How are MIL-STD packaging materials certified and tested?

MIL-STD packaging is certified through a structured testing process in which the packaging is subjected to extreme conditions such as vibration, shock, moisture, and temperature fluctuations. Tests are conducted by accredited laboratories or defense agencies in accordance with specific military standards. This article answers the most frequently asked questions about MIL-STD certification, from applicable standards to supplier requirements.

Which MIL-STD standards apply to military packaging?

The two most widely used MIL-STD standards for military packaging are MIL-STD-810 and MIL-STD-2073. MIL-STD-810 focuses on environmental testing of equipment and packaging, while MIL-STD-2073 defines the standard procedures for military packaging and preservation. Together, they form the backbone of any certified packaging program for defense applications.

In addition to these two core standards, there are supplementary standards that may apply depending on the specific application:

• MIL-STD-648: Guidelines for packaging development and specifications
• MIL-STD-129: Marking and labeling of military packaging
• MIL-PRF-121: Requirements for barrier materials providing moisture protection
• ASTM D4169: Frequently used as a supplementary test standard alongside MIL-STD-810

Which standard applies depends on the nature of the equipment being packaged, the transport route, and the intended end use. Sensitive electronics or communications equipment are subject to different requirements than mechanical components or ammunition. It is therefore essential to determine which standards are relevant to your specific situation during the design phase.

How does the testing process for MIL-STD certified packaging work?

The testing process for MIL-STD packaging proceeds in phases: first, the packaging is designed and prototyped in accordance with the applicable standards; next, laboratory testing is conducted under simulated environmental conditions; and finally, evaluation and documentation are carried out by an accredited body. The entire process requires careful planning and thorough technical documentation.

In practice, the process unfolds as follows:

1. Specification phase: Requirements are established based on the equipment to be transported, the mission criteria, and the relevant MIL-STD standards.
2. Design and engineering: The packaging is developed in detail, including material selection, foam interiors, and closure mechanisms.
3. Prototyping: One or more prototypes are manufactured for testing purposes.
4. Laboratory testing: The prototype is subjected to the prescribed test conditions (see the following section).
5. Evaluation and reporting: Test results are documented and assessed against the applicable standards.
6. Certification: Upon approval, the packaging receives formal certification or a test report demonstrating conformity.

This process can take anywhere from a few weeks to several months, depending on the complexity of the packaging and the number of tests required. Thorough preparation and close collaboration with an experienced packaging supplier can significantly reduce this lead time.

What exactly is tested during a MIL-STD packaging inspection?

During a MIL-STD packaging inspection, the packaging is tested for resistance to mechanical stress, extreme temperatures, moisture, pressure changes, and electrostatic discharge. The exact test parameters are defined in the applicable MIL-STD standard and are tailored to the expected transport conditions and operational environment.

The most common test types include:

• Vibration and shock test: Simulates transport over rough terrain, in aircraft, or in military vehicles. The packaging must keep its contents intact under repeated mechanical stress.
• Drop test: The packaging is dropped from various heights and angles to assess its shock absorption performance.
• Temperature cycling test: Exposure to extreme heat and cold, including rapid temperature changes, to detect material failure.
• Humidity and water resistance test: Checks for condensation, water tightness, and corrosion resistance under high humidity conditions.
• Pressure test (altitude test): Simulates low air pressure, such as that experienced during air freight transport at high altitude.
• Electrostatic discharge test (ESD): Relevant for electronically sensitive equipment, requiring the packaging to provide protection against static electricity.

The intensity and duration of each test are determined by the specific MIL-STD method. For mission-critical equipment such as drones or communications systems, test requirements are generally more stringent than for standard logistics equipment.

Who is authorized to certify MIL-STD packaging?

MIL-STD packaging is certified by accredited test laboratories, defense agencies, or accredited third parties authorized to conduct and evaluate the prescribed tests. In practice, these are typically ISO 17025-accredited laboratories or defense-related inspection bodies.

In the Netherlands and across Europe, several parties are involved in this process:

• Accredited test laboratories: Laboratories holding ISO 17025 accreditation are authorized to issue official test reports that serve as proof of conformity.
• Defense agencies: National defense organizations, such as the Dutch Ministry of Defense, may conduct inspections themselves or require that testing be performed by parties they have approved.
• NATO-related bodies: For NATO contracts, additional requirements apply, and conformity with STANAG standards must be demonstrable.
• Suppliers with in-house test facilities: Some packaging suppliers have their own test equipment and can perform pre-compliance testing, but formal certification typically requires an independent party.

It is important to verify in advance which certifying body is accepted by the client or the relevant defense program. This prevents the need to repeat testing with a different party.

What is the difference between MIL-STD-810 and MIL-STD-2073?

MIL-STD-810 is an environmental test standard that describes how equipment and packaging must be tested for resistance to physical and climatic conditions. MIL-STD-2073 is a packaging standard that defines the procedures and material requirements for military packaging and preservation. The two standards complement each other and are often applied together.

MIL-STD-810: Environmental testing

MIL-STD-810 focuses on testing the performance of equipment and packaging under realistic operational conditions. The standard describes more than thirty test methods, including vibration, shock, extreme temperatures, moisture, and sandstorms. Its purpose is to demonstrate that the packaging protects its contents under the conditions in which the equipment is actually deployed or transported. MIL-STD-810 is technical in nature and strongly oriented toward test procedures and measurement methods.

MIL-STD-2073: Packaging procedures

MIL-STD-2073 defines the standard procedures for packaging, preserving, and labeling military equipment. The standard specifies which packaging materials, barrier layers, and preservation methods are permitted, and how the packaging must be assembled to ensure shelf life and transport durability. Where MIL-STD-810 is the test method, MIL-STD-2073 is the implementation standard for the packaging process itself.

In practice, when developing MIL-STD packaging, the design is first aligned with the requirements of MIL-STD-2073, after which the packaging is tested in accordance with the methods of MIL-STD-810. Both standards are therefore complementary and frequently reference each other.

How long is a MIL-STD certification valid?

A MIL-STD certification does not have a fixed universal validity period. Its validity depends on the specific standard, the contractual requirements of the client, and any changes to the design or production of the packaging. Once the design or materials used are modified, recertification is generally required.

In practice, the following guidelines apply:

• Contract-bound validity: Many defense contracts specify a validity period for inspection reports, typically between two and five years.
• Design changes: Any modification to the packaging design, materials, or production processes requires a renewed assessment and potentially retesting.
• Standard revisions: When a MIL-STD standard is revised, it may be necessary to have existing packaging reassessed against the updated requirements.
• Periodic audits: Some defense programs require periodic audits or requalifications to ensure ongoing conformity.

It is advisable to actively manage the validity period of a certification and to initiate the recertification process in a timely manner, so that no interruption occurs in the ability to fulfill defense contracts.

What must a packaging supplier meet to deliver MIL-STD packaging?

A packaging supplier seeking to deliver MIL-STD certified packaging must possess technical knowledge of the relevant standards, access to certified test facilities, a documented quality management system, and demonstrable experience with defense-related projects. Qualifications such as ISO 9001 and familiarity with AQAP standards are virtually indispensable in the defense sector.

In concrete terms, a qualified supplier must meet the following requirements:

• Knowledge of military standards: In-depth knowledge of MIL-STD-810, MIL-STD-2073, and related standards, including their correct interpretation and application in design.
• Quality management system: A certified quality system, preferably ISO 9001, that ensures traceability and documentation throughout the entire production process.
• Engineering capability: In-house engineers capable of designing and calculating packaging based on the specific requirements of the equipment to be protected.
• Access to test facilities: Direct collaboration with or access to accredited test laboratories for the required environmental tests.
• Defense sector experience: Demonstrable references in defense or security-related projects, including knowledge of the associated procurement processes and documentation requirements.
• Material management: Use of approved materials that comply with the requirements of MIL-STD-2073, including barrier materials and preservatives.

The more of these competencies a supplier has in-house, the more efficient and reliable the certification process will be. A supplier that integrates engineering, production, and test management significantly reduces the risk of delays and miscommunication.

How Faes supports MIL-STD packaging for defense

Faes.nl delivers complete end-to-end packaging solutions for defense clients that must comply with MIL-STD requirements. With more than 35 years of experience in custom industrial packaging and in-depth knowledge of military standards, Faes supports you from initial design through test management to final delivery.

What Faes offers for defense applications:

• In-house engineering: Technical specialists who design packaging in accordance with MIL-STD-810 and MIL-STD-2073, tailored to your specific equipment.
• Custom flight cases, transport crates, and foam interiors: Fully custom-made for sensitive equipment such as drones, communications systems, and military electronics.
• Test management: Faes guides the testing process and works with accredited laboratories to obtain the required certification.
• Knowledge of defense standards: Thorough expertise in MIL-STD, STANAG, and related standards, ensuring your packaging meets the requirements of national and international defense programs.
• Sustainable, reusable solutions: Circular packaging that is cost-efficient across the full lifecycle of the equipment.

Want to find out how Faes can support your defense project with certified MIL-STD packaging? Visit the Faes defense solutions page and get in touch for a no-obligation consultation with one of our packaging specialists.