A drop test simulates realistic transport shocks to test whether industrial cases and crates protect their contents from impact. By dropping cases from various angles and heights in accordance with standards such as ISTA and MIL-STD-810, the reliability of the packaging is validated.
Summary of this article
Many things can happen to cases and crates during transportation. An unexpected bump, a hard landing or a fall from a pallet can be enough to damage valuable or sensitive products. Especially in industrial applications, where contents are often complex, fragile or high value, damage can lead to delays, extra costs and dissatisfied customers. To mitigate these risks, it is important to know in advance how well a package can withstand drops and bumps. That is exactly what a drop test is for: the controlled simulation of realistic transportation situations to test the protective performance of a case or crate.
At Faes, we cooperate with renowned partners for this purpose. Thus, we combine our knowledge of packaging requirements and design optimization with the objective test results of experienced testing bodies. The result: a packaging solution that protects not only in theory, but also in practice.
A drop test is a standardized method of verifying that a package including its contents can withstand the shocks and forces that occur during a fall. In a test rig, the crate is lowered onto sides, edges and corners from a predetermined height, with the standard prescribing how often and on which parts the drop test should be performed. In this way, it simulates what can happen during loading and unloading, in a distribution center or during transport by road, sea or air.
The purpose of a drop test goes beyond detecting weaknesses. It is an important step in meeting international standards and regulations, such as ASTM D4169 or ISTA protocols, and is often part of certification processes, for example, for UN-approved packaging. A successful drop test proves that the packaging effectively protects the contents, that the closures and seals remain sufficiently intact to protect the contents, and that no hazardous situations arise. The requirement in a drop test is that the contents of the package do not come out and/or are not damaged. In the event of a fall on a closure, the closure may be damaged, as long as it does not affect the protection and integrity of the contents.
For companies, this means that the packaging protects the product when used up to a certain weight and under specific conditions. This reduces the risk of “dead on arrival” cases while contributing to higher customer satisfaction. It also provides insight to improve packaging in a targeted way, often without adding additional material or weight.
In a drop test, the standard is always central: it determines how the test should be performed and what conditions apply. For example, the standard prescribes how the correct drop height is calculated based on weight and dimensions and which positions should be tested. Once the test protocol is defined, the test takes place in a controlled environment with specialized equipment, such as a precision drop tester or a high-speed drop rig. This involves first weighing and measuring the test object, then setting the appropriate drop height according to the standard. Then the test is performed by dropping the case or crate into the prescribed positions. Each position simulates a realistic scenario that may occur during transport. In order to mimic real-world situations as closely as possible, we often perform these tests with a dummy. A dummy is an object that is similar in shape and especially weight to the product the customer ultimately wants to transport.
Our reputable partners carry out these tests according to international standards and guidelines, also paying attention to the condition of the interior, the functionality of closures and the protection of the contents. Afterwards, all findings are recorded in a test report with photos, measured values and a conclusion as to whether or not they meet the requirements set by the standards and guidelines.
Based on the test report, we determine whether a package is suitable for its intended application. Because standards do not always give an unequivocal go/no-go, we translate the test results into a practical judgment. In doing so, we decide whether the packaging is adequate, or whether further modifications are needed in construction, choice of materials or interior design. This provides a reliable picture of the performance in practice, even before the packaging is actually put into use.
A drop test never stands alone, but is part of a carefully prepared test plan. In this, the circumstances, the test set-up, the results and the composition of the packaging are accurately recorded. This creates a structured process in which Faes guides customers from the initial specification to the optimal design of a packaging solution.
Requirements determine
Together with the customer, we identify all relevant product and transport characteristics, as well as applicable standards. Consider dimensions, weight, fragility, transport modalities and any sector- or customer-specific guidelines. This analysis forms the basis for the packaging design and testing requirements.
Design and optimization
Our engineers translate the specifications into packaging that meets all requirements. This includes the choice of materials, the construction of the case or crate, and the interior design that protects the contents. Any improvements from previous test results are incorporated immediately.
Coordinate the test
Faes works with reputable partners to carry out the test professionally and according to proper standards. We take care of the logistical coordination, deliver the packaging to the testing authority and ensure that all documentation is available and correct.
Evaluation and improvement
After completion, we analyze the test results and discuss them with the customer. If necessary, we make improvements in the design or choice of materials so that the packaging performs optimally in practice.
Through this integrated approach, we ensure that customers receive not just a test result, but a complete, validated packaging solution that is proven in practice.
A drop test is more than a technical formality. It is an investment in security, quality and customer satisfaction. By simulating realistic transport situations, it becomes clear how a suitcase or crate performs when it really matters. This can prevent damage and contributes to a reliable image towards your customers.
With Faes, you choose a partner who supervises the entire process: from determining the requirements and designing the packaging to coordinating the test and implementing improvements. Thanks to our cooperation with renowned partners, you can be sure that the results are reliable.
Want assurance about the performance of your packaging? Contact us to find out how we make your case or crate drop-proof, tested and validated.
Tim van de Puttelaar is the Engineering Manager at Faes and specializes in packaging engineering and custom solutions. In his articles, he shares insights on optimization, testing, and engineering projects that contribute to more efficient and sustainable packaging solutions within complex supply chains.
More articles by Tim van de PuttelaarGood packaging doesn’t just happen by chance. Using a tried-and-tested approach, our specialists guide you step by step from the initial idea to the finished product.
