How does a drop test for cases and cases work?

What is a drop test and why is it important?

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.

How does a drop test work?

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.