Step
1 - Applying to a Third Party Agent for Certification
The
process begins by submitting a package to an authorized
TPA, along with a description of the packaging, drawings
and material specifications. This information is required
before testing can begin and is available from the manufacturers
of the packaging materials. The specifications are used
to prepare a detailed inventory of the package. A copy
of the Material Safety Data Sheet (MSDS) must be provided.
The Applicant is required to submit the total number of
complete package assemblies needed for performance testing.
The number depends on the type of package and certification
requirements and will be discussed during the initial
contact.
For
example, a 4G-combination package requires eleven complete
packages for testing. The packages are prepared as they
would be for normal shipment. Primary inners containing
liquid are typically filled with water. The 4G example
is used throughout this presentation because it is the
most common package-type certified.
Step
2 - Audit Process & Package Preparation
The
TPA prepares a test report for each certification. This
report must contain a description of all packaging with
applicable measurements and characteristics. This data
determines the type of conditioning and the severity level
requirements for testing. During the audit process the
TPA validates all packaging specifications and takes actual
measurements. This data is compiled into an Audit Summary
for the test report.
Combination
packages are acclimated to ambient conditions, 73ºF
(23ºC) & 50% R.H. for 24 hours prior to testing.
Primary inner packages (i.e. bottles) made of plastic
are conditioned to 0ºF (-18ºC) for 24 hours
prior to testing.
Step
3 - Testing Process
The
following tests are performed on a 4G-combination package.
The Packing Group and relative density of the actual filler
determines performance levels.
Cobb
Water Absorption Test - This test is performed on 5-inch
square corrugated samples taken from five of the test
packages. These are soaked in water for 30-minutes. The
five samples are weighed before and after soaking. The
delta weight cannot exceed 1.55 grams for each sample.
Drop
Test - Five complete packages are dropped from the required
drop height; each sample is dropped once, in one of five
different orientations. Drop height is determined by the
assigned Packing Group and the relative density of the
filler used.
Stacking
Test - This test is performed on three complete packages
by loading each box with a weight equivalent to a 3-meter
stack of identically filled packages. This load is determined
from a formula specified in the regulations.
The
test can be performed with or without the primary inner
packaging, but the selected condition must be clearly
stated in the test report. The test duration is 24 hours
per sample. It is important to emphasize that the load
is to be applied to individual packages and not simultaneously
to all three.
After
the stacking test a stackability test is performed on
the same three packages. In this test, two fully packed
containers are placed on top of each package used in the
stacking test. Test duration is one hour.
Vibration
Test - This test is performed on three complete packages
and requires the operator to determine the acceleration
needed to cause the package to leave the surface of the
shaker table. This is accomplished by increasing frequency
of the shaker table until the package separates enough
to allow a 1/16-inch shim to slide between the package
and the table surface. Once the test frequency is determined,
the test continues for one hour. Reference: 49 CFR §178.608.
UN Regulations do not require vibration testing at this
time.
Step
4 - Further Testing
Depending
on the transportation mode, further tests may be required.
This can include;
Hydrostatic
Pressure/Vacuum Test - This test is only required for
inner packages that contain liquid and will be shipped
by air. The test is performed on three primary inner packages
by subjecting the containers to the required pressure
for a specified time period.
ISTA
Test - Procedure 1A of this regulation specifies drop
and vibration tests to be performed on three complete
package designs. A ten-drop sequence is performed on each
package followed by a loose load vibration test. This
test is only required if the Applicant intends to ship
via United Parcel Service (UPS).
Step
5 - Certification & Test Report
Upon successful completion of all required tests the
TPA will issue a certificate of compliance, which allows
the Applicant to apply the appropriate UN markings to
the tested package design. The marking may look like this;
This
certifies a 4G-type package for Packing Group II products,
having a gross mass not exceeding 9.1 kg. The "S"
denotes it is either a solid or a combination package
and 04 is the date of manufacture (2004) of the outer
package. The +AJ is the TPA's identification symbol (+AJ
is specific to DDL). Additional markings may be required
such as placards, UN identification numbers, and labels.
The
test report is prepared after testing and must include
specific elements such as the name and address of the
TPA and the Applicant, a unique ID, date, manufacturer
of the package, audit information, maximum capacity, sample
characteristics, test description and results and it must
be signed with the name and title of the signatory. Reports
are enhanced by the use of color photos and drawings.
Typically only an electronic copy of the final test report
is provided, while the original remains on file.
