Packaging testing to increase package sustainability

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Pre-Shipment testing; a critical tool for achieving sustainability

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To simulate real life in the lab under controlled yet accelerated conditions.

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Micom:• Third party laboratory• Dorval, QC• 15 years in business• 15 employees• 15 000 sq feet• ISTA accredited lab• ISTA technical council

member• Transport Canada• Standards Council of Canada • CGSB• PAC member

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Packaging Sustainability

• (2009) World food industry: $US: 4.2 trillions (USDA)• Only 43 % of food calories produced are consumed (International Waste

Management Institute)

• Damage to products in distribution within Europe estimated to be: $US 3 billion (EU, SRETS, final report1999).

• Worldwide annual losses in distribution: > $US 100 billions

$$$

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Packaging Sustainability

Environmental impacts• Waste• Product replacement (raw materials, extra manufacturing)• Additional distribution

Initiatives• ISTA –Responsible Packaging by Design Guide• PAC-NEXT• ASTM D-6198 – Standard Guide for Transport Packaging

Design• Large Retailers

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Packaging Sustainability vs Distribution:

LTL: E=MC2=Expect Movement, Contact and Compression

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Small parcel= MC2 + Drops2

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Emerging Markets:

E= MC2 + Drops2 + Cultural shock

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The Distribution Equation:

Distribution = Product + Packaging

Distribution = Product + PackagingDistribution = Product + Packaging

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Packaging Sustainability vs Distribution (3):


• Product design should be done jointly with pkg design (team)

• The design should be done with the distribution environment in mind

• A well optimized design for one distribution channel may not work well for a different distribution channel

How do we define the stress levels?

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Test standards

ASTM D-4169

ISTA standards

Distribution Channel simulations: Field measurements

observations

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ASTM D-4169Standard Practice for Performance testing of Shipping

Containers and Systems• 18 Distribution cycles

• General - undefined distribution cycle• Single package without pallet or skid• Motor freight LTL unitized• Rail, TOFC and COFC• Air (Intercity) and motor freight (local) over 150 lb or

unitized• …

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ASTM D-4169

DC

Schedule (Hazard element)

Test

Level I = high intensityLevel III = low intensity

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ISTA standards

• 1 Series: Non-Simulation integrity Performance Tests (7)

• 2 Series: Partial Simulation Performance tests (3)• 3 Series: General Simulation Performance Tests (6)• 4 Series: Enhanced Simulation Performance Test

(1)• 5 …• 6 Series: Member Performance Tests (3)• 7…

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ISTA standards

• 2C: Furniture Packages• *3A: Small Parcel Delivery system• *3B: LTL (standard, cylindrical, palletized)• *3E: Unitized loads (truck loads)• 3F: Packaged Products for Distribution Center to

Retail Outlet Shipment (100 lb)• 3H: Products or Packaged-Products in Mechanically

Handled Bulk Transport Containers• 3K: Fast Moving Consumer Goods in the European

Retail Supply Chain

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ISTA standards

Member performance tests

• ISTA 6-FEDEX• ISTA 6-SamsClub

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ISTA standards

Enhanced simulation

• 4AB Packaged-Products for Shipment in Known Distribution Channels

• including vibration spectra for China and India

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Custom testing

• Data loggers 3 axes Drop heights Vibrations Temperature Relative humidity Atmospheric pressure GPS (link with Google Earth)

• Resonance search

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VALIDATE YOUR PACKAGING

TO TRUST IS GOOD, TO VALIDATE IS BETTER

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Laboratory testing

• Controlled conditions =• Reproducible • Allows to break down complex

distribution dynamics into individual test parameters

• Allows to observe in real time how the packaging reacts to the applied stress.

• More accurate assessment of the packaging design which can prevent over packaging.

• Representative results with limited number of samples.

Real Shipping Test

• Easy design of experiment• Easy to carry• Apparently cheap

• False feeling of security

• Uncontrolled conditions• No real time information.• Limited reproducibility

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Damage probability during trial shipment:

Damage rate: 10% 3%Success rate for first shipment: 90% 97%Success rate for 2nd shipment: 81% 94% “ “ “ 3rd : 73% 91% “ “ “ 4th : 66% 89% “ “ “ 5th : 59% 86% “ “ “ 6th : 53% 83% “ “ “ 22nd : 10% 51%

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SUMMARY:

• Rule #1: A sustainable package is package that allows the product to get to the end user in good condition

• Distribution: E = MC2 + other distribution hazards• Product and packaging development should be done

concurrently, not sequentially, as a function of the expected distribution channel(s)


• Test standards can be used as design criteria for product/packaging designs

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Michel Comtois, President ([email protected])

1-888-99-MICOM

David Rousseau, Lab Manager([email protected])

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Science

Packaging testing to increase package sustainability