d 6198 – 01 ;Rdyxotgtmde

NOTICE: This standard has either been superseded and replaced by a new version or discontinued. Contact ASTM International (www.astm.org) for the latest information. Desi De sign gnat atio ion: n: D 6198 6198 – 01

Stan Standa dard rd Guid Guide e for for

Transpo ransport rt Packag Packaging ing Des Design ign1

This standard is issued under the fixed designation D 6198; the number immediately following the designation indicates the year of  original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A superscript superscript epsilon epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope Scope

D 1974 1974 Practice Practice for Method Methodss of Closin Closing, g, Sealin Sealing, g, and Reinforcing Fiberboard Boxes 2 D 3332 Test Methods Methods for Mechanica Mechanical-Sh l-Shock ock Fragility Fragility of  2 Products, Using Shock Machines D 3580 Test Test Method for Vibration (Vertical (Vertical Linear Motion) 2 Test of Products D 4003 Test Test Methods for Programmable Horizontal Horizontal Impact Test for Shipping Containers and Systems 2 D 4169 Practice for Performance Testing Testing of Shipping Con2 tainers and Systems D 4728 4728 Test Method Method for Random Random Vibrati ibration on Testing esting of  2 Shipping Containers D 4919 Specificat Specification ion for Testing esting of Hazardous Hazardous Material Materialss 2 Packagings D 5276 Test Test Method for Drop Test Test of Loaded Containers by 2 Free Fall D 5487 5487 Test Method for Simulated Simulated Drop of Loaded Loaded Con2 tainers by Shock Machines D 6055 Test Test Methods for Mechanical Handling of Unitized Loads and Large Shipping Cases and Crates 2 D 6179 6179 Test Method Methodss for Rough Rough Handli Handling ng of Unitiz Unitized ed 2 Loads and Large Shipping Cases and Crates D 6344 Test Test Method for Concentrated Impacts to Transport Transport 2 Packages D 6537 6537 Practice Practice for Instrume Instrumented nted Package Package Shock Testing Testing 2 for Determination of Package Performance Standard: 2.2 ISO Standard: ISO 4180 Complete Filled Filled Transpor Transportt Packages—G Packages—Gener eneral al Rules for the Compilation of Performance Test Schedules 3 2.3 Other Documents: National Motor Freight Classification 4 Uniform Freight Classification, Rail Publication Service 5 International Civil Aviation Organization Technical Instructions for the Safe Transport of Dangerous Goods by Air 6 IMDG IMDG Code, Code, Intern Internati ationa onall Mariti Maritime me Danger Dangerous ous Goods Goods 7 Code

1.1 This guide covers covers an approach approach to design of packaging packaging for distributing goods through the hazards of handling, storage, and transportation. 1.2 The principal principal content of this guide is the identificat identification ion of the key steps involved in development of transport packages, including shipping containers, interior protective packaging, and unit loads. It is recognized that actual usage and application to individual design projects may vary appreciably without diminishing the value of the process. Consult with a packaging professional whenever needed. 1.3 This guide is not intended intended for design of primary packaging aging unless unless the primar primary y packag packagee is planne planned d for use as a shipping container. 1.4 The user of this guide guide must be aware of the carrier carrier rules regarding packaging for shipment via each mode of transportation in which the transport package may move, such as the National Motor Freight Classification (less-than truckload) and the Uniform Uniform Freight Freight Classifica Classification tion (railroa (railroad). d). For hazardous hazardous material materialss packaging, packaging, the packaging packaging must perform perform to the requirements of the applicable modal regulations listed in Section 2. standard d does does not purpor purportt to addre address ss all of the 1.5   This standar safe safety ty conc concer erns ns,, if any any, asso associ ciat ated ed with with its its use. use. It is the the responsibility of the user of this standard to establish appro priate safety and health practices and determine the applicability of regulatory limitations prior to use. 2. Referenced Documents 2.1   ASTM Standards: D 642 Test Method Method for Determini Determining ng Compressi Compressive ve ResisResistance tance of Shippi Shipping ng Contai Container ners, s, Compon Component ents, s, and Unit Unit Loads2 D 880 Test Test Method for Impact Testing Testing of Shipping Containers and Systems 2 D 996 Terminology Terminology of Packaging Packaging and Distribution EnvironEnvironments2 D 999 Test Test Method Methodss for Vibrati ibration on Testing esting of Shippi Shipping ng Containers2

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Available Available from American National Standards Institute, 25 W. 43rd St., 4th Floor, New York, NY 10036. 4 Available Available from National National Motor Freight Freight Traffic Traffic Association, Association, Inc., American Trucking Associations, 2200 Mill Road, Alexandria, VA 22314. 5 Available Available from 151 Ellis Street NE, Suite 200, Atlanta, Atlanta, GA, 33035-6021. 33035-6021. 6 Available from ICAO, Suite 400, 1000 Sherbrooke St. W., Montreal, Quebec, H3A 2R2 Canada. 7 Available Available from International International Marine Organization Organization,, 4 Albert Embankment, Embankment, London, London, Ontario 5E1 7SR Canada. Canada.

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This guide is under the jurisdiction of ASTM Committee D10 on Packaging and is the direct responsibility of Subcommittee D10.21 on Application of Performance Test Methods. Current Current edition edition approved approved Oct. 10, 2001. 2001. Published Published December 2001. 2001. Originally Originally published published as D 6198 – 98. Last previous previous edition D 6198 – 00. 2  Annual Book of ASTM Standards Standards,, Vol 15.09.

Copyright © ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.

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D 6198 IATA Dangerous Goods Regulations 8 United States Code of Federal Regulations Title 49, Transportation (CFR-49) 9 International Safe Transit Association Procedures 10

packaging that will eventually be required. The user of this guide is encouraged to examine each particular situation and decide the best order in which to proceed, without omitting any of the basic steps that follow. Identif tifyy Phys Physica icall Char Charact acteris eristic ticss of the Pack Package age 5.2 Iden Contents—It is imp import ortant ant to kno know w mor moree abo about ut the package package contents (goods) than simply its dimensions and weight. The packag pac kagee des design igner er mus mustt be awa aware re of phy physic sical al and che chemic mical al characteristics and hazardous properties so proper packaging can be devel developed. oped. These incl include: ude: susceptibili susceptibility ty to abras abrasion, ion, corrosion, temperature, static electricity, or magnetic fields; the ability to hold a load in compression, the contents’ ability to withstand the effects of shock and vibration during handling and transportation, and intended shelf life. See Test Methods D 3332 3332 and D 3580 3580 for met method hodss of det determ ermini ining ng sho shock ck and vibration fragility of products. 5.3   Determine Marketing and Distribution Requirements : 5.3.1 Package design must include include consideration of marketmarketing and distribution requisites in addition to product characteristics. isti cs. These requirements requirements,, in many case cases, s, take the form of  marketing marke ting grap graphics, hics, produ product ct ident identificat ification, ion, and compl compliance iance labeling. 5.3.1.1 5.3 .1.1 Complia Compliance nce lab labeli eling ng can als also o tak takee man many y for forms ms.. Some items to consider are identification of country of origin, hazardous materials transportation regulations, Truth in Packaging requirements, and bar coding. Besides the actual printed grap gr aphi hics cs,, on onee ma may y wa want nt to co cons nsid ider er pr prop oper er su subs bstr trat atee fo forr printing and any required coatings. 5.3.1.2 Distribution requirements requirements can likewise take on many forms of consideration including: the number of units that will ship shi p in a con contai tainer ner;; the com compos posit ition ion and att attrib ribute utess of the primary package; the identity of customers and their handling and storage requirements; the package disposal criteria; total volumee expec volum expected ted per shif shift/da t/day/yea y/year; r; expec expected ted life cycle; the planned modes of transport; domestic and international rules or regulations for packaging via those transport modes; types of  distributi distr ibution on chann channels; els; maxi maximizi mizing ng loads in carr carrier ier vehic vehicles; les; freight classification; handling and storage requirements; production equipment; environmental issues; etc. 5.3.1.3 This listing listing is not all inclusive inclusive and other consider consider-ations than these also may be important to the total package design. Identify Envi Environ ronmenta mentall Hazar Hazards ds Your Packa Packages ges May 5.4   Identify  Encounter —Knowledge —Knowledge of the distribution environment is key to designing an optimum transport package. Major hazards to be expected in the environment are: rough handling; vibration and shock in-transit; compression in storage or in-transit; high humidity and water; atmospheric pressure; salt/corrosion; static electricity; temperature extremes; pilferage; insect infestation; and concentrated impact forces. Identifying these hazards and quantifyi quant ifying ng them may incl include ude obser observati vation, on, condu conductin cting g measurements, or reading research reports (see the references listed in Practice D 4169). 5.5  Consider All Available Alternatives : 5.5.1 There are many alte alternati rnatives ves avai available lable for shipp shipping ing container conta iners, s, inte interior rior prot protecti ective ve pack packaging aging,, and unit load loads. s. All should be considered and reviewed before selecting the final types for further development. Trade-off comparison analysis

3. Terminology 3.1   Definitions— Gen Genera erall defi definit nition ionss for pac packag kaging ing and distribution environments are found in Terminology D 996. 3.2   Definitions of Terms Specific to This Standard: 3.2.1  interior protective packaging —packaging materials or forms used within shipping containers to protect contents from damage in distribution by cushioning, bracing, spacing from container walls, preventing abrasion, filling voids, and so forth. 3.2.2   transport packaging —packaging for containment and protection of goods during handling, storage, and transportation in the physical distribution process. The scope of transport packaging includes all of industrial packaging as well as the shipping containers, interior protective packaging and unitizing required for consumer packages. 4. Signi Significanc ficancee and Use 4.1 This guide assists assists users in design and development development of  packaging intended for the protection of goods while they are in transit from point of origin to final destination. By following all steps steps of thi thiss gui guide, de, users will be ass assure ured d tha thatt the most import imp ortant ant fac factor torss are inc includ luded ed in pac packag kagee des design ign.. In som somee cases, the sequence of steps may be changed, and often the steps may occur simultaneously with concurrent work activities. 4.2 The design process process focuses on prote protection ction from hazards hazards of handling and shipping while recognizing the economics of  all other facets of distribution, including packaging materials and labor, handling, storage, and transportation. 5. Proc Procedur eduree 5.1   Introduction : 5.1.1 Although no single procedure procedure can be expected to to meet all requirements for all design options, there are general areas of information that are necessary for the design process to be most useful. The more information in each of these areas that can be obt obtain ained ed acc accura uratel tely y, the gre greate aterr the pro probab babili ility ty of  optimizing the final design for cost performance utility, timeliness, line ss, and envir environmen onmental tal consi considerat derations. ions. Other inte interest rested ed parties, such as customers or end users, should be contacted for any specific package design criteria. 5.1.2 The following following sequence, sequence, list listed ed in 5.2-5 5.2-5.12, .12, may not always alw ays be app applic licabl ablee to eve every ry des design ign process process and may be changed chang ed to fit part particul icular ar circ circumst umstances ances,, produ products, cts, mark markets, ets, distribution methods, etc. Environmental hazards presented by the dis distri tribut bution ion env enviro ironme nment nt (se (seee 5.4 5.4)) may be kno known wn lon long g before a new product (see 5.2) is fully designed or ready for distribution (see 5.3). Such knowledge can in fact contribute to the design of the product to ultimately reduce the amount of 

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Available from IATA, Customer Service Rep., 2000 Peel St., Montreal, Quebec H3A 2R4. 9 Available Av ailable from Super Superintend intendent ent of Docum Documents, ents, U.S. Govern Government ment Printing Office, Washington, DC 20402-9371. 10 Available from ISTA, 1400 1400 Abbott Road, #310, East Lansing, MI 48823-1900.

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D 6198 technique techni quess oft often en hel help p in the sel select ection ion pro proces cess. s. Rat Rather her tha than n consid con sideri ering ng onl only y ma mater terial ialss tha thatt one has exp experi erienc encee wit with, h, comparing paper versus plastic versus wood versus metal is a good exercise at times to assure the optimum solution for a particular project. 5.5.2 Three major factors influencing influencing selection selection of alte alternarnatives are: package performance, total system cost, and environmental impact of materials. 5.5.2.1 The final package design will will also have a significant impact on overall distribution costs. It will influence materials costs, labor costs, capital requirements, overhead allocations, handling costs, freight and transportation costs, damage costs, and those costs and issues involved with the eventual disposal of the package components. 5.5.2.2 5.5.2. 2 The overall environmen environmental tal impact of a desi design gn may be quite difficult to quantify. Factors such as broad access to recycling systems or markets will have significant impact on thiss iss thi issue. ue. One com common monly ly use used d app approa roach ch to dea dealin ling g wit with h environmental impact for broadly distributed goods has been to use a desi design gn appro approach ach prioritizin prioritizing g the common concerns of  Reduce, Reuse, Recycle, Energy Recovery, and Safe Disposal. For packages developed for products having focused markets in specific locations, it may be more beneficial to emphasize a single element of the preceding concerns (that is, returnable packaging for products sold only locally, and so forth). The design des ign app approa roach ch cou could ld als also o be alt altere ered d to eit either her inc increa rease se environmen envir onmental tal ef effficie iciency ncy or comp comply ly with appro appropriat priatee regul regulaations, legislation, or organization policies. 5.5.2.3 One means of evaluating the overall overall effectiveness effectiveness of  a package design is to benchmark or compare it to designs from competitors for like products or to designs from companies or organizations recognized for packaging excellence. Often such compariso comp arisons ns can help confirm orig original inal desi design gn assu assumpti mptions ons (required performance levels, acceptable costs, and so forth) and can provide an additional level of confidence for a new design. desig n. If a benc benchmark hmarking ing effort effort indi indicate catess the design is not within the original design assumptions, a design review might be in order. 5.6   Design the Transport Package : 5.6.1 Afte Afterr basi basicc mate material rialss and information information are esta establis blished hed in the pre previo vious us ste steps, ps, the des design igner er can the then n sys system temati atical cally ly develop a transport package, and unit load where appropriate. Each Eac h com compon ponent ent of the tra transp nsport ort pac packag kagee is ana analyz lyzed ed for strength and other required properties and compared to technical data available from suppliers. Some packaging materials have good design data available, but most do not. Designers frequently rely on experience to reach a successful solution, but others may find that lack of information makes it difficult to arrive at an optimum solution. Such lack of information may require requi re that the desi designer gner approach approach the supplier or suppl suppliers iers involved to request that they take whatever steps are necessary to pro provid videe the inf inform ormati ation on nee needed ded.. If thi thiss app approa roach ch is not feasible, feas ible, thir third-pa d-party rty labo laborator ratories, ies, consu consultant ltants, s, or acad academic emic institutions may be an alternative resource. 5.6.2 Evaluation and improvement improvement of package package design can be be shortened by conducting engineering tests in package development. Most helpful in the design process is the establishment of test requirements prior to finalizing for sample making. Tests

such as impact, vibration, and compression not only identify shor sh ortc tcom omin ings gs in de desi sign gn,, bu butt al also so he help lp to fin finee-tu tune ne to an optimum solution for anticipated hazards. Test Methods D 642, D 880 880,, D 999 999,, D 400 4003, 3, D 47 4728 28,, D 527 5276, 6, D 54 5487 87,, D 60 6055 55,, D 6179, and D 6344 are frequently utilized for this purpose. (See Section 2 for these test methods.) 5.6.3 5.6 .3 An add additi itiona onall ben benefit efit of eng engine ineeri ering ng tes tests ts dur during ing packag pac kagee dev develo elopme pment nt can be rea realiz lized ed by the inc inclus lusion ion of  instrume inst rumentat ntation ion duri during ng the test proc procedur edures es (se (seee Prac Practic ticee D 6537) 6537).. Throu Through gh inst instrumen rumented ted meas measurem urements ents of the package’s performance during such testing, the designer can determine more precisely the margin by which the package being tested tes ted eit either her mee meets ts or fai fails ls the des design ign cri criter teria. ia. For tho those se instances in which the package is insufficient, the designer can use the measured values to establish the best and most efficient ways in which to improve the design. When the package passes the design criteria, the designer can also gain valuable information mat ion thr throug ough h ins instru trumen mentat tation ion to det determ ermine ine whe whethe therr the design is too conservative and might result in overpackaging. 5.7   Selec Selectt the Pr Prope operr Type of Clo Closur suree for the Shi Shippi pping ng Container —The —The ef effec fectiv tivene eness ss of the tra transp nsport ort pac packag kagee in retain ret aining ing and pro protec tectin ting g its con conten tents ts dur during ing han handli dling ng and transportation is influenced by the package closure method. In addition to handling hazards, method of packing, and type of  produc pro ductt to be pac packed ked,, the sel select ection ion of the clo closur suree sho should uld include consideration of any rules or regulations pertaining to the product, package, or transport mode. For fiberboard boxes, Test Method D 1974 provides guidance for methods of closure. 5.8   Determine Adequacy of Overall Protection by Performance Tests: 5.8.1 5.8 .1 Aft After er the shipping shipping unit des design ign is com comple pleted ted,, its adequacy for protecting goods in-transit should be checked prior to ac actu tual al sh ship ipme ment nt.. Th Thee ac acce cept pted ed pr prac acti tice ce is to pe perf rfor orm m laboratory pre-shipment testing procedures designated as perform fo rman ance ce te test sts. s. Th This is co cons nsis ists ts of su subj bjec ecti ting ng th thee un unit it to a sequence of anticipated hazards/tests in the laboratory for the purpose of a pass/fail decision. Will the shipping unit protect its contents all the way through distribution? In developing a testt pla tes plan n tha thatt wou would ld bes bestt sub subjec jectt the shipping shipping units to the hazards that may be encountered within the distribution cycle, refer to the following: Practice D 4169, ISO 4180, Rule 180 (NMFC), ISTA, or CFR 49, or Specification D 4919. 5.8.2 5.8 .2 The per perfor forman mance ce tes tests ts in Pra Practi ctice ce D 416 4169 9 uti utiliz lizee ASTM test methods having considerable experience and history tor y beh behind ind the their ir dev develo elopme pment nt and use use,, and a suc succes cessfu sfull completion of a properly designed and formulated performance test sequence greatly increases the probability of damage-free shipments for the distribution cycle intended. For users who can cle clearl arly y defi define ne the their ir dis distri tribut bution ion cyc cycles les,, but find the them m different than the standard cycles listed, Practice D 4169 also provides a means of developing a unique sequence of tests, result res ulting ing in per perfor forman mance ce tes tests ts whi which ch can mor moree pre precis cisely ely simulate the actual conditions of the user’s environment. 5.8.3 The inclu inclusion sion of inst instrume rumentat ntation ion durin during g perf performa ormance nce testing for verification of design may provide added beneficial informati infor mation on (see Prac Practice tice D 6537) 6537).. Throu Through gh such meas measureurements men ts of the pac packag kage’s e’s per perfor forman mance ce in suc such h tes testin ting, g, the designer can determine more precisely the margin by which the 3

D 6198 package being tested either meets or fail package failss the performance performance criteria. For those instances in which the package is insufficient, the designer can use the measured performance values to establish the best and most efficient ways in which to improve thee de th desi sign gn.. Ev Even en if th thee pa pack ckag agee pa pass sses es th thee pe perf rfor orma manc ncee verification procedures, the designer can gain valuable information mat ion thr throug ough h ins instru trumen mentat tation ion to det determ ermine ine whe whethe therr the design is too conservative and might result in overpackaging. 5.9   Redesign the Package or Product if Required : 5.9.1 If the package or product product fails to pass pass the performance tests, one or both need to be redesigned and the performance test repeated. 5.9.2 Testi esting ng may reve reveal al poten potential tial produ product ct impr improveme ovements nts thatt may hel tha help p inc increa rease se the str streng ength th of the pro produc ductt thr throug ough h product redesign. This is especially important when the cost of  the product redesign is less than the extra packaging that would be req requir uired ed if pro produc ductt im impro provem vement entss wer weree not mad made. e. Use Product Fragility Test Methods D 3332 and D 3580 to identify product improvement opportunities and measure the increase in strength when product improvements have been made. 5.10   Develop the Methods of Packing —An important part of package design is deter determini mining ng the optimum method method and equipment equip ment for packi packing ng of goods in ship shipping ping containers. containers. Although this may be the responsibility of someone else, that is, industrial engineering, the package designer must be aware of  cost factors and the appropriateness of mechanizing or automating all or part of the operations. Sometimes a trade-off of  package design for improved packing methods is required to achieve overall system economy. Ease and economy of packing, closure, and opening are key factors to consider. Whenever

an improved packing method or equipment requires a new or modi mo difie fied d pa pack ckag agee de desi sign gn,, be su sure re to te test st th thee re rede desi sign gned ed package. 5.11   Document ALL Work —One —One step often overlooked in the design process is documentation. This includes documenting original requirements, test results, specifications, drawings, and methods of packing. Names of persons involved should always be included on all documents. Drawings should be in company compa ny stan standard dard form formats ats with appr appropria opriate te desi designati gnations ons for reference refer ence in the corpo corporate rate specification specification system. Relyi Relying ng on supplier sketches or drawings as the reference document is not advisable. They should be transferred to company format so purcha pur chasin sing, g, man manufa ufactu cturin ring g and eng engine ineeri ering ng can ref refere erence nce them. 5.12   Monitor Shipping Experience —When a new or modified packaging design has been implemented, it is beneficial to monitor its performance during actual production, warehousing, shipping, sale, and use. One method is to use customer complaints compl aints as a meas measurem urement, ent, alth although ough this may under understat statee actuall probl actua problems. ems. It is ofte often n bett better er to proa proactive ctively ly audi auditt field performance by inspections, customer feedback forms, or by direct customer interviews. Feedback on this shipping experiencee can be use enc used d as the package package design design is con consid sidere ered d for modification. 6. Keyw Keywords ords 6.1 comp compressi ression; on; dist distribut ribution ion envi environme ronment; nt; handl handling; ing; impact; interior protective packaging; performance test; shipping container; shock; transport package; unit load; vibration

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