and random vibration testing (with & without top
Standard, Flat, Elongated loads)
2D Flat fixed displacement vibration and shock testing
2E Elongated fixed displacement vibration and shock testing

Less-Than-Truckload (LTL) Delivery Mode

Test Package Type Basic Requirements

3B Standard, 200 lb (91 kg) or less atmospheric conditioning, shock, impact, random vibration with top load,
tip/tipover
3B Standard, over 200 lb (91 kg) atmospheric conditioning, shock, impact, random vibration with top load,
tip/tipover
3B Cylindrical atmospheric conditioning, shock, impact, random vibration with & without top loads
3B Palletized or Skidded atmospheric conditioning, shock, impact, random vibration with top load,
tip/tipover, fork lift handling

Any Distribution Mode and Unitized as a Single Load

Test Package Type Basic Requirements

1E Unitized vertical linear or random vibration and shock

3E Unitized atmospheric conditioning, compression, random vibration, and shock testing

Any Distribution Mode and Reusable Systems

Test Package Type Basic Requirements

3H Mechanically Handled Bulk atmospheric conditioning, random vibration & shock testing (optional compression
testing)

Other
Test Package Type Basic Requirements

2C Furniture Packages atmospheric conditioning, top load vibration, and shock testing
2F LTL Shipments atomspheric conditioning, compression/vibration, vibration, shock testing
(NMFC Item 180)
3F Non Unitized DC to Retail atmospheric conditioning, compression, random vibration, and shock testing
100 lb (45 kg) or Less
4AB Varies Web-based Enhanced Simulation Performance Test
5B Thermal Performance focused simulation development
6 Series-Member Performance Test Varies Requirements set by member. See 6 series section.

Development Tests
Test Package Type Basic Requirements

7A Open Container 60 lb (27 kg) or compression and shock (optional atmospheric conditioning)
Less
7B Closed Container 150 lb (68 kg) fixed displacement and random vibration, shock, compression, atmospheric
or Less conditioning
7C Intermediate Bulk Container atmospheric conditioning, compression, random vibration, and shock testing

7D Thermal Performance atmospheric conditioning (optional vibration conditioning and shock testing)

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