ISTA 1E_2005

ISTA 1E 2005 - Page 1 of 10 ISTA, Your Alliance in Transport Packaging, is the world leader in Performance Tests for Packaged-Products. ISTA 1 Series are the most basic category of performance tests. • They challenge the capability of the package and product to withstand transport hazards, but • They are not simulations of actual transport hazards, and • Do not necessarily comply with carrier packaging regulations. When properly applied, ISTA procedures will provide tangible benefits of: • Shortened packaged development time and confidence in product launch • Protection of products and profits with reduced damage and product loss • Economically balanced distribution costs • Customer satisfaction and continued business. There are three sections: Overview, Testing and Report • Overview provides the general knowledge required before going into the testing laboratory and • Testing presents the specific instructions to do the testing in the laboratory and • Report indicates what data shall be recorded to submit a test report to ISTA. Two systems of weights and measures are presented in ISTA test procedures. They are the English system (Inch-Pound) and the international system SI (Metric). Inch-Pound units are shown first with Metric units in brackets, except in some tables where they are shown separately. • Either system may be used as the unit of measure (standard units), but • The standard units chosen shall be used consistently throughout the procedure. • Units are converted to two significant figures and • Not exact equivalents. VERY IMPORTANT: The entire document shall be read and understood before proceeding with a test. OVERVIEW OF PROCEDURE 1E Test Procedure 1E is an integrity test for unitized loads of the same retail or institutional packaged-products. A unitized load is defined as one or more products or packaged-products usually on a skid or pallet, but always secured together or restrained for distribution as a single load. Examples would be a stretch wrapped pallet load of individual containers, a single non-packaged machine banded to a pallet and a pallet with a corrugated tray, tube and a cap. • It can be used to evaluate the performance of a packaged-product. • It can be used to compare relative performance of package and product design alternatives. • The package and product are considered together and not separately. • Some conditions of transit, such as moisture, pressure or unusual handling, may not be covered. Other ISTA Procedures may be appropriate for different conditions or to meet different objectives. Specific suggestions: • Consider ISTA General Simulation Performance Test Procedure 3E. • Refer to Guidelines for Selecting and Using ISTA Procedures and Projects for additional information. Copyright ©2005 by International Safe Transit Association. All rights Reserved. 1E 2 0 0 5 Unitized Loads of Same Product ISTA 1 Series Non-Simulation Integrity Performance Test Procedure Preface OVERVIEW FOR PROCEDURE 1E ISTA 1E 2005 - Page 2 of 10 Test Procedure 1E covers testing of unitized loads, made up of either single or multiple products or packages of the same products. The shipper shall determine the following prior to testing: • what constitutes damage to the product and • what damage tolerance level is allowable, if any, and • the correct methodology to determine product condition at the conclusion of the test and • the acceptable package condition at the conclusion of the test. For additional information on this determination process refer to Guidelines for Selecting and Using ISTA Procedures and Projects. Samples should be the untested actual package and product, but if one or both are not available, the substitutes shall be as identical as possible to actual items. Number of samples required: One sample (unitized load) is required for the tests in this procedure. Replicate Testing Recommended: To permit an adequate determination of representative performance of the packaged-product, ISTA: • Requires the procedure to be performed one time, but • Recommends performing the procedure five or more times using new samples with each test. NOTE: Packages that have already been subjected to the rigors of transportation cannot be assumed to represent standard conditions. In order to insure testing in perfect condition, products and packages shipped to certified laboratories for testing must be: • over-packaged for shipment to the laboratory or • repackaged in new packaging at the laboratory. The tests shall be performed on each test sample in the sequence indicated in the following table: Sequence # Test Category Test Type Test Level For ISTA Certification Vertical Linear Fixed Displacement 1 in. (25mm) peak to peak at a freq. to be determined 1 Vibration Alternative Random Overall Gr m s level of 1.15 Required Incline (Conbur) 69 inches (1.7 m) per second impact velocity 2 Shock Alternative Horizontal Impact 69 inches (1.7 m) per second velocity change Required 3 Shock Rotational Edge Drop 8 inches (200 mm) Required Scope Product Damage Tolerance and Degradation Allowance Test Sequence 1E EQUIPMENT REQUIRED FOR PROCEDURE 1E ISTA 1E 2005 - Page 3 of 10 The following alternatives are acceptable for the equipment required for the Vibration Test: Fixed Displacement Vibration Test: • Vibration Test System with a 1 inch (25 mm) fixed or controlled displacement complying with Method A1 or A2 of the apparatus section of ASTM D 999-01. Only vertical linear motion of the platform is acceptable, rotary motion is not acceptable. • Metal shim 0.06 inch (1.5 mm), thick approximately 2.0 inches (50 mm) wide and at a convenient length. • Tachometer or suitable indicator for determining vibration frequency in cycles per second (Hz) or cycles per minute (CPM). • Automatic timer or stopwatch. Random Vibration Test: • Random Vibration Test System complying with the apparatus section of ASTM D 4728-01. Rotational Edge Drop Test: • Rotational Edge Drop Test System complying with the apparatus section of ASTM D 6179-97. The following alternatives are acceptable for the equipment required for the Impact Test: Type of Shock Test Equipment In compliance with the apparatus section of: Incline Test Incline impact tester (conbur) ASTM D 880-92(02) Horizontal Test Horizontal impact test system ASTM D 4003-98 Equipment Required Vibration Equipment Required Shock 1E BEFORE YOU BEGIN PROCEDURE 1E ISTA 1E 2005 - Page 4 of 10 Prior to beginning the tests identify the faces and edges according to the procedure below. Step Action 1 Place the unit load in its designed transport orientation. 2 Position one of the smallest width faces of the unit load directly in front of you. 3 Identify faces according to the diagram below. 4 Identify edges using the numbers of the two faces forming that edge. Example: Edge 3-4 is the edge formed by face 3 and face 4 of the unit load. Identification of Faces and Edges 1E BEFORE YOU BEGIN PROCEDURE 1E ISTA 1E 2005 - Page 5 of 10 You shall know the unit loads: • gross weight in pounds (kg), and • outside dimensions of Length, Width and Height (L x W x H) in inches (mm or m) CAUTION: A restraining device or devices shall be used with the vibration test system to: • Prevent the test specimen from moving off the platform and • Maintain test orientation of the packaged-product, but • The device or devices shall not restrict the vertical motion of the test specimen during the test. Select Fixed Displacement Vibration or Random Vibration as a test method. For Fixed Displacement Vibration: Familiarity with the following formula is required to calculate the test duration after the frequency required to bounce the packaged-product is determined in the Vibration Test Block: 11,800 Vibratory Impacts Test Duration in Minutes = Cycles Per Minute (CPM) or [Cycles Per Second (Hz) x 60] The chart below shows example Test Duration’s calculated for several frequencies: CPM Hz Test Duration in Minutes 150 2.5 79 180 3.0 66 210 3.5 57 240 4.0 50 270 4.5 44 300 5.0 40 For Random Vibration: The following breakpoints shall be programmed into the vibration controller to produce the acceleration versus frequency profile (spectrum) below with an overall Gr m s level of 1.15: Frequency (Hz) PSD Level, g2/Hz 1.0 0.0001 4.0 0.01 100.0 0.01 200.0 0.001 Before You Begin Vibration Testing Unit Load Weight and Size Measurement Random Vibration Spectrum 0.0001 0.001 0.01 0.1 1 10 100 1000 Frequency, Hz PS D , g 2 /H z 1E BEFORE YOU BEGIN PROCEDURE 1E ISTA 1E 2005 - Page 6 of 10 CAUTION: If the Unit Load: • has a length equal to or greater than twice the width and • a center of gravity above the midpoint of the height. • There is the possibility that Unit Load could tip over when testing one of the longest edges, therefore • You may conduct the Rotational Edge Drop test on one of the longest edges. Test the unitized load at a minimum of 69 inches per second (1.7 meters per second). NOTE: 69 inches per second is equal to 5.75 feet per second. If any Test in the sequence is below the required 69 inches per second (1.7 meters per second) minimum, that sequence event must be repeated until it meets the minimum. Before You Begin Shock Testing 1E TEST SEQUENCE FOR PROCEDURE 1E ISTA 1E 2005 - Page 7 of 10 The test blocks that follow contain tables that indicate the required steps for each test in the procedure. FIXED DISPLACEMENT Step Action Determine if testing is going to be Fixed Displacement or Random Vibration. IF Vibration testing is going to be … THEN go to … Fixed Displacement Step 2. 1 Random the Random Vibration Test Block. 2 Put the unitized load on the vibration table so that face 3 rests on the platform. 3 Start the test machine to vibrate at 1 inch (25 mm) total displacement at the machine’s lowest frequency using vertical linear motion only. 4 Maintain a fixed displacement at 1 inch (25 mm) and slowly increase the frequency (speed) of the vibration table until the packaged-product begins to momentarily leave the surface of the platform. 5 Hold the vibration frequency to that determined in Step 4. 6 Can a metal shim be intermittently moved between the bottom of the longest dimension of the packaged- product and the surface of the platform? • If Yes, hold that frequency and then continue to next Step. • If No, then increase the frequency until the requirement of Step 6 is met and hold that vibration frequency. 7 Determine test duration in minutes using the formula indicated in the Before You Begin block and the CPM or Hz frequency identified in Step 6. 8 Begin vibration duration. 9 Complete vibration duration. 10 Inspection of the packaged-product for visible damage is allowed, provided inspection does not alter, in any way, the current condition of the package or the condition or position of the product(s). 11 Vibration testing is now complete. Go to the Shock Test Block. RANDOM Step Action 1 Put the packaged-product on the vibration table so that face 3 rests on the platform. 2 Start the vibration system to produce the random vibration spectrum indicated in the Before You Begin Block. 3 Stop the vibration testing at the end of 60 minutes. 4 Inspection of the packaged-product for visible damage is allowed, provided inspection does not alter, in any way, the current condition of the package or the condition or position of the product(s). 5 Vibration testing is now complete. Go to the Shock Test Block. Vibration Test Block 1E TEST SEQUENCE FOR PROCEDURE 1E ISTA 1E 2005 - Page 8 of 10 IMPACT Step Action 1 Do the packaged-products overhang the edge of the pallet? • If Yes, then go to Step 3. • If No, then continue with the next Step. 2 Center the unitized load on the carriage with the pallet edge flat against the backstop or sail and parallel to the leading edge of the carriage and go to Step 4. 3 Center the unitized load on the carriage with the vertical face of the unitized load flat against the backstop or sail and parallel to the leading edge of the carriage. Test the unitized load at a minimum of 69 inches per second (1.7 meters per second). If any Test in the sequence is below the required 69 inches per second (1.7 meters per second) minimum, that sequence event must be repeated until it meets the minimum. Follow the sequence in the table below. Sequence # Orientation Specific face 1 Face one of the smallest vertical faces 2 Face opposite small vertical face 3 Face one of the largest vertical faces 4 4 Face opposite large vertical face 5 Impact testing is now complete. Go to the Rotational Edge Drop Block. Shock Test Block 1E TEST SEQUENCE FOR PROCEDURE 1E ISTA 1E 2005 - Page 9 of 10 ROTATIONAL EDGE DROP Step Action Perform a rotational edge drop. Follow the sequence in the table below. Sequence # Action 1 Place the unitized load onto a flat, rigid surface such as steel or concrete. 2 Support any face 3 edge with a timber or support 3.5 to 4.0 inches (90 to 100 mm) in height and width. See CAUTION Statement on Page 6. 3 Support one of the shortest face 3 edges with a timber or support 3.5 to 4.0 inches (90 to 100 mm) in height and width. Then go to Step 5. 4 Support any face 3 edge with a timber or support 3.5 to 4.0 inches (90 to 100 mm) in height and width. 5 Lift the opposite face 3 edge to 8 inches (200 mm) off the surface. 1 6 Release the edge so that it falls freely onto a flat, rigid surface. 2 Does the Unit Load have a length equal to or greater than twice the width and a center of gravity above the midpoint of the height? • If Yes, then go to Step 4. • If No, then continue with the next step. 3 Repeat Step 1 on one of the face 3 edges radiating 90° from the edge just tested in Step 1 Sequence 4. Then go to Step 5. 4 Repeat Step 1 on the face 3 edge opposite the edge just tested in Step 1 Sequence 3. Then go to the next Step. 5 All testing is now complete. Go to the Test Report Block. Shock Test Block 1E TEST REPORT FOR PROCEDURE 1E ISTA 1E 2005 - Page 10 of 10 The packaged-product has satisfactorily passed the test if, upon examination, it meets the Product Damage Tolerance and Package Degradation. ISTA Certified Testing Laboratories: • Should file a test report on all ISTA Test Procedures or Projects conducted. • Shall file a test report on all ISTA Test Procedures or Projects conducted to obtain Transit Tested Package Certification or Acknowledgement. For additional information, refer to Guidelines for Selecting and Using ISTA Procedures and Projects. ISTA Transit Tested Program The ISTA Transit Tested Certification Mark as shown is a: • registered certification mark and • can only be used by license agreement and • by a member of the International Safe Transit Association. When a member prints this certification mark on a packaged-product with their license number they are showing their customer and the carrier that it has passed the requirements of ISTA preshipment testing. In order to maintain its certified status and eligibility for identification with the TRANSIT TESTED Certification Mark, each packaged-product must be re-tested whenever a change is made in the: • Product or • Process or • Package. Changes in the product include changes in: • Design or • Size or • Materials. Changes in the process include changes in: • Manufacturing or • Assembly or • Filling. Changes in the package include changes in: • Configuration or • Dimensions or • Weight or • Materials or • Components. As a quality control procedure, packaged-products should be re-tested frequently, for example, yearly. This Test Procedure is published by: International Safe Transit Association 1400 Abbott Road, Suite 160, East Lansing, Mi 48823-1900 USA Copyright © 2005 by International Safe Transit Association. All rights Reserved No part of the contents of this Test Procedure may be reproduced or transmitted in any form or by any means without the written permission of the publisher. Order Information: Additional copies of this Test Procedure, the ISTA RESOURCE BOOK (in print or on CD ROM) may be ordered online at www.ista.org or by contacting ISTA at (+1) 517.333.3437. TRANSIT TESTED The manufacturer cert ifies that this PACK AGED-PRODUCT has passed preshipment test ing requirements established by ISTA. MANUFACTURER’S LICENSE NUMBER: ® INTERNATIONAL SAFE TRANSIT ASSOCIATION Before You Begin Report 1E