ISTA Standard: Complete Guide to Packaging Drop and Transit Tests

Packaging plays a critical role in protecting products during transportation, storage, and handling. The International Safe Transit Association (ISTA) has developed a comprehensive set of standards known as ISTA tests. 

These Procedures and Projects provide guidelines for designing and testing packaging solutions amidst the challenges of product protection during transportation.

This article will discover the ISTA standards and the key 7 series of ISTA packaging test for brands and manufactures to ensure product safety and customer satisfaction.

What is ISTA？

The International Safe Transit Association (ISTA) is a global organization that established and continues to develop the most frequently used packaging standards for manufacturers and retailers.

A product’s packaging needs to be robust enough to withstand the common knocks, bumps and shocks that can affect goods when in transit. ISTA provides the facilities and certification for suppliers to prove that the packaging being produced has been successfully tested by an accredited third-party lab.

Founded in 1948, ISTA is widely recognized by manufacturers, retailers, logistics companies, and e-commerce platforms worldwide. Many retailers and buyers require that their suppliers use a testing lab that is ISTA accredited and that the packaging being produced has been ISTA approved.

To reflect the complexity of modern shipping methods, ISTA has developed a series of seven different standards for specific types of transportation, products and requirements from various buyers.

The 7 Series of ISTA Testing Standards

1 Series: Non-Simulation Integrity Performance Tests

1 Series Non-Simulation Integrity Performance Tests challenge the strength and robustness of the product and package combination. Useful as screening tests, particularly when used as a consistent benchmark over time.

There are 7 testing procedures of 1 series which are 1A, 1B, 1C, 1D, 1E, 1G and 1H, they are all useful as a screening tool early in the design process:

• Procedure 1A: Integrity Testing for Packaged-Products weighing 68 kg (150 lbs) or Less
• Procedure 1B: Integrity Testing Packaged-Products weighing Over 68 kg (150 lbs)
• Procedure 1C: Extended Integrity Testing for Individual Packaged-Products weighing 68 kg (150 lbs) or Less
• Procedure 1D: Extended Integrity Testing for Individual Packaged-Products weighing Over 68 kg (150 lbs)
• Procedure 1E: Integrity Testing for Unitized Loads
• Procedure 1G: Packaged-Products weighing 68 kg (150 lbs) or Less utilizing Random Vibration
• Procedure 1H: Integrity Testing for Packaged-Products weighing Over 68 kg (150 lbs) utilizing Random Vibration

Note: ISTA 1A is commonly used worldwide in the third-party quality inspection. The carton drop test is typically performed during Pre-Shipment Inspection (PSI).

Read more: Carton Drop Test: ISTA Standards and Third-Party Quality Inspection

2 Series: Partial Simulation Performance Tests

ISTA 2-Series protocols are Partial Simulation Performance Tests that includes tests with at least one element of a 3-Series type General Simulation performance test, such as atmospheric conditioning or mode-shaped random vibration, in addition to basic elements of a 1-Series type Non-Simulation Integrity test.

The are 3 testing procedures of 2 series which are 2A, 2B and 2C:

Procedure 2A: Packaged-Products weighing 68 kg (150 lbs) or Less

Testing of individual packaged-products weighing 68 kg (150 lbs) or less when prepared for shipment.

Procedure 2B: Packaged-Products weighing over 68 kg (150 lbs)

A partial simulation test for individual packaged furniture products transported in a container (Case Goods).

Procedure 2C: Furniture Packages

A partial simulation test for individual packaged furniture products transported in a container (Case Goods).

3 Series: General Simulation Performance Tests

The 3 series is 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.

The are 5 testing procedures as procedures 3A, 3B, 3E, 3F and 3H and 2 testing project as Project 3K and 3L of 3 series:

Procedure 3A: Parcel Delivery System Shipments 70kg (150 lb) or Less

Test for individual packaged-products shipped through a parcel delivery system and is appropriate for standard, small, flat and elongated packages distributed as individual packages, either by air or ground.

Procedure 3B: Less-Than-Truckload (LTL) Shipment

Test for packaged-products commonly shipped through an LTL delivery system such as Standard, Cylindrical, and Palletized or Skidded, where different types of packaged-products, often from different shippers and intended for different ultimate destinations, are mixed in the same load.

Procedure 3E: Similar Packaged-Products in Unitized Loads for Truckload Shipment

Test for unitised loads of similar retail or institutional packaged-products shipped through a Full Truckload (FTL) delivery system where an entire trailer-load is filled with unitised packaged-products, often of similar retail packaged-products, intended for one destination such as from a manufacturing location to a distribution centre.

Procedure 3F: Distribution center to retail outlet shipment 45 kg (100 lbs)

Test for an individual packaged-product weighing 45 kg (100 lbs) or less shipped as part of a mixed pallet configuration for regional shipment; typically, from a distribution centre to a retail facility.

Procedure 3H: Mechanically Handled Bulk Transport Containers

Test for bulk loads made up of one transport container or system consisting of the same product that because of their size and/or weight must be handled by mechanical means such as automotive parts in a reusable rack.

Project 3K: Fast Moving Consumer Goods for the European Retail Supply Chain

Test for fast moving packaged consumer products shipped through the multiple-retail supply chain environment in Europe. This method applies equally to shelf ready and non-shelf ready packages where retailer operations include shipment of store-specific mixed loads in roll cages or as mixed pallets.

Project 3L: Generalized E-commerce Retailer Fulfillment

Test for individual packaged-products intended to ship into a retailer fulfilment location through the retailer and carrier distribution systems to the final customers’ destination.

4 Series: Enhanced Simulation Tests

4 series is 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 online 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.

4AB Project: Packaged-Products for Shipment in Known Distribution Channels

5 Series: Focused Simulation Guides **NOT AN ACTIVE SERIES**

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 the establishment of user-defined Focused Simulation tests.

6 Series: Member Performance Tests

The 6 series is test protocols created by ISTA members or by ISTA in cooperation with a member company, 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.

The ISTA Testing Council reviews and accepts these tests, but the primary responsibility rests with the originating members.

6-Amazon.com-SIOC Project:

Ships in Own Container (SIOC) for Amazon.com Distribution System Shipment

General simulation test for packaged-products shipped by Vendors to Amazon Fulfillment Centers (FC) and delivered to final customer destinations via Parcel or Less-Than-Truckload (LTL) outbound shipment methods without any additional packaging or preparation by Amazon. It challenges the capability of both package and product to withstand the hazards normally encountered from receipt at an FC through handling and transport by a carrier

6-Amazon.com-Over Boxing Project:

e-Commerce Fulfillment for Parcel Delivery Shipment

General simulation test for individual retail packaged-product weighing 70 pounds (32 kilograms) or less being placed into a master shipping container (Over Box), by Amazon, either by itself with the addition of dunnage (air pillows, etc.) or with multiple individual retail packaged-products with dunnage for shipment from Amazon.com to an end consumer through a parcel delivery system.

6-SAMSCLUB Project:

Packaged-Products for Sam’s Club Distribution System Shipment

General simulation test for packaged-products shipped through the Sam’s Club® distribution system to final destinations in the U.S. In this system, packaged-products are typically shipped from a domestic or international manufacturer through one or more Distribution Centers (DCs), and then to the clubs (stores). The original shipment configuration may be altered at a DC to fit the needs of the system but typically final shipment to the club is on a pallet.

6-FEDEX-A FedEx Procedures:

Testing Packaged Products Weighing Up to 150 lbs (domestic and international)

Pre-shipment tests to simulate FedEx air and ground shipping environments.

6-FEDEX-B FedEx Procedures:

Testing Packaged Products Weighing More Than 150 lbs (domestic and international)

Pre-shipment tests to simulate the FedEx Express Freight shipping environment.

7 Series: Development Tests

ISTA 7-Series protocols 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.

Procedure 7D: Temperature Test for Transport Packaging

Procedure 7D is a development test to evaluate the effects of external temperature exposures of individual package-products.

Standard 7E: Testing Standard for Thermal Transport Packaging Used in Parcel Delivery System Shipment

Standard 7E is designed to evaluate the effects of external temperature exposures of individual packaged-products shipped through a parcel delivery system. The profile set was developed by characterising the transport environment and is designed to represent annual heat and cold seasonal maxima and minima. It can be used as a “standalone” profile or in conjunction with a process standard such as ISTA Standard 20.

Resource: https://ista.org/test_procedures.php

Conclusion

The ISTA standard is the global benchmark for packaging durability and transit safety. Protecting your products with ISTA packaging standards will bring a range of business benefits to your organization, including increased profits through reduced damage and claims and product loss, improved customer satisfaction and an improved reputation for delivery of high-quality products.

Whether you are an importer, e-commerce seller, or manufacturer, adopting ISTA-compliant packaging and leveraging third-party quality inspection is not an expense—it is a long-term investment in reliability, customer loyalty, and brand success.