Even the best packaging designs, whether for palletized shipments or individual parcels, can fail during transport. Palletized boxes can shift, compress, and tip when loads aren’t secured properly and the stacked weight is high. Individual shipping boxes move through multiple handoffs and automated systems, where impacts, drops, and rough handling increase the risk of damage. Package testing services from Abbott-Action provide quantitative data to support box integrity from packaging through its destination. Below, we cover testing from the component through the program level.

Testing Services for Material and Print Characteristics

Before a box is even cut, testing is done to ensure the corrugated board meets the packaging requirements. These tests verify that the material and print quality align with performance standards. Accurate measurements of strength, stiffness, and color consistency help maintain quality control and reduce costly errors during converting and printing.

Basis weight testing – The weight of 1000 ft² of linerboard is called the basis weight (lb./ft²). In a corrugated sheet, the basis weight of each component (liners and corrugated medium) may differ, depending on the desired strength. During testing, the sheet is separated into its individual layers, and each one is weighed. This quality-control step confirms the material matches the specified board grade and that production remains accurate and consistent.

Edge crush testing – This test measures the edgewise compression strength of corrugated board. A sample of corrugated board is placed on edge (flutes perpendicular) between two parallel platens, and force is applied until the sample collapses. The results are recorded in pounds per lineal inch of load-bearing edge but represented as ECT. For example, you may see a box rated as 40 ECT.

Chalmer’s dynamic strength testing (DST) – DST measures the machine direction (MD) torsional stiffness of corrugated board. A sample is placed in self-centering clamps, and one side is rotated and released. The tester measures the natural angular frequency (the frequency at which it oscillates naturally when disturbed); this measurement is used to calculate torsional stiffness. While the ECT measures the strength of the board, the DST measurement correlates with the amount of damage incurred during the printing and converting processes and with how well it will protect its contents.

Score Bend Testing – This test measures the force required to bend a scored corrugated board. A sample is placed in the center between the pressure bar and a U-channel opening, aligning the score with the upper jig. The upper jig applies pressure to the corrugated board at the score, forcing it to bend. The test equipment measures the force required to bend the carton score to 90 degrees. This gives an indication of how well a box will fold without cracking and will maintain its shape.

Color Spectrophotometer analysis – A color spectrophotometer measures how printed samples reflect light across the visible spectrum, then converts that data into objective color values. A small aperture is placed against the inked area, and the device scans the sample under controlled illumination. The resulting measurements indicate whether the printed color matches the approved standard, the extent of the deviation, and whether the variation is within tolerance. This analysis helps verify ink formulation, press consistency, and overall color accuracy from run to run.

Package Testing Services for Performance

Once materials pass initial checks, the next step is to evaluate how the finished box performs in real-world conditions. Package testing services for performance simulate stacking, handling, and impact scenarios to confirm that packaging can withstand the rigors of distribution.

Box Compression Testing – This test measures how much weight a box can withstand before it collapses. To perform the test, a finished box is placed between two flat plates in a compression machine. The plates slowly press down on the box until it starts to fail, and the force required is recorded. This test determines whether a box can withstand the stacking and pressure it will encounter during storage and shipping.

Drop Testing – Drop testing checks how well a package protects its contents when dropped during handling. The box is filled as it would be for shipping and then dropped from specific heights onto different surfaces of the box, including flat, an edge, and a corner. The goal is to see if the contents stay safe and the box remains intact. This test helps prevent product damage and customer complaints by confirming the packaging can handle real-world mishandling.

Palletization and Load Design Testing

Proper palletization is critical for minimizing damage during transport. Load design testing examines how boxes stack, distribute weight, and maintain stability under pressure. This allows engineers to optimize pallet configurations to reduce shifting, tipping, and crushing during transit. This proactive approach helps lower freight costs and prevent product loss.

Cape Pack Palletization Modeling – this software is used to determine the optimum case count, size, and arrangement for shipping as well as analyze compression strength of cases and pallets to improve material and cube utilization.

Transit Simulation Tests

Even well-designed packaging is subject to unpredictable conditions during shipping. This is why package testing services that include transit simulation test can be critical. Transit simulation tests replicate the conditions and environmental stress encountered in transit. These tests can assess whether changes, such as lightweighting, have compromised the box’s protective qualities.

Transportation Vibration Simulation – This test mimics the shaking and jolting a box and its contents experience during shipping by truck, rail, or conveyor systems. The box is placed on a vibration table that moves in controlled patterns and speeds for a set time, simulating real transit conditions.

ISTA Testing – For more complete transit testing, ISTA (International Safe Transit Association) testing is a standardized set of procedures that combine drop testing, vibration testing, compression testing, and environmental conditions to simulate actual shipping conditions. Packages are tested according to specific ISTA protocols based on their distribution method.

Amazon Program Certification Testing

For businesses selling through Amazon, compliance with APASS standards is essential. Certification testing ensures packaging meets Amazon’s requirements for damage-free delivery, easy opening, and sustainability. By completing these tests, companies can streamline product onboarding, reduce chargebacks, and maintain positive customer experiences in the e-commerce marketplace.

Discover the Benefits of Our Packaging Testing Services

Ready to protect your products and improve shipping efficiency? Partner with us for advanced packaging testing solutions that ensure your items arrive safely and cost-effectively. Contact us today to learn how our expertise can produce better results and greater customer satisfaction.