ISTA package testing is a form of packaging reliability testing that puts your shipping cartons through their paces to provide you with peace of mind that your products will arrive undamaged.
A shipping packaging will typically go through temperature extremes, vibrations, humidity, and drops while it is being delivered. Can you be sure that it’s up to the task? Let’s find out what the testing is, its costs, and when to do it here.
What is ISTA package testing?
ISTA, or the international safe transit association, devised a number of ANSI-accredited testing standards for packaging reliability. We recommend performing them as a starting point, although sometimes our customers provide us with information about their supply chain and we can then devise a custom testing standard that is better suited to their needs. Testing packages is necessary because the cost of damage to products in transit almost always outweighs the cost of the tests themselves.
As ISTA says on its site, its mission is to empower organizations and their people to minimize product damage throughout distribution and optimize resource usage through effective package design.:
The decisions supported by preshipment performance testing of transport packaging are typically about how well the package will protect the contents during distribution.
Ultimately, ISTA package testing is performed to help you control product damage, the use of resources, and your costs.
What different ISTA test procedures are there?
There are 6 categories of ISTA test procedures:
- Non-simulation tests
- Partial simulation tests
- General simulation tests
- Enhanced simulation tests
- Member performance tests
- Development tests (for transport packages)
We’ll focus on three test procedures that are particularly beneficial for today’s importers in our opinion: ISTA – 1a, ISTA – 2a, and ISTA – 3a which are all for packages of 150 lbs. (68 kg) or less.
Before performing any tests, you will need to define what ‘damage’ to the product due to shipping would be, what level of damage is acceptable (if any), and also what packaging and product condition when the test is completed is acceptable.
When the tests are performed, the shipping carton will also need to be filled with real samples of the products in their retail packaging and any dunnage to provide consistent results that will be relevant to the packages that are actually being shipped.
Also, the tests must be done in same order as outlined in the procedures, as ISTA formulated them in this way to provide the most relevant or realistic results. Mixing the test order will not provide correct results.
Passing the tests will result in an ISTA certification for that packaging, but all of the required tests must be done for this.
ISTA-1a
This test procedure doesn’t simulate the conditions that a package will go through during shipping, but it will give you a rough idea of whether the shipping carton is strong enough to provide adequate protection for the products during shipping and is good for lower-cost products where high quality is not critical.
It’s often used as a screening test for packaging types during your design and development phases. We’d say that it’s generally worth paying a little extra for 2a or even 3a ISTA package testing.
This standard includes the fewest tests with the packaging undergoing these 3:
- Atmospheric preconditioning testing at an ambient and temperature and humidity
- Vibration testing (fixed displacement or random)
- Shock/drop test (you will select which type of drop: straight drop, incline drop, or horizontal impact).
The drop test height varies by weight:
- 0-10kg = 760mm
- 10-19kg = 610mm
- 19-28kg = 460mm
- 28-45kg = 310mm
- 45-68kg = 200mm
For more detail you can read ISTA’s overview for ISTA-1a.
ISTA-2a
This procedure is a good all-round choice and a compromise between cost and results. It provides a partial simulation of the conditions packaging needs to stand up to during shipping. In general, most importers might choose this one.
Since it includes 6 tests, you can see that it’s a more detailed test than ISTA-1a. Although a ‘partial’ simulation, this testing should provide enough data for importers to be satisfied that the packaging chosen has adequate integrity and strength.
Packaging will undergo all of these required tests:
- Atmospheric preconditioning testing at an ambient temperature and humidity (this may typically be for around 6 hours or so)
- Atmospheric conditioning testing at controlled conditions (recommended 72 hours of testing in the chamber at 120°F and 85% Relative Humidity)
- Compression testing (either machine apply & release, or machine apply & hold, or weight & load spreader)
- Vibration testing (fixed displacement or random)
- Shock/drop testing (you will select which type of drop: straight drop, incline drop, or horizontal impact) + see the 1a section for drop heights per weight
- Vibration testing for the second time (fixed displacement or random)
For more detail you can read ISTA’s overview for ISTA-2a.
ISTA-3a
A more comprehensive test, this test includes 11 tests and is meant to be a general simulation of the conditions, motions, and damage-causing events your packages will need to cope with during transit.
As it goes through more tests you will receive the most assurances that your packaging is unlikely to fail you and lead to product damage during shipping.
Arguably, though, only importers with particularly fragile or high-value products need to select this type of testing for their packages. In most cases, 2a will more than likely be adequate.
The testing procedure includes:
- Atmospheric preconditioning testing at an ambient temperature and humidity
- Atmospheric conditioning testing at controlled conditions*
- Shock/drop testing (9 drops)
- Vibration testing (random with and without top load)
- Vibration testing (random under low pressure)*
- Shock/drop testing (8 drops including drop onto hazard)
- Shock/drop testing (rotational edge drop) – flat & elongated packages only
- Shock/drop testing (full rotational flat drop) – flat & elongated packages only
- Shock/drop testing (concentrated impact) – flat packages only
- Shock/drop testing (bridge impact) – elongated packages only
- Leak testing – for liquids’ integrity only
*optional tests for standard, flat, and elongated packages
Please note, we’re providing a rough introduction here, for more detail you can read ISTA’s overview for ISTA-3a.
When should you test your packaging?
ISTA package testing is a useful tool for importers to use during the new product development process in order to decide which type of packaging they wish to use for the shipping cartons well before anything reaches the dock.
Given that you will need to use real samples of your product and retail packaging to be packed into the shipping cartons to be tested following your final packaging model, too, we suggest sourcing and testing packaging while you are developing the last product prototype build (approximately 2-3 months before mass production starts).
Your final prototype will provide you with a realistic picture of the product’s shape, form, weight, and probably even the retail packaging, all of which allow your ISTA testing to provide accurate results.
Which packaging material and size is right for you?
The type of packaging you select is determined by the product type and the weight the shipping carton will need to hold without losing integrity.
In terms of carton size, this depends on how many retail packages need to fit inside it and your packaging plan. For instance, will they be packed in tightly to maximise the number per shipping carton or will there be dunnage of some kind for extra protection?
Shipping cartons are commonly made from corrugated cardboard and, if you find that you need more strength, you can select 2 or even 3-ply cardboard and various ways of reinforcing corners, etc.
What do the ISTA tests cost?
The costs vary and increase as you go from 1a to 3a due to the increasing number of tests and complexity:
- 1a – approximate cost of US$500.
- 2a – approximately US$600-1,500.
- 3a – approximately US$1,000-3,500.
As you can see, these costs are relatively affordable, especially in the context of you receiving a container load of products that have been damaged during shipping due to inadequate packaging.
What if your package fails the tests?
As mentioned, ISTA package testing needs to be performed in a specific sequence. When it comes to a failed test it’s necessary to look at which sequence the package failed on.
If it immediately fails then you’ve probably chosen a carton that’s just not strong enough and you need to go back to the drawing board and source and test another option. However, if it fails on, say, the final sequence, you might make the decision to let it go anyway, as in all likelihood it will probably be able to cope with shipment without collapsing as the tests (especially 2a and 3a) are designed to push packaging to limits that are probably beyond what they will experience in the field.
Of course, if you require the ISTA certification for some reason such as a vendor demanding it, then you’ll need to pass all of the sequences, but since it isn’t mandatory, you could just use the testing as guidance for your peace of mind.
Either way, a failed test is a learning experience.
Conclusion: Why you need ISTA package testing
Due to its relatively affordable cost, it makes sense to perform ISTA package testing during your new product development. By assessing your shipping carton’s strength and reliability in this way, you’re reducing your risks of:
- Scrapped products
- Angry customers
- Product returns
- Delayed deliveries (if subsequent productions must be ordered to replace damaged units)
Simply put, having robust enough shipping packaging gives you the peace of mind that the many months and money spent on designing, developing, and manufacturing your products won’t be wasted by them being damaged during shipping.
Get help
We do provide packaging reliability testing in our lab here at Agilian. If you have any questions about it, get in touch for a conversation.
You may also like to read:
- Packaging Inspection Guideline: What Is Usually Checked?
- Why Packaging Is Important For Both Protection & Product Differentiation
- What Is A Package Drop Test?
- What Is A Package Vibration Test?
- Carton Compression Test (what it is and its procedure)
- What Is A Packaging Atmospheric Conditioning Test?
- How To Check Humidity In Wood And Cardboard
