Packaging testing is the cornerstone of product integrity and consumer safety in today’s global marketplace. As packaging engineering experts at Creopack, we understand that thorough testing is not just a regulatory requirement—it’s a critical investment in your brand’s reputation and customer trust.

In this complete guide, we’ll explore the diverse methods and technologies used in modern packaging testing. Whether you’re developing a new product line or optimizing existing packaging solutions, understanding these testing principles is essential for success in today’s competitive market.

What is Packaging Testing?

At its core, packaging testing is a systematic evaluation of packaging materials, designs, and performance under various conditions. This process ensures that your product reaches its destination in perfect condition, regardless of the challenges it may face during storage, transportation, or handling.

The goals of packaging testing extend far beyond mere product protection. While safeguarding items from physical damage is crucial, comprehensive testing addresses multiple objectives:

Safety is paramount, guaranteeing that packaging can securely contain and protect hazardous materials during transit.
Packaging quality assurance is essential to prevent product damage and minimize costly returns, ensuring that products arrive at their destination in pristine condition.
Compliance with international shipping regulations and industry standards is non-negotiable. Rigorous testing verifies that packaging meets or exceeds these requirements.
Ultimately, customer satisfaction hinges on receiving products in perfect condition. Packaging testing is a cornerstone of achieving this goal.

Types of Packaging Testing

In the demanding industrial landscape, the integrity of packaging is paramount. To ensure that shipping crates, boxes, and other containers can withstand the rigors of transportation and storage, manufacturers employ a suite of rigorous testing methods. These assessments evaluate durability, safety, and compliance with industry standards, ultimately safeguarding the precious products they enclose.

Physical Testing

Physical testing methods are employed to evaluate how different packaging solutions like crates and boxes withstand various stresses during handling, transportation, and storage. Here are the key physical testing methods used in the industry:

Compression testing assesses a package’s ability to withstand external pressures without deformation or damage. During this test, the packaging is gradually compressed between two parallel plates. This method is particularly useful for evaluating packaging intended to be stacked or stored in tight spaces, ensuring that the structural integrity is maintained under load.
Drop and impact testing simulate the effects of mishandling during transportation. Packages are subjected to controlled drops from specified heights to evaluate their ability to protect contents from damage. This test helps manufacturers refine packaging designs to minimize product loss and ensure compliance with industry standards.
Vibration testing evaluates a package’s resistance to vibrational stresses encountered during transportation. This test involves placing a package on a vibrating table that simulates the vibrations experienced during transit. It helps assess the effectiveness of cushioning materials and the sturdiness of the packaging design.
Shock testing simulates sudden impacts or shocks that a package might experience during handling or transport. This can include free-fall drops or other impact scenarios. Shock tests help determine the packaging’s ability to absorb energy and protect its contents from sudden jolts.
Puncture resistance testing measures the energy required to create a hole in the packaging material. This test is essential for assessing how well a package can withstand sharp objects or edges that might be encountered during handling or shipping.
Tensile strength testing evaluates the strength of packaging materials by measuring their resistance to being pulled apart. This test provides data on elongation, yield point, and tensile strength, which are critical for understanding how materials will behave under stress.

Environmental Testing

Environmental testing evaluates how packaging materials perform under various environmental conditions, ensuring they can withstand the stresses of transit and storage.

Temperature testing assesses how packaging materials react to extreme temperatures. This is crucial for packages that may be exposed to both hot and cold environments during transportation. The test involves subjecting the packaging to a range of temperatures, from extreme cold to high heat, to determine its durability and performance under such conditions.
Humidity testing evaluates the effects of moisture on packaging materials. High humidity can lead to material degradation, mold growth, and compromised structural integrity. This test simulates high moisture environments to ensure that the packaging can protect its contents effectively in humid conditions
Altitude testing examines how changes in atmospheric pressure affect packaging. This is particularly important for air transport, where packages are exposed to lower pressures at high altitudes. The test ensures that the packaging remains intact and functional despite these pressure changes.
Light exposure testing, or photostability testing, assesses the impact of light on packaging materials. This includes exposure to UV, visible, and infrared light, which can cause fading, brittleness, or other forms of degradation. The test helps ensure that the packaging maintains its integrity and appearance when subjected to sunlight or artificial lighting.
Weathering testing simulates long-term exposure to environmental elements like sunlight, rain, and temperature fluctuations. This accelerated testing method predicts how well the packaging will endure outdoor conditions over time. It is essential for packages that might be stored or used outdoors.
Corrosion testing evaluates how well packaging materials resist corrosive environments. This is especially relevant for metal components or coatings exposed to salt spray or industrial pollutants. The test helps ensure that the packaging can withstand corrosive conditions without degrading.

Chemical Testing

Chemical testing focuses on assessing how packaging materials interact chemically with the products they contain, as well as their compliance with safety regulations.

Migration testing evaluates the transfer of chemicals from packaging materials into the products they encase. This is particularly important for materials that may come into contact with sensitive goods, such as food or pharmaceuticals.
Compatibility testing ensures that packaging materials do not adversely react with the contents they hold. This involves analyzing both the packaging and the product to prevent any chemical interactions that could compromise safety or quality. For example, certain foods might react with metal containers, leading to corrosion and contamination
Restricted substance testing identifies and quantifies substances within packaging materials that are restricted by international regulations. It focuses on ensuring that harmful chemicals like BPA, lead, and other heavy metals are not present above permissible levels.
Permeability testing measures how gases pass through packaging materials, which can be required to maintain product integrity. This includes assessing the material’s ability to act as a barrier against oxygen, carbon dioxide, and moisture.

Functional Testing

Functional testing is a cornerstone of industrial packaging, ensuring that crates, boxes, and other large-scale containers meet the demands of diverse environments.

Seal integrity testing evaluates whether a package remains intact when exposed to external forces. This test is essential for maintaining the sterility and shelf life of products, particularly in industries like pharmaceuticals and food manufacturing. It ensures that the entire package can withstand environmental stresses such as distribution, storage, and handling without compromising its contents.
Closure testing focuses on the effectiveness of caps, lids, and other sealing mechanisms. This type of testing ensures that closures maintain their integrity during transportation and storage, preventing contamination or spoilage. Closure testing often involves assessing the mechanical strength required to open or close a package, ensuring that it is both secure and user-friendly.
Barrier property testing measures a package’s ability to protect its contents from external elements such as moisture, gases, and light. This can be critical for preserving product quality and extending shelf life. Tests like the Moisture Vapor Transmission Rate (MVTR) and Oxygen Transmission Rate (OTR) are used to quantify how well packaging materials prevent the ingress of these elements.
Tamper-evident feature testing assesses whether packaging includes indicators that alert users to potential tampering. This is particularly important for safety-sensitive products like pharmaceuticals. Acceptable tamper-evident features include film wrappers, blister packs, and heat shrink bands, which provide visible evidence if breached.

User Experience Testing

User experience testing ensures that packaging not only meets the functional and protective needs of industrial goods but also aligns with user expectations and preferences.

Sensory testing evaluates packaging based on human senses, providing insights into how users perceive the packaging from the moment they encounter it. This approach goes beyond visual appeal to include tactile, auditory, and sometimes even olfactory elements. Sensory testing helps ensure that the packaging communicates the intended message and meets user expectations in terms of quality and functionality.
A/B testing is a method where two versions of a packaging design are compared to determine which one performs better in terms of user preference and market response. In industrial settings, A/B testing can help identify which design elements resonate more with users, such as ease of handling or clarity of information.
Ergonomic testing focuses on how comfortable and efficient it is for users to interact with the packaging. It considers factors such as the ease of lifting, holding, and opening the package, as well as its suitability for various handling conditions. Ergonomic design aims to minimize strain and maximize comfort, which is especially important in industrial settings where workers may handle packaging frequently and in large quantities.
Accessibility testing ensures that packaging can be easily used by all individuals, regardless of their physical or cognitive abilities. This involves designing packaging that is simple to open, handle, and understand, which can include features like clear labeling, intuitive opening mechanisms, and minimal force requirements.

Industry-Specific Packaging Tests

In addition to the most common testing methods, there are specialized testing approaches for different industry sectors.

Testing methods for food packaging include both chemical and physical assessments. Chemical testing focuses on ensuring that materials do not react adversely with the food, potentially leading to contamination. This includes migration tests to measure the transfer of substances from packaging into food.
Medical and pharmaceutical packaging must adhere to stringent regulatory standards to ensure drug safety and efficacy. Testing involves verifying that packaging materials do not interact with the drug in a way that could alter its properties or effectiveness. Key tests include seal integrity to prevent contamination and barrier property assessments to protect against external factors like moisture or light.
Packaging for hazardous materials is governed by strict regulations to ensure safe transportation. In Canada, this is regulated under TP14850, while in the United States, it falls under 49 CFR Parts 171-180.
E-commerce has unique packaging requirements due to the diverse range of products shipped directly to consumers. The International Safe Transit Association (ISTA) provides standardized test procedures to evaluate how well e-commerce packages protect their contents during distribution.

Packaging Testing Standards and Regulations

Package testing involves adhering to various standards and regulations that guide the testing processes. Below are the key standards and regulations in the packaging industry.

ASTM International, formerly known as the American Society for Testing and Materials, is a globally recognized leader in developing standards for materials, products, systems, and services. In the context of packaging, ASTM provides a comprehensive set of standards that cover various aspects of packaging testing. These include:

Compression Testing (ASTM D642): Evaluates the compressive resistance of shipping containers.
Impact Testing (ASTM D880): Assesses the impact resistance of shipping containers.
Vibration Testing (ASTM D999): Tests the ability of packaging to withstand vibration during transit.
Drop Testing (ASTM D5276): Determines the ability of packaging to protect its contents from damage when dropped.

The International Organization for Standardization (ISO) develops worldwide proprietary, industrial, and commercial standards. ISO standards relevant to packaging include:

ISO 11607: Specifies requirements for packaging systems used for terminally sterilized medical devices, ensuring they remain sterile until use.
ISO 8317: Focuses on child-resistant packaging requirements to prevent children from accessing harmful substances.

The International Safe Transit Association (ISTA) provides test protocols that simulate real-world conditions during transportation. These protocols help in assessing whether a package can endure the rigors of shipping. ISTA tests cover factors such as vibration, shock, temperature, and humidity.

Different regions also have specific regulations governing packaging:

European Union (EU): The EU has stringent regulations like the Medical Device Regulation (MDR) which requires compliance with safety standards before products can be marketed.
United States (FDA): The Food and Drug Administration regulates packaging for medical devices to ensure they meet safety and effectiveness criteria.

Advanced Packaging Testing Techniques

Modern packaging engineering has embraced sophisticated testing methods that go beyond traditional approaches. Non-destructive testing (NDT) techniques like computed tomography and digital radiography allow for thorough inspection without damaging the package, providing detailed insights into structural integrity and potential flaws.

Accelerated aging tests simulate the effects of time on packaging materials, allowing companies to assess long-term performance in a fraction of the time. Virtual and simulation-based testing has revolutionized the packaging development process. Using advanced software, engineers can create digital models of packaging designs and subject them to various stresses and environmental conditions.

Artificial intelligence (AI) is making significant inroads in packaging testing. AI-powered systems can analyze vast amounts of data from various sensors and testing equipment, identifying patterns and potential issues that might escape human observers.

Sustainability in Packaging Testing

As businesses seek to minimize their environmental footprint, sustainability has become a paramount concern in packaging testing.

Recyclability testing assesses how easily packaging materials can be processed and reused, fostering a circular economy.
Biodegradability testing measures the rate at which packaging decomposes in various environments, ensuring minimal landfill impact.
Life cycle assessment offers a holistic view of a package’s environmental impact, from production to disposal, enabling companies to identify areas for improvement across the supply chain.
Sustainable materials testing explores innovative eco-friendly alternatives, from eco-friendly crates to bioplastics or recycled content, to meet performance standards while reducing reliance on virgin resources.

These testing methods not only help companies comply with environmental regulations but also meet the increasing consumer demand for sustainable packaging solutions.

Interpreting and Applying Test Results

When analyzing test results, it’s essential to consider both quantitative and qualitative data. Numerical values from strength tests, barrier property measurements, and durability assessments offer concrete metrics for comparison against industry standards and internal benchmarks. Meanwhile, qualitative observations from visual inspections and user experience tests provide context and nuance that numbers alone cannot capture.

To effectively apply test results to improve packaging design, package testing companies like Creopack will:

Identify patterns and trends across multiple tests to gain a comprehensive understanding of the packaging’s performance
Compare results against predetermined acceptance criteria to determine if the packaging meets required standards
Prioritize addressing any critical failures or significant deviations from expected performance
Consider the interplay between different packaging components and how improvements in one area might affect others

Cost Considerations in Packaging Testing

One of the primary decisions to make is whether to conduct testing in-house or outsource it to specialized laboratories. In-house testing can offer more control and potentially lower costs over time, especially for companies with high testing volumes. However, it requires significant upfront investment in equipment and trained personnel. Outsourcing, on the other hand, provides access to expert knowledge and state-of-the-art facilities without the need for capital expenditure, but may be more expensive per test.

The return on investment of packaging testing is often substantial, though not always immediately apparent. Effective testing can prevent costly product damage, recalls, and reputation damage. It can also lead to optimized packaging designs that reduce material costs and improve sustainability. To maximize ROI, companies should:

Focus on critical tests that address the most significant risks
Use data from testing to continuously improve packaging designs
Leverage testing results to negotiate better shipping rates and insurance premiums

Test and Optimize Your Packaging with Creopack

Creopack’s packaging evaluation process offers a robust solution for companies seeking to validate the resilience and performance of their packaging solutions. Our advanced testing facilities recreate accelerated transport conditions, providing an authentic replication of actual shipping and handling scenarios.

Don’t leave your packaging performance to chance. Contact Creopack today to experience our cutting-edge evaluation process and ensure your products arrive at their destination intact and undamaged.

The Complete Guide to Packaging Testing Methods