ISTA 1G_2001

ISTA 1G 2001 - Page 1 of 8 ISTA, Your Alliance in Transport Packaging, is the world leader in Performance Tests for Packaged-Products. ISTA 1 Series are the most basic category of performance tests. • They challenge the capability of the package and product to withstand transport hazards, but • They are not simulations of actual transport hazards, and • Do not necessarily comply with carrier packaging regulations. When properly applied, ISTA procedures will provide tangible benefits of: • Shortened packaged development time and confidence in product launch • Protection of products and profits with reduced damage and product loss • Economically balanced distribution costs • Customer satisfaction and continued business. There are three sections: Overview, Testing and Report • Overview provides the general knowledge required before going into the testing laboratory and • Testing presents the specific instructions to do the testing in the laboratory and • Report indicates what data shall be recorded to submit a test report to ISTA. Two systems of weights and measures are presented in ISTA test procedures. They are the English system (Inch-Pound) and the international system SI (Metric). Inch-Pound units are shown first with Metric units in brackets, except in some tables where they are shown separately. • Either system may be used as the unit of measure (standard units), but • The standard units chosen shall be used consistently throughout the procedure. • Units are converted to two significant figures and • Not exact equivalents. VERY IMPORTANT: The entire document shall be read and understood before proceeding with a test. OVERVIEW OF PROCEDURE 1G Test Procedure 1G is an integrity test for individual packaged-products. • It can be used to evaluate the performance of a packaged-product. • It can be used to compare relative performance of package and product design alternatives. • The package and product are considered together and not separately. • Some conditions of transit, such as moisture, pressure or unusual handling, may not be covered. Other ISTA Procedures may be appropriate for different conditions or to meet different objectives. Specific suggestions: • To use fixed displacement vibration instead of random vibration, use ISTA Test Procedure 1A and not 1G. • For packaged-products where a minimum compression value should be tested, use ISTA Test Procedure 1C. • For packaged-products intended for international distribution consider ISTA Partial-Simulation Performance Test Procedure 2A. • For packaged-products that may be transported in a small parcel delivery system consider ISTA General Simulation Performance Test Procedure 3A. • Refer to Guidelines for Selecting and Using ISTA Procedures and Projects for additional information. Copyright ©2005 by International Safe Transit Association. All rights Reserved. 1G2 0 0 1 ISTA 1 Series Non-Simulation Integrity Performance Test Procedure Packaged-Products 150 lb (68 kg) or Less (Random Vibration) Preface ISTA 1G 2001 - Page 2 of 8 OVERVIEW OF PROCEDURE 1G Test Procedure 1G covers testing of individual packaged-products weighing 150 pounds (68 kg) or less when prepared for shipment. EXCEPTION: Individual packaged-products on a visible skid or pallet and that weigh more than 100 pounds (45 kg) may be tested according to Test Procedure 1E. The shipper shall determine the following prior to testing: • What constitutes damage to the product and • what damage tolerance level is allowable, if any, and • the correct methodology to determine product condition at the conclusion of the test and • the acceptable package condition at the conclusion of the test. For additional information on this determination process refer to Guidelines for Selecting and Using ISTA Procedures and Projects. Samples should be the untested actual package and product, but if one or both are not available, the substitutes shall be as identical as possible to actual items. Number of samples required: One sample is required for the tests in this procedure. Replicate Testing Recommended: To permit an adequate determination of representative performance of the packaged-product, ISTA: • Requires the procedure to be performed one time, but • Recommends performing the procedure five or more times using new samples with each test. NOTE: Packages that have already been subjected to the rigors of transportation cannot be assumed to represent standard conditions. In order to insure testing in perfect condition, products and packages shipped to certified laboratories for testing must be: • over-packaged for shipment to the laboratory or • repackaged in new packaging at the laboratory. The tests shall be performed on each test sample in the sequence indicated in the following table: Sequence # Test Category Test Type Test Level For ISTA Certification 1 Vibration Random Overall Gr m s level of 1.15 Required Drop Height varies with packaged-product weight Alternative Incline (Conbur) Impact Velocity varies with packaged-product weight 2 Shock Alternative Horizontal Impact Impact Velocity varies with packaged-product weight Required Scope Product Damage Tolerance and Degradation Allowance Samples Test Sequence 1G ISTA 1G 2001 - Page 3 of 8 EQUIPMENT REQUIRED FOR PROCEDURE 1G Random Vibration Test: • Random Vibration Test System complying with the apparatus section of ASTM D 4728-01. The following alternatives are acceptable for the equipment required for the Shock Test: Type of Shock Test Type of Equipment In compliance with the apparatus section of … Drop Test Free fall drop tester ASTM D 5276-98 Vertical Shock Test Shock test machine ASTM D 5487-98(02) Alternative Incline Test Incline impact tester (conbur) ASTM D 880-92(02) Alternative Horizontal Test Horizontal impact test system ASTM D 4003-98 Equipment Required Vibration Equipment Required Shock 1G ISTA 1G 2001 - Page 4 of 8 BEFORE YOU BEGIN PROCEDURE 1G Prior to beginning the tests identify the faces, edges and corners according to the procedure below. Step Action 1 Place the packaged-product in its intended shipping position as determined by shipper. If the shipping position can be variable, place the packaged-product so that the primary shipping label location is on the top face. 2 Does the packaged-product have only six faces (2 sides, 2 ends, top and bottom)? • If Yes, then go to Step 5. • If No, continue to next Step. 3 Develop a method to identify each face, edge and corner and document with a diagram. 4 Go to the next Block. 5 Is the package a corrugated container? • If Yes, continue to next step. • If No, then go to Step 8. 6 Does the package have a manufacturer's joint connecting a side and an end face? • If Yes, continue to next step. • If No, then go to Step 8. 7 Turn the packaged-product so that you are looking directly at a face with the manufacturer’s joint on the observer’s right and go to Step 9. 8 Position one of the smallest width faces of the packaged-product directly in front of you. 9 Identify faces according to the diagram below. 1 6 Edge 1-2 2 4 5 Manufacturer’s Joint 3 Corner 2-3-5 10 Identify edges using the numbers of the two faces forming that edge. Example: Edge 1-2 is the edge formed by face 1 and face 2 of the packaged-product. 11 Identify corners using the numbers of the three faces that meet to form that corner. Example: Corner 2-3-5 is the corner formed by face 2, face 3, and face 5 of the packaged-product. 12 Go to next Block. Identification of Faces, Edges and Corners 1G ISTA 1G 2001 - Page 5 of 8 BEFORE YOU BEGIN PROCEDURE 1G You shall know the packaged-products: • gross weight in pounds (kg), and • outside dimensions of Length, Width and Height (L x W x H) in inches (mm or m) CAUTION: A restraining device or devices shall be used with the vibration test system to: • Prevent the test specimen from moving off the platform and • Maintain test orientation of the packaged-product, but • The device or devices shall not restrict the vertical motion of the test specimen during the test. The following breakpoints shall be programmed into the vibration controller to produce the acceleration versus frequency profile (spectrum) below with an overall Gr m s level of 1.15: Frequency (Hz) PSD Level, g2/Hz 1.0 0.0001 4.0 0.01 100.0 0.01 200.0 0.001 The test drop height varies with the weight of the packaged-product. Find the weight of the packaged-product in the following chart to determine a drop height or an equivalent impact velocity to be used for a substituted drop: Packaged-Product Weight Drop Height Impact Velocity Equal to or greater than But Less than Free Fall Incline or Horizontal lb kg lb kg in. mm ft/s m/s 0 0 21 10 30 760 13 3.9 21 10 41 19 24 610 11 3.5 41 19 61 28 18 460 10 3.0 61 28 100 45 12 310 8.0 2.5 100 45 150 68 8 200 6.6 2.0 The test method requires the packaged-product to be dropped in several different package orientations. A drop test must be performed in all required orientations where dropping the packaged-product is practical. If dropping in a required orientation is not practical an equivalent incline or horizontal test can be substituted for that orientation. When using impact velocity, if any test in a Test Sequence is below the required minimum level, that sequence event must be repeated until the test impact velocity meets the minimum. Before You Begin Vibration Testing Before You Begin Shock Testing Packaged-Product Weight and Size Measurement Random Vibration Spectrum 0.0001 0.001 0.01 0.1 1 10 100 1000 Frequency, Hz PS D , g 2 /H z 1G ISTA 1G 2001 - Page 6 of 8 TEST SEQUENCE FOR PROCEDURE 1G The test blocks that follow contain tables that indicate the required steps for each test in the procedure. RANDOM Step Action 1 Put the packaged-product on the vibration table so that face 3 rests on the platform. 2 Start the vibration system to produce the random vibration spectrum indicated in the Before You Begin Block. 3 Stop the vibration system after the completion of 30 minutes. Invert the packaged-product so that face 1 (top) rests on the platform. 4 Begin the vibration duration for this orientation. 5 Stop the vibration system after the completion of 10 minutes. Place the packaged-product so that either face 2 or 4 rests on the platform. 6 Begin the vibration duration for this orientation. 7 Stop the vibration system after the completion of 10 minutes. Place the packaged-product so that either face 5 or 6 rests on the platform. 8 Begin the vibration duration for this orientation. 9 Stop the vibration testing at the end of 10 minutes. 10 Inspection of the package-product for visible damage is allowed, provided inspection does not alter, in any way, the current condition of the package or the condition or position of the product(s). 11 Vibration testing is now complete. Go to the Shock Test Block. DROP Step Action 1 Determine the method(s) of test and the required drop height or impact velocity in the Before You Begin block. 2 Do you have a packaged-product with only 6 faces as identified in the Face, Edge and Corner Identification Block? • If Yes, continue with the next Step. • If No, then go to Step 6. 3 Test the packaged-product according to the method(s) and level(s) determined in Step 1. Follow the sequence in the table on the next page. Continued Vibration Test Block Shock Test Block 1G ISTA 1G 2001 - Page 7 of 8 TEST SEQUENCE FOR PROCEDURE 1G Sequence # Orientation Specific face, edge or corner 1 Corner most fragile face-3 corner, if not known, test 2-3-5 2 Edge shortest edge radiating from the corner tested 3 Edge next longest edge radiating from the corner tested 4 Edge longest edge radiating from the corner tested 5 Face one of the smallest faces 6 Face opposite small face 7 Face one of the medium faces 8 Face opposite medium face 9 Face one of the largest faces 4 10 Face opposite large face 5 All testing is now complete. Go to the Test Report Block. 6 Select a bottom face corner to replace the corner required in Step 4 Sequence 1 to begin the test. 7 Identify the edges of the packaged-product that meet the Step 4 Sequence 2 through 4 requirements. 8 Select any 6 faces to replace the faces required in Step 4 Sequence 5 through 10. 9 Using the corner, edges and faces from Steps 6 through 8 go to Step 3 and proceed. 10 All testing is now complete. Go to the Test Report Block. 1G ISTA 1G 2001 - Page 8 of 8 TEST REPORT FOR PROCEDURE 1G The packaged-product has satisfactorily passed the test if, upon examination, it meets the Product Damage Tolerance and Package Degradation Allowance. ISTA Certified Testing Laboratories: • Should file a test report on all ISTA Test Procedures or Projects conducted. • Shall file a test report on all ISTA Test Procedures or Projects conducted to obtain Transit Tested Package Certification or Acknowledgement. For additional information, refer to Guidelines for Selecting and Using ISTA Procedures and Projects. ISTA Transit Tested Program The ISTA Transit Tested Certification Mark as shown is a: • registered certification mark and • can only be used by license agreement and • by a member of the International Safe Transit Association. When a member prints this certification mark on a packaged-product with their license number they are showing their customer and the carrier that it has passed the requirements of ISTA preshipment testing. In order to maintain its certified status and eligibility for identification with the TRANSIT TESTED Certification Mark, each packaged-product must be re-tested whenever a change is made in the: • Product or • Process or • Package. Changes in the product include changes in: • Design or • Size or • Materials. Changes in the process include changes in: • Manufacturing or • Assembly or • Filling. Changes in the package include changes in: • Configuration or • Dimensions or • Weight or • Materials or • Components. As a quality control procedure, packaged-products should be re-tested frequently, for example, yearly. This Test Procedure is published by: International Safe Transit Association 1400 Abbott Road, Suite 160, East Lansing, Mi 48823-1900 USA Copyright © 2005 by International Safe Transit Association. All rights Reserved No part of the contents of this Test Procedure may be reproduced or transmitted in any form or by any means without the written permission of the publisher. Order Information: Additional copies of this Test Procedure, the ISTA RESOURCE BOOK (in print or on CD ROM) may be ordered online at www.ista.org or by contacting ISTA at (+1) 517.333.3437. TRANSIT TESTED The manufacturer cert ifies that this PACK AGED-PRODUCT has passed preshipment test ing requirements established by ISTA. MANUFACTURER’S LICENSE NUMBER: ® INTERNATIONAL SAFE TRANSIT ASSOCIATION Before You Begin Report 1G