Standard Packing Guideline JICA
Standard Packing Guideline JICA
Standard Packing Guideline JICA
The main objective of the packaging is to protect the product transported from production
centers up to the end consumers. Factors which can produce damages on the packaging of the
cargo are: the impacts due to drops due handling, the vibrations of the vehicles utilized, the
stress produced due to piling on the warehouses, the ambient temperature and humidity
variations, etc. Among all the factors, the damages caused by the drop during handling could be
the most important one. The part of the engineering which is aiming to give the necessary
protection against impacts due to drops is the “cushioning design”. The objective of the design
is to smoothing the external impacts and to protecting the products, protecting them so that it
does not suffer the load of the impact, making all the system to a point that the impact forces are
becoming within allowable values for the product. The “cushioning design” is an engineering
field developed basically for industrial products and the steps are structured basically on the
following 3 items:
(1) Cushioning calculation: Defining the required thickness and areas of cushioning
materials
(2) Defining cushioning materials: To determine the location points of cushioning
materials
(3) Drawings preparation: To define the geometrical shapes of the cushioning materials
Furthermore, considering the development of all the packaging of a packed cargo, all the
steps of the packaging design and cushioning design can be summarized according to the
following flow chart.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
calculation of (Yes)
cushioning area
calculation
Calculation by new (Yes)
corners
conditions (Yes)
compensation
(No) Creep
Calc cushion mat for
analysis
vertical load
Verif. Projections
and remain. thick (Yes)
End
Source: Kiyohide Hasegawa – “Cushioning packaging Technology- Test Methods” Course XXXIX - Nikkan Publishing Co., 2005
Fig. 6.3-1 Flow Diagram for the Cushioning Design of Packaging
If it is observed the process related to Cushioning Design, the steps can be analyzed on the
flow diagram described below. Once the initial conditions for the design are defined, all the
processes can be followed up systematically through the related graphics. However, for the
study of the drops on corners and edges, since they are no standardized methods, the factors are
defined based on experience. Regarding the compensation factors of cushioning
characteristics of the materials, such as corrugated board, considering that they are variable
depending on the shape of the packaging (boxes) and materials, it is required a certain level of
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
Start
Compensat. Available
thickness
Verif. product data
Calc remaining "t" f/maximum
1.Verif resistance to Impact deformation instant
2.Product mass
3.Shape, sizes of prod.
4.Resistant area (each face)
Remaining ? Projection
5.Projection sizes
thickness ≦ sizes
Drawings preparation
Cushion calculation
(Yes) Compensation
required?
(No) Available ? Required
thickness ≦ thickness (No)
End
(Yes)
Source: Kiyohide Hasegawa – “Cushioning packaging Technology- Test Methods” Course XXXIX - Nikkan Publishing Co., 2005
Fig. 6.3-2 Flow Diagram for the Cushioning Design
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
into account the social and environmental needs, the adaptation to new technologies and the
coordination with others international standards.
Example:
Packed Cargoes-General Rules for
JIS Z 0200 : 1999 Testing
The JIS standards, as general rule, consist of a main text and an explanation, and depending
on the subject, it could include a series of normative annex (specification) and reference
annex(comments).
Within this structure of the document, the format for the main part and the normative annex
are specified by the standard itself, they are constituing the standard as a whole. But the
reference annex are not part of the document.
The list of the JIS standards applicable for industrial packaging is as follows:
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
Within the frame of the Study, and according to the results of data analysis of collected data
during the Transportation Environmental Surveys, it is expected the issue of the MERCOSUR
Standard (Draft) through the developments of the improvements of packaging design and the
Model Project (Transportation Survey by using the new improved packaging). The draft of the
standard is based on the JIS standards and is shown in the chapter 6.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
6.3.1.2 Evaluation of Dairy Products Packaged for Transportation, based on JIS, ISO
Standards
(1) Reference Values for Evaluation of dairy products packaged for transportation
(Draft)
The reference values, by applying the JIS, ISO and others standards, are as follows.
Tests for Packed dairy products (Evaluation of dairy products packaging)
JIS Z 0232 (2004) ISO 8318 (2000) , ISO 13355 (2001)
Packaged freights – Method for Vibration Test
Random Vibration
Test conditions * Use accelerations RMS (G2/Hz) totals and PSDs obtained by Transportation Environment Surveys
in MERCOSUR.
* Perform the tests within safety limits of accelerations (m2/s2).
PSD G2/Hz ( m2/s2 )
Total rms acceleration* m/s2 ( G )
Vibration period min
(depending on transportation vehicle and distances)
Vibration direction Vertical
(ISO 8318, ISO 13355 standards does not consider horizontal
vibrations)
Frequency range Hz
*The rms value is related to the total route.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
10
90
80
70
D ro p H eig ht (cm )
60
50
40
30
LevelⅠ
20 Level Ⅱ
Level Ⅲ
10 Level Ⅳ
10 20 30 40 50 60 70 80 90 100
Mass (kg)
LEVELⅠ Re-piling times is high, and possible high external extreme loads.
LEVELⅡ Re-piling times is high, and possible relatively high external loads.
LEVELⅢ Re-piling times and external loads are normal level, as expected.
LEVELⅣ Re-piling times is low, and they are expected no extreme loads.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
The tests are performed by using test apparatus as per JIS Z0212 and Method A.
Note: The Method A is a compression test, and basically investigates the damages on products caused by compression loads.
It is recommended as quantity of specimen more than 3.
The Method B is a compression test to investigate the resistance to compression of the secondary packaging, such as empty cardboard
boxes.
It is recommended as quantity of specimen more than 5.
【Method A】
The specimen must be conditioned before the test, according to JIS Z0203. In this case,
the temperature and humidity of the conditioning process is determined depending on the
purpose of the test. The compression direction will be selected according to the faces to be
under compression due to stacking, and the loading speed will be as per following formula,
where is indicated the load and a increasing speed of 10±3mm per minute, recording the
observed values immediately. The specimen quantity must be more than 3 pieces.
F = 9.8 × K × M × ( n-1)
F : Load (N)
K : Load factor (See table below)
M : Specimen mass (kg)
n : Maximum number of stacked boxes on transport (box nbr)
Load Factor
Classification by packaging characteristics
When the external When the external When the external
Classification depending on the packaging has no packaging has packaging has high
load possibility to absorb possibility to absorb possibility to absorb
moisture, or it is not moisture moisture or the product is
considered liquid
When the load is supported by
external portion of the package 4 5 7
(such as cardboard boxes)
When the load is supported by the
content, the isolation materials, the
2 3 4
container and external packaging
as a whole
When the load is supported by the
content and external packaging, but
1 1 1
it is not necessary to consider the
load on the last one
Note: Adjustments of Load Factor of ±1 is allowed, depending on the distribution conditions (time, humidity,
vibrations)
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
Method “B”: In measuring compression, the initial reading (datum point) for cardboard
boxes at initial load shall be according to following table.
Unit: N (kg)
Corrugated cardboard boxes single liner 196N ( 20kgf )
Corrugated CB boxes multiple flutes 392N ( 40kgf )
Other cases Agreed between parties
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
Particularly, the resistance tests are regulated as per item 2) indicated above, according to
the ordinance about dairy products for following products: milk, processed milk, special milk,
pasteurized lamb milk, low fat milk, controlled powder milk (for infants), cream, fermented mil,
yoghurt, and beverage milk.
(a) Seal resistance test
(b) Pin hole tests
(c) Bursting resistance test
(d) Puncture test
It is aiming to keep the physical resistance of containers to vibrations- impacts, impacts due
to drop, compression shocks during the transportation from factory up to end of user, ensuring
the quality of the product.
Proposal
The packaging for dairy products for transportation does not use cushioning materials, since
they are placed on boxes or baskets. Particularly, for the vibration tests it is necessary a
quality control, such as verification of leaks, to confirm the damage level of containers.
As examples, 1) A route with several portions with bad roads C type, such as grade 4 or 5
in the distribution process, or 2) when according to the transportation conditions the selected
load severity is high as per JIS Z0202, (specially if the product is liquid, or containers with
aluminum foil cap for yoghurts or beverage milk, fermented milk as liquid yoghurt) to get a
proper container design for “adequate seal resistance” and “easy opening” of “universal design”
aiming to ensure quality up to the consumer, it is fundamental the “resistance test” established
by the ordinance of dairy products of Japan.
Concretely, for the MERCOSUR market, the aluminum seal cap is strongly adhered to the
container, so that leaks are avoided during transportation, but frequent faults are observed when
opening.
Also, regarding to the vibration tests and drop tests according to JIS-Z standards, it is
specified the “recording data” (deformations, damages, cracks, leaks etc and descriptions) so
that, after those tests, it will incorporated another test of “pin hole test” for the complete test of
containers.
On the other hand, regarding to the MERCOSUR region, we would like to propose a study
for analyze the introduction of reference values, such as the case a of “seal resistance test” or
“bursting test” for cardboard containers, for packaging evaluation for transportation, equivalent
to the ordinance for dairy products of Japan.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
Note: The above indicated standards are applied for containers made of combination of cardboard, plastics ,Al/PE, PE, PS, PET
or aluminum foil cap for sealing.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
(3) Japan Regulation No.52 (Dairy Products) of Ministry of Health, Work and Social
Welfare – Motions for their modification
The regulation have been officialy promulgated on 1951, and it was modified few times
after their issuance. However, in practice, it was observed that this regulation has not the same
guidelines compared with other international regulations in this matter.
The Dairy Product Regulation of Japan, has been conceived on a basis considering the milk
product and other by-products as “food product for infant and convalescent persons”.
Through the years, the food products have been diversified and in paralell with the
development of containers and industrial equipment for packaging, the necessity to establish
common standards related to packaging and equipment are aroused. These standards must
cover all type of food products, not only dairy but also others products, aiming to provide to
public a good level of safety for all products.
According to the regulations actually in force, they are not suitable to cover the needs for
all types and shape of packaging of products and also for the transportation mode actually
applied. However, these standards are specifiying same aspects of resitance tests.
Therefore, it is expected that these standards would be modified partially, including the
chapter of resistance tests for packaging.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
Mercosur Council, through the SGT assigned this association the mission of regulating all
MERCOSUR standards, under the name of AMN.
Secretariat
SCM 1 SCM n°
Technical Standard
Notes
CSM: Mercosur Sectors Committes. Representing the National Standard organizations
SCM: Mercosur Sectors Sub-Committes
Source: AMN, JICA Study Team
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
JOINT PARLIAMENT
COMMITTEE High Level Convergence
Mercosur Permanent
Group & Integration Process
Representative Committee
Law based Countries Promotion Finance
Center
SGT01 Communications - Services Group - Biotechnology for Agri - Science and Technology - Ministers of Social Develop.
SGT02 Institutional Affairs - Public SubContracts Group culture & Stockbreeding - Tourism - Ministers of Culture
SGT03 Technical Regulation - Regulations incorporation - Cigarrettes commerce - Infrastructure for integration - Ministers of Education
& conformance evaluation Technical Meeting - Countries border inte - Promotion of commerce - Ministers of Home Office
SGT04 Financial Affairs - Automotive Committee gration - Family level agriculture - Ministers of Justice
SGT05 Tranportation - Technical Cooperation - Foreign affairs - Cooperatives
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SGT06 Environment Committee (CCT) - Sanitary & Fito-sanitary - Cinema & Audiovisual
SGT07 Industry - Mercosur Labor-social Affairs authorities - High Level Authorities
SGT08 Agriculture Committee - Sugar industry sector - Social communication Meeting for Mercosur Human
SGT09 Energy - Budget affairs Group of - Consultation group for Rights
SGT10 Labor/Employment & Mercosur Secretariat negotiations with WCO
Social Insurance - Mercosur Associated and SGPC between - The women
SGT11 Health Counties, states, provinces Developing Countries - Drugs authorities related to
SGT12 Investments Consultation Forum drug abuse, and rehabili
SGT13 Electronic Commerce tation
SGT14 Economic & Commer - Ombudsmen
ce Situation monitoring - Public Ministries
SGT15 _________________ - Government organization
for internal control
NOTES:
CDCS Direct Link
CT5 CT7
.Committee of Commercial Coordination
.Competitivity Protection .Consumer Protection
Protection & Saveguards Monitoring
Approval
Director Council
l AMN level
Mercosur Packaging Sector Committee
According to the AMN, normally for a presentation of a new standard, the application must
be submitted by one of the AMN member institutions to the related CSM (Mercosur -Sector
Committee), in this case to the Packaging Sector Committee. Once submitted the proposal, it is
analysed by all the National Committees.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
In each of the countries, the coordinator is the institute having the role of secretariat.
These are respectively: IRAM in Argentina, AMNT in Brazil, UNIT in Uruguay, and INTN in
Paraguay.
After that, in a period defined from the date of submittal according to AMN regulations,
AMN issues a statement in writing (there is a standard form) for further higher level
applications, or, for comments.
Once the AMN issued their statement, the CSM –in this case the Packaging Sector
Committee, expected to be established promptly- will take into consideration the new
MERCOSUR Standard and will make the consultations with the private sector. For this
purpose, they will organize consultation meetings for study and analysis, the factibility of
application, giving priority the application at national levels considering the other existing
standards.
Once approved by the Sectoral Committee, the regulation is finally voted in the AMN
Directive Council, formed by 4 representatives, one from each of the Countries.
One year-time is usually elapsed from the submittal of a Standard to its final approval.
Furthermore, the standards approved by AMN up today, the major portion is related to
proposals from Brazil and Argentina, and only few from Paraguay and Uruguay. Regarding to
this matter, the percentages of quantity of standards issued per country are: Brazil 60%,
Argentina 30%, Paraguay 5% and Uruguay 5%.
The number of approved and under study standards per each institution, starting from the
date of establishment of AMN on 1996, is indicated in the following Table.
According to AMN, the intensity of activities on this matter varies, depending on the
related CSM sectorial committee. In the practice, if it is observed the number of standards
approve by each commitee, the leader is CSM-02 (Steel Industry) with 198 cases, followed by
CSM-05 (Cement and Concrete) with 72, and then followed by CSM06 (Machinery and
Mechanical Equipment) with 70 cases, which is indicating the prevalence of the industrial
manufacturing sector.
In the contrary, they are cases such as CSM23 (Tourism) recently established, which has no
records of issuance of any document at the moment.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.1 Method of Designating Component Codes of Packaging MERCIS E001:2006
1. Scope
This Standard specifies the method of designation of codes on packaged freights and
containers utilized in the tests.
2. Normative References
The meaning of the main terms used in this Standard are defined in MERCIS E 000.
(Faces) The faces are identified by numbers: upper side 1, right side 2, bottom 3, left
side 4, front face 5, and back face 6. Also, in case that the packaging or
product has a front side and back side, the first will be identified as 5 and the
second as 6.
(Edges) The edges are identified by the numbers of the component faces, separated
by a hyphen. In this case, the numbers are ordered from lower to higher.
Example: edge 2-3
(Corners) The corners are identified by the numbers of the component faces, separated
by a hyphen. In this case, the numbers are ordered from lower to higher.
Example: corner 2-3-5
(6.3.3.1) - 1
Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.1 Method of Designating Component Codes of Packaging MERCIS E001:2006
(6.3.3.1) - 2
Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.1 Method of Designating Component Codes of Packaging MERCIS E001:2006
(6.3.3.1) - 3
Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.2 Packaged Freights-Conditioning for Testing MERCIS E002:2006
Introduction
This Standard has been prepared based to a translation, without any modification of
ISO 2233 Standard (Packaging-Complete, filled transport packages and unit loads -
Conditioning for testing), issued on 1994 as 3rd revision, maintaining the technical concepts
and the standard format.
1. Scope
This Standard specifies the methodology of conditioning for drop tests, compression
tests and vibration tests of packaged freights.
This conditioning procedure can be applied on the elements to be tested, whether on
the products to be a part of packaged freight or the materials of the packaging.
2. Principles
The packaged freights will be under the designated temperature and humidity
conditions during a certain period of time.
Table 1
Temp and Temperature Relative humidity
humidity
deg C deg K %
conditions
A -55 218 -
B -35 238 -
C -18 255 -
D +5 278 85
E +20 293 65
F +20 293 90
G +23 296 50
H +27 300 65
J +30 303 90
K +40 313 -
L +40 313 90
M +55 328 30
(6.3.3.2) - 1
Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.2 Packaged Freights-Conditioning for Testing MERCIS E002:2006
4. Allowable Values
4.1 Temperature
4.1.1 Deviation between the peak values
Regarding the temperature-humidity conditions of A, B, C and K, the maximum
allowable range for 10 sequential values of temperature distributed around the
specified point is ±3 deg C for a period of at least 1 hour.
For the others temperature-humidity conditions, the maximum allowable range is ± 2
deg C.
Notes: 3. The average values of relative humidity will be taken from at least 10 sequential
read values per hour, or they can also be taken from continuous type recorders.
4. Regarding the peak values of humidity of conditioning chamber, the maximum
variation is defined as ±5%, but in the case of modern developed conditioning
chambers, this value can be maintained within ±2%.
(6.3.3.2) - 2
Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.2 Packaged Freights-Conditioning for Testing MERCIS E002:2006
For almost all packaged freights, the reaction against variations of outdoor
ambient humidity is relatively slow compared with the variations of relative
humidity of the conditioning chamber. Also, even in the case that high
variation of humidity occurs, due to opening of conditioning chamber door, if the
average humidity on this stage or during the tests is kept below ±5%, it can be
considered that the moisture content in the packaging material is not affected.
5. Equipment
5.1 Preconditioning chamber
On the working space of the preconditioning chamber, the temperature and humidity
are recorded continuously, and it is required to maintain the control conditions indicated in
the clause 4. The working space is the area where the control conditions are maintained,
and they are determined by each preconditioning chamber.
6. Procedure
The appropriate temperature, relative humidity for transportation and storage of sample
packaged freight are selected.
The packaged freight is placed on the working space of the preconditioning chamber
and minimum time periods are selected among 4, 8, 16, 24, 48, 72 hours, 1, 2, 3, or 4 weeks,
in which the specified conditions will be maintained.
The packaged freight must be placed so that more than 75% of the surface of upper
side face, side faces and bottom face has direct contact with the environment of the
preconditioning chamber.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.2 Packaged Freights-Conditioning for Testing MERCIS E002:2006
Once the packaged freight is placed in the chamber, the ambient is returned to the
specified conditions. After 1 hour, it is considered that the time counting for conditioning is
started.
In case that the materials used are paper or cardboard having curves of moisture
content with hysteresis, it is occasionally required a freight drying period before the
conditioning process.
This previous treatment requires placing the freight in the drying chamber for more than
24 hours, and the transition to the conditioning ambient conditions must be done gradually,
meanwhile the packaged freight should adsorb the moisture to counterbalance.
The previous drying process is not necessary in case that the specified relative humidity
is below 40%.
7. Test Method
For the preparation of packaged freights test reports, previously preconditioned
according to the statement of this standard, the following items are defined for drop tests,
compression tests and vibration tests.
a) MERCIS standard number.
b) Temperature and humidity conditions (see Table 1) and applied conditioning time.
c) Temperature and humidity values of testing ambient, at the time of testing.
(6.3.3.2) - 4
Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.3 Packed freights and Containers - Method of Compression test MERCIS E 201:2006
1. Scope
This Standard specifies a method for testing the resistance to compression of
packages and containers made by metals, wood, corrugated cardboard, laminated paper,
plastics and the combination of these materials, by using compression testers.
Notes: 1. This method may be appropriate for testing the resistance to compression of
freights, when the package and contents are stacked and subjected to
compressive forces during the transportation and distribution process, and also
for testing the resistance to cargo handling by using side clamp hooks.
However, the method stated in the Annex is appropriate for evaluating actual
transportation conditions.
2. The numbers and units stated in this Standard, and indicated between keys { }
are usual values and units, and they are mentioned as an example.
2. Normative References
The following Standards, through reference in this text, constitute provisions of this
Standard. These reference Standards are valid of applying the most recent editions.
MERCIS E 001 Method of Designating on Component Codes of Packaging
MERCIS E 002 Packaged Freights – Conditioning of Testing
3. Apparatus
3.1 Compressor Tester
The equipment must accomplish the following conditions:
a) The compression platen must be dimensioned so as it can support with enough
margins the test specimen.
b) The compression speed is fixed at a rate of 10±3mm per minute. In case that the
resistance to deformation of the specimen is particularly high, the compression speed
must be slightly reduced.
c) It is recommended to adjust and calibrate the compression tester, by appropriate
methods, at least once a year.
(6.3.3.3) - 1
Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.3 Packed freights and Containers - Method of Compression test MERCIS E 201:2006
4. Test Specimen
The products or materials subject to test must be as follows:
a) The designation on components of the specimen must be according to MERCIS E
001. The packages other than cylindrical or rectangular parallelepiped shape samples
shall be designated by suitable method, according to the reference Standards.
b) The recommended quantity of specimens to be tested is more than 3 (three) for
Testing Methods A and B, and more than 5 (five) for Method C.
c) In the Testing Method C, the specimen shall be the empty box, and on method A and
B the specimen shall be the boxes containing the actual products or others of similar
characteristics of those to be contained. The packaging of the specimen shall be
carried out in the same condition as in shipping, and treated, as required, with air tight
sealing, seal, typing bundling.
d) The specimen made by corrugated cardboards or fiberboards, having flaps, shall be
assembled and sealed with the same materials as in actual shipping. The bending of
flaps to outer side must be up to 90 degree angle.
e) Prior to the tests, the external dimensions and total mass of the specimen shall be
measured.
5. Preparation Measures
Before the execution of the test, preliminary measures shall be taken according to
MERCIS E 002. On this, the atmospheric temperature and humidity conditions are
specified, depending on the purpose of the tests. If necessary, other tests shall be done,
such as submersion tests, sprinkle test, etc.
6. Test Methods
6.1 Method A
Basically, it consists of a compression test of packaged specimen to study the
damages that can be produced due to compression loads.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.3 Packed freights and Containers - Method of Compression test MERCIS E 201:2006
6.2 Method B
Basically, it consists of a compression test on side faces of packaged freights by using
side clamp hooks, to study the damages that can be produced due to side compression
loads.
6.3 Method C
This is a compression test carry out on a package or on an empty container, to study
their resistance to compression.
6.4 Procedure
6.4.1 Vertical compression tests (Methods A and C)
The following procedure shall be applied on test methods of 6.1 and 6.3.
a) The compression load shall be applied to opposite faces.
b) The specimen shall be placed centrally on the lower platen of the test machine, in
order to avoid unbalanced loads on the package to be tested.
c) In measuring compression, the initial reading (datum point) shall be taken at an
initial load according to Table 1.
(6.3.3.3) - 3
Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.3 Packed freights and Containers - Method of Compression test MERCIS E 201:2006
3) When the package or container structure starts to collapse and the content
becomes visible.
4) When the predetermined collapse conditions are verified.
5) When the predetermined load is reached.
f) The predetermined load in Method A shall be calculated by the following formula:
F = 9.8 x K x M x (N -1)
Where:
F: Load (N)
K: Load coefficient (see Table 2)
n: Number of piled boxes
M: Gross mass of specimen (kg)
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.3 Packed freights and Containers - Method of Compression test MERCIS E 201:2006
7. Test Report
The test report shall include the following information.
a) Detail of the content, in case of packaged products (product name, type, and mass.
In case of variety of products, their details, etc.)
b) Gross mass, dimensions, materials, structure of specimen, packaging method
c) Quantity (in units) of specimen
d) Model and capacity of used testing machine
e) Test method applied (method, load direction, shape of auxiliary plate inserted
between compression platen and the specimen, specimen external view
description at the test stage, differences respect the items specified on this
Standard, necessity to adjust the internal flap, etc.)
f) Additional conditions incorporated to the specimen or product before the test
g) Records of the results of the test (Maximum load N{kgf}, datum point, elapsed time
and their relation with compression variation, deformations (mm), occurrence of
damages and their details )
h) Test date and ambient temperature and relative humidity conditions of that date
i) General comments about the results of the test
j) Name and signature of test executor
k) Other topics which are considered to be recorded
Example: In the case of containers made of wood or paper, it is necessary to record the
moisture content of the product.
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
6.3.3.3 Packed freights and Containers - Method of Compression test MERCIS E 201:2006
ANNNEX (Normative)
Piling Tests
1. Continuous range: This Annex specifies the compression test method for piled
packed cargoes under static loads, during a defined period of time.
2. Test Apparatus
The equipment to be used for the tests must follow the following rules.
a) The compression test apparatus must be in accordance to the specification of the
main part of this standard. Furthermore, they must be furnished with accesories
suitable for covering the following conditions.
b) The apparatus must be capable to apply a defined load during defined period of
time.
c) The variations of the load to be applied must be ± 4%.
d) The compression plates must be designed in such way that their relative
displacement does not goes beyond the necessary value, in order to keep the
predetermined compression load.
e) The recorder instruments must follow the specifications of the main part of this
standard. Furthermore, they must be capable to recording the loads applied during
the predetermined time and the compression plates displacements.
3. Test Method
The test method must be according to the following rules.
a) The test specimen must be placed accurately on the center portion of the
compression plate, in order to avoid unbalanced loads.
b) Before starting the measurement of compression, an initial preload will be applied,
according to the Table 1 of the main part of this standard. From this point, the
predetermined load will be applied. The predetermined load will be applied
gradually up to the predetermined time is elapsed, or up to the occurrence of
damages on the packed cargo. The applied loads, the displacement of the
compression plates and elapsed times will be recorded.
c) For special conditions of loading, additional auxiliary plates can be placed, having
special shapes, between the compression plate and packed cargo, to make easier
the monitoring of the effects of the compression. (1)
Note (1) : The special condition of load means, for example the case of using one
face pallet as an auxiliary device, and monitoring the effects on the lower
face of this pallet.
4. Test Reports
The following items must be contained in the test reports.
a) In the case of packed cargoes, the content must be stated (description, type, mass,
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6.3.3.3 Packed freights and Containers - Method of Compression test MERCIS E 201:2006
1. Scope
This Annex specifies the compression test method for packaged freights subject to
static loads applied during long time periods.
2. Apparatus
The test equipment must accomplish the following.
a) The compression test equipment must accomplish the specifications of the main
part of this Standard, and additionally, it must cover the following conditions.
b) It must have the capability of applying a fixed load during a determined period of
time.
c) The variations of the fixed load must be ±4%.
d) In order to keep the fixed load, the compression platen shall not generate
unnecessary movements.
e) The recorder must accomplish the specifications of the main part of this Standard,
and additionally it must be capable to record the applied loads and platen
displacement during the predetermined period of time.
3. Test Method
The test method shall be carried out according to the following items.
a) The specimen shall be placed centrally on the lower platen of the test machine, in
order to avoid unbalanced loads on the package to be tested.
b) As indicated in the main part of this Standard, the starting point of the test is taken
at the moment of applying the datum point, and then the predetermined loads are
applied. The predetermined loads are applied during the fixed time, or up to until
collapse occurs, whichever first, and the deformations, the load and elapsed time are
recorded.
c) In order to make easy the observation of the effects of the compression due to
predetermined load conditions (1), as required, it can be inserted an auxiliary plate
with specified shape, between the compression platen and the specimen.
Note: (1) The predetermined load conditions are, for example, the use of one face pallet as
auxiliary plate, and to verify the effects of the compression by the deck board.
4. Test Report
The test report shall include the following information.
a) Detail of the content, in case of packaged products (product name, type, and mass. In
case of variety of products, their details, etc.).
b) Gross mass, dimensions, materials, structure of specimen, and packaging method
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c) Moisture content of the specimen (for containers made of paper of wood, if necessary)
d) Quantity (in units) of specimen
e) Model and capacity of used testing machine
f) Test method applied (method, load direction, shape of auxiliary plate inserted between
compression platen and the specimen, specimen external view description at the test
stage, differences respect the items specified on this Standard, necessity to adjust the
internal flap, etc.)
g) Additional conditions incorporated to the specimen or product before the test
h) Records of the results of the test (Maximum load N{kgf}, datum point, elapsed time and
their relation with compression variation, deformations (mm), occurrence of damages
and their details)
i) Test date and ambient temperature and relative humidity conditions of that date
j) General comments about the results of the test
k) Name and signature of test executor
l) Other topics which are considered to be recorded.
1. Introduction
This Standard specifies the test method for evaluating the resistance level required for
packaged freights transported within MERCOSUR region, related to compression loads
due to piling during storage, or horizontal opposite compression loads due to forces applied
by side clamp forks.
Furthermore, this Standards has been prepared taking as main reference to the JIS Z
0212 and the JIS Z 0200 (3) Standards.
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6.3.3.3 Packed freights and Containers - Method of Compression test MERCIS E 201:2006
plate, it will imply the measuring of the resistance of the portion of the box having higher
height.
Due to this reason, the results can show slight differences depending on the
application of one or other device utilized in the test.
This Standard allows the use of both types of devices. The only condition is that it
must be clearly indicated the type of device used during the test, by the statements in the
test report.
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subject to a particularly high compression, for avoiding their fall, so that sometimes
collapses occur in the product.
The horizontal compression test is applied to verify the resistance of the packaged
cargo against this type of horizontal loads. Consequently, in this test the specimen must
contain the product and including all fastening elements and the envelope, reproducing all
the conditions in transportation.
The compression test equipment can apply the load only on vertical direction, so that
the specimen must be placed sideways.
Also, in the case of medium size packaged cargoes, it is possible to make test under
more realistic conditions by placing multiple boxes between plates of similar size as side
clamp panels, so that the handling conditions are reproduced as actual handling conditions.
7. Piling test
This test is carried out to verify the compression resistance level of the packaged cargo
when it is stored during a long period of time. For the execution of this test, it is
recommended the use of deadweights for applying the loads, instead of the use of the
compression test equipment.
For the measuring of the deformations of the specimen due to the compression, it is
necessary to take 2 measuring minimum per each corner. If possible, it is desirable that
the all the faces of the packaged container is measured.
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
1. Scope
This Standard specifies a method for drop test of packaged freights made by metals,
wood, corrugated cardboard, laminated paper, plastics and the combination of these
materials.
2. Normative References
The following Standards, through reference in this text, constitute provisions of this
Standard. Regarding the standards having edition date, only the editions indicated are valid,
and the further editions and/or revisions are not applicable. Regarding the standards without
edition date, they are valid of applying the most recent editions (including the revisions).
Also, in case of reference standards others than MERCOSUR Common Standards,
they will be applied under the same criteria as describe above.
The following are the incorporated standards:
(1) MERCIS E 001:”Method of Designating on Component Codes of Packaging”
(2) MERCIS E 002:”Packaged Freights – Preconditioning for Testing”
3. Glossary
The definitions of the terms used in this Standard are as follows:
4. Preconditioning
The specimen shall be conditioned prior to the test, according to the method indicated in
MERCIS E 002. The temperature and humidity conditions for the preconditioning will be
fixed depending on the purpose of the test. Also, as required, water submersion or water
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sprinkling can be done. However, special conditions can be established under the
agreement by the parties involved.
5. Specimen
The specimen shall cover the following conditions.
(a) The specimen must contain the actual product. However, a model product can be
utilized as replacement, under the condition that they have same physical characteristics
such as dimensions, mass and the location of the center of gravity. In each case, the
air tight sealing, seal, typing bundling and othres must be the same as in actual shipping.
(b) The components designation of the specimen is in accordance with MERCIS E 001.
(c) More than 3 specimens to be tested are desirable.
6. Testing Apparatus
6.1 The free drop test apparatus shall be provided with the following conditions (see
Annex Fig. 1).
(1) The specimen must be free to adopt any position, with the purpose of executing the
drop and impact on correct way.
(2) The drop height must be adjustable for easy and exact control.
(3) The handling and hoisting of the specimen must be easy to carry out.
(4) It must be provided with hoisting devices so that it can not damage the specimen.
(5) The dropping surface must accomplish the following conditions:
(a) The mass of the material which comprises dropping surface must be 50 times larger
than the specimen mass.
(b) For the entire flat surface, the leveling tolerance shall be less than 2 mm.
(c) For the entire flat surface, the deformations shall be less than 0.1mm with a static
load of 98N{10kgf}/100mm2.
(d) The dropping surface shall be large enough so that the dropping of the specimen is
completed.
(e) The dropping surface shall be made by structural materials such as concrete,
stones or steel plate.
6.2 The single support edge drop test apparatus shall be provided with the following
conditions.
(1) The specimen must be free to adopt any position, with the purpose of executing the
drop and impact on correct way.
(2) The drop height must be adjustable for easy and exact control.
(3) The handling and hoisting of the specimen must be doable easily.
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
(4) It must be provided with hoisting device so that it can not damage the specimen.
(5) The dropping surface must accomplish the following conditions:
(a) The mass of the material of dropping surface must be 50 times larger than the
specimen mass.
(b) For the entire flat surface, the leveling tolerance shall be less than 2 mm.
(c) For the entire flat surface, the deformations shall be less than 0.1mm with a static
load of 98N{10kgf}/100mm2.
(d) The dropping surface shall be large enough so that the dropping of the specimen is
completed.
(e) The dropping surface shall be made by a structural material such as cement, stones
or steel plate.
6.3 The impact test apparatus shall be provided with the following conditions (see Annex
Fig. 2).
(1) The main structure of the impact testing apparatus shall be in accordance with ISO
8568.
(2) The impact platform, where the specimen is placed, shall be resistant and suitable to
maintain the flatness during the test and supported by a mechanical guide so that their
displacement is going strictly on the falling down direction.
(3) The pulse generated on the impact platform, as result of the impact, should have an
effective time less than 3 ms by a semi-sinusoidal wave.
(4) The setting of the drop height, for changes in the fixed speed variation, shall be
precise, easy to adjust; and the repeatability for these changes shall be ±5%.
(5) The impact platform shall be provided with a breaking function to avoid the second
impact after the first one, due to the rebounding.
(6) The impact platform shall be provided with a device to keep the specimen in position
for testing.
(7) The apparatus shall be provided with measuring and recorder devices suitable for the
accelerations, covering the following items.
(a) The frequency range shall be between a low limit of 1 Hz, and high limit higher than
500Hz.
(b) For the frequency full range, the measuring errors must be less than 4%.
(c) Further the acceleration wave generated in the impact platform, it is
recommendable to take measuring by more than 4 channels, in order to determine the
characteristics of weak points of the product.
(d) The maximum acceleration that can be measured shall be of 5880m/s2 {600G}.
(e) The speed variation generated on the impact platform shall be measured.
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
7. Testing Method
7.1 Testing Environment
The environment where the test is carried out, shall be as close as possible to those of
the preconditioning.
7.3.1 The free drop test (Method A) by using the free drop test apparatus
This test shall be carried out as follows:
(1) Setting of drop position
(a) The setting of the specimen looking the face to drop shall be set up with horizontality
within 2°. The horizontality of the face at the instant of the impact is recommended to
be within 2° also.
(b) Single support edge drop and corner support drop: The dropping position of the
specimen shall be arranged so that the vertical line passing through the center of
gravity of the specimen is passing through the edge or corner to have the impact. Also,
the horizontality of the dropping edge at the moment of the impact shall be within 2º.
(2) Drop height: It shall be determined depending on the purpose of the test. However,
the height allowed range shall be ±2% or ±10mm, whichever higher value.
(3) Dropping portion and the number of times of dropping: They shall be determined
depending on the purpose of the test.
(4) The packaged freight shall not be touched until the movements are completely
stopped.
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
8. Test Report
The following items must be states in the test report:
(1) Detail of the content (product name, type and mass)
(2) Gross mass, volumes, dimensions, materials, structure of specimen, packaging
method
(3) Quantity (in units) of specimen
(4) Model and capacity of used testing machine
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
(5) Test method and applied conditions (method, portion to drop, drop height, speed
variation, and number of dropping times)
(6) Additional conditions incorporated to the specimen prior to test
(7) Records of the results of the test (details of deformations and damages)
(8) Test date and test place ambient temperature and relative humidity conditions
(9) General comments about the results of the test
(10) Special note
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
1. Introduction
This Annex is an additional text to the main part and it does not constitute provisions for
this Standard. However, the users of this Standards, who does not have the actual data of
transportation survey, can confirm the protection level of the packaging against possible
impacts in actual handling in the transportation process, by the following provisions
mentioning in this Annex.
2. Test Method
For the execution of the test, it will be carried out following the sequence indicated in
Annex 1 Table 1, and dropping from a height indicated in Annex 1 Table 2.
2.1 The necessary conditions, such as the portion to drop, drop height, sequence of drop
and number of times of dropping, shall be established depending on the purpose of the
test. In case that there is no defined specifications, conditions must be established
by using the following parameters as a reference:
2.1.1 Free Drop Test (Method A)
For the drop portion and drop sequence, the Annex 1 Figure 1 must be taken as a
basis. The number of dropping shall be, in principle, 1 for each drop portion.
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
1. Introduction
This Standard specifies the method for testing the required resistance level against
impacts occurred during the packaged cargoes handling which are transported in the
MERCOSUR region.
This Standard has been referred to the guideline for vibration test given by the ISO
and JIS standards. However, and apart from the aforementioned standards, the test
conditions indicated in the Annex 1 have been developed based on the results of impacts
measurements on handling cargoes, in cooperation of JICA between 2005 and 2006(1)and
taking as reference the ISO 4180, JIS Z0200, NF H00-051 and packaging standards of
Japanese companies for export packaging.
2. Drop Test
(1) The free drop test is to reproduce the estimated impact of individual freight during
the cargo handling. Thus, this test is basically to be carried out on individual cargo, but
in case of multiple products bundled or packed together in one packaging, the test can
be executed on bundled packages as one unit.
(2) For the setting of the angle of face drop test, and the angle of the drop face at the
moment of the impact, the specimen ought to be placed horizontality within 1 degree.
However, since the settings under this condition are very difficult, it was established a
horizontality of 2 degrees.
(3) For the edge drop and corner drop, they are applied two methods for setting the
specimen: The first is to hold the specimen so that the center of gravity is located
exactly on the vertical line of the edge or corner to be impacted on the dropping
surface. The second is positioning the specimen so as to the opposite edge or corner
to be impacted on the dropping surface is coming on the vertical line of those edge or
corner (Normally named as “opposite edge” and “opposite corner” method).
In this Standard, it was adopted the method of positioning the center of gravity on the
vertical line of the dropping edge or corner, which is harder condition for the package
than another. By testing under this method, and in case that the setting of the
dropping direction is perfect, the packaged specimen is likely to stop in upright position
in the instant of the specimen collides with the surface, so that it can be clearly
confirmed the accuracy of the setting.
(4) During the edge drop and corner drop tests, the test executor sometimes may hold
the specimen just after the drop, to avoid falling down stemmed from any impacts other
than the drop itself. However, in the case of the actual cargo handling during the
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
distribution of the goods, normally there is no margin for the prevention of falling before
stopping the cargo. For this reason, it was incorporated the warning to avoid the
touch of the specimen until the complete stop.
(2) For the single support edge drop test, the hoisting device could be the hook for free
drop test, in principle. But, fork lift can also be used.
(2) The main difference between the free drop test and the drop test using the impact test
apparatus is that, in the first method, a secondary impact occurs due to the fall after
the drop against edge or corner. This, however, is not happened on the second
method.
(3) In the case of drop test by using the impact test apparatus, the impact value and speed
change must be recorded every time when the impact occurs. If the values are out of
specified range, the test must be restarted from scratch.
(4) For measuring the acceleration, it is recommended to record the waves by not using
the low pass filter. This device is recommended for the further analysis of the waves.
(5) The low pass filter must have a frequency of 200Hz minimum. The use of filters,
having lower frequencies than above value, will distort the wave signal and it unable to
measure the exact acceleration.
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
reference the ISO 4180, JIS Z0200, NF H00-051 and packaging standards of Japanese
companies for export packaging.
In the particular case of MERCOSUR, the reference values of this standards have
been obtained from publicly known standards and the data obtained from drop heights
data during cargo handling limited to following conditions: a) packaged freight of less than
10kg mass, b) packaged freight from 70kg and less than 100kg. Therefore, the drop
heights stated in this standard must be considered as reference only, for the purpose of
determining the test conditions.
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6.3.3.4 Packaged Freights - Method of Drop Test MERCIS E 202: 2006
Narrative- Fig. 2: Relationship between specimen mass and drop height for
single edge support drop test
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
1. Scope
This standard specifies the test method to evaluate whether packed freights can withstand
vertical vibrations suffered during the transportation.
2. Normative References
The reference standards listed below are part of this Standard. For those standards listed
with issue date, issues to be considered are only those quoted herein. Later issues shall not
be applicable. For those standards which issue date is not quoted, the latest edition is
applicable (including revisions).
Additionally, for those reference standards which are not part of the MERCOSUR
Technical Standards, above mentioned considerations shall be applied as well.
The standards taken as a reference are the following:
3. Glossary
The definitions of technical terms used herein are as follows:
(1) Power Spectrum Density (PSD)
The root mean square of the acceleration signal once passed through a narrow band
filter with a central frequency. The limit value when averaging time tends to infinity and
band width approaches to zero, expressed by the unit band width.
4. Conditioning
The specimens to be tested shall be conditioned as per the MERCIS E 002 Standard prior
to the test.
Special conditions can be agreed among the concerned parties.
5. Test Specimens
Test specimens shall comply with the following statements:
(a) Test specimens shall contain real products. However, a model product can be utilized as
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replacement, under the condition that they have same characteristics such as
dimensions, mass and the location of the center of gravity. In each case, the air tight
sealing, seal, typing bundling, etc must be the same as in actual shipping.
(b) Test specimen component designation shall be in accordance with MERCIS E 001
Standard.
6. Test Apparatus
The equipment to be used within the scope of the standards considered herein shall
comply with the following conditions:
6.1 Direction of Vibrations: The equipment shall be able to apply vertical (up-and-down)
vibrations to the specimen.
6.2 Accelerations: As a minimum requirement, the apparatus shall generate vibrations with
an effective acceleration value calculated from the preestablished PSD for test
specimens on loaded condition.
6.3 Vibration Frequency Range: Variable frequency range shall be greater than the
frequency range corresponding to preestablished PSD.
6.4 Vibration Board: Vibration board shall be big and rigid enough to hold the test
specimens and to maintain its surface leveled during the test. Minimum resonance
frequency shall be higher than the preestablished test frequency range.
6.5 Accessories for the Vibration Board:
Optional accessories can be added to the vibration board:
a) An enclosure to avoid lateral or back-and-forth displacement of the specimens
during the test
b) A kind of restriction device for model testing
6.6 Vibration Measurement and Control System: The following devices and functions
shall be equipped for vibration measurement and vibration control system:
a) Acceleration Sensor: It measures the acceleration generated at the vibration board.
b) Vibration Amplifier: It amplifies the acceleration sensor signals and sends it to the
control system.
c) Vibration Control System: It controls the vibrations at the vibration board by means of
the feedback signal from the vibration control system.
d) Data Output Equipment: It indicates the vibration status at the vibration board.
e) Data Recorder: It record the PSD features of the vibration data generated at the vibration
board and the vibration effective value.
f) Frequency Features: The values of frequencies gathered for measurement shall be
within ±5% in vibration frequency range.
g) Number of Measuring Channels: It is recommended to have several sensors to
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measure test specimen reaction, besides the control sensor at the vibration board.
8. Test Methods
8.1 The testing area environment shall be, whenever possible, the same as the one at the
conditioning area.
8.2 Test Specimen Setting: The test specimens shall be placed on the vibration table
(board) in the way most resembling their actual loading conditions, including fixation
methods and piling-up for transportation. In the case that the specimens shall be tied-up,
the specimen’s center of gravity must be as the nearest possible to the vibration board
center. An offhand cage can be prepared to avoid displacement of untied specimens. A
body can be piled-up on the specimen, provided its weight is the same as the one
present in real transportation conditions.
8.3 Measurement of Imparted Acceleration: The acceleration imparted to the specimens
shall be measured at the nearest possible point to the specimen.
8.4 Test Interruption: The test can be interrupted at any moment for visual inspection.
8.5 Vibration Signal Application: Vibration of the vibration board shall begin at low levels,
such as 6db, and increase gradually to the pre-established level, in order to achieve the
preestablished PSD. Once reached, the pre-established vibration level shall be
maintained during the preestablished time.
8.6 Bouncing Vibration Test: The bouncing vibration test shall be performed after the
Random vibration test as established herein.
8.7 Once the test is completed, the specimens shall be examined for damages.
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9. Test Reports
The items for the Test Report shall be as follows:
a) Applied Standard
b) Company and test location, test requester name and location (address)
c) Test Report identification number
d) Specimens receipt date and test performance date
e) Name, position and signature of test responsible personnel
f) Statement about the fact that the test results are limited to present test specimens
only
g) Declaration of full-text duplication forbiddance without laboratory authorization
h) Quantity of specimens used for the test
i) Details: specific gravity, dimensions, volume, specimen specification brochures,
fixation method, cushioning method, packaging structure protection method,
packaging closing and bundling method
j) Content details (product name, type and specific gravity:) In case of model
specimens or dummy are used, all related information shall be detailed therein
k) Total mass of specimen
l) Temperature, relative humidity of the conditioning area and test area
m) Test Conditions (frequency range, PSD and test time); Effective acceleration and
PSD test records
n) When piling-up stress has been tested, the product or weights used and the loading
time have to be stated
o) Statement about restraints or cages (if any, detail applied method)
p) Deviations to the test methods described herein
q) Diagnosis related to the recorded PSD
r) Posture of specimen during the test
s) General information on test apparatus and its identification data (e.g. manufacturer
number)
t) Test results record (description of deformation and/or collapse)
u) General view of test results
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
ANNEX A (reference)
PSD Diagrams and Conditions for Bouncing Test
1. Introduction
This Annex has the purpose to supplement the specifications indicated in the main part
of this Standard and it is not a part of this Standard.
However, for the user of this Standard who does not have the transportation survey data,
the development of tests following the indications of this Annex will allow to get test
conditions very close to actual transportation conditions.
The tests are structured on two types of tests, the vibration tests and the bouncing
vibration test, based on pre-established PSD. By carrying out these two tests, it can be
considered that the vibration tests are complete.
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
In case that the selection criterion is difficult to be distinguished, Pattern A will be selected.
3. Test conditions
Annex-A Table 3-1(a) Pattern A, Level I
Freq PSD
Point 2 3 2 Remarks
Hz m /s {G /Hz}
1 5 0.2964 0.003086
2 11 0.0209 0.000218 Distance: 4651 km
3 13 0.0209 0.000218
4 18 0.5229 0.005445 Equivalent stretch:
5 20 0.5229 0.005445 Aimogasta - Iguazu &
6 30 0.2267 0.002360 Belem - Sao Paulo
7 35 0.7670 0.007986
8 50 0.2440 0.002541
9 100 0.2440 0.002541
2
Effect.Accel 5.19m/s {0.53G}
Accel Time 1 hr
Annex-A Table 3-1(b) Conditions for Bouncing Test (10 Hz, 10,78 m/s (1.1G) )
Testing Method Duration (min) Impact Test (1.4m/sec or 10cm drop)
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Annex-A Table 3-2(b) Conditions for Bouncing Test (10 Hz, 10.78 m/s {1.1G} )
Testing Method Duration (min) Impact Test (1.4m/sec or 10cm drop)
Bouncing test (only) 17.1 ――
Combined w/Impact Test 5 1 time
.
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
Annex-A Table 3-3(b) Conditions for Bouncing Test (10 Hz, 10.78 m/s {1,1G} )
Testing Method Duration (min) Impact Test (1.4m/sec or 10cm drop)
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Annex-A Table 3-4(b) Conditions for Bouncing Test (10 Hz, 10.78 m/s {1.1G} )
Testing Method Duration (min) Impact Test (1.4m/sec or 10cm drop)
Bouncing test (only) 243.6 ――
Combined w/Impact Test 5 24 time
.
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
Annex-A Table 3-5(b) Conditions for Bouncing Test (10 Hz, 10.78 m/s {1.1G} )
Testing Method Duration (min) Impact Test (1.4m/sec or 10cm drop)
Bouncing test (only) 17.1 ――
Combined w/Impact Test 5 1 time
.
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
Annex-A Table 3-6(b) Conditions for Bouncing Test (10 Hz, 10.78 m/s {1.1G} )
Testing Method Duration (min) Impact Test (1.4m/sec or 10cm drop)
Bouncing test (only) 15.6 ――
Combined w/Impact Test 5 1 time
.
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ANNEX-B (Reference)
Characteristics of Random Vibration Tests
This Annex has the purpose to supplement the specifications indicated in the main part of
this Standard, and it is not part of the Standard.
1. General
The loading platform of the transportation vehicles, during the movement, receives the
oscillations coming from the irregularities of the road surface through the tires and the
suspension.
Since the irregularities of the roads have no defined patterns, the vibrations of the loading
platform are Random type. However, considering that on the way of transmission of these
vibrations up to the loading platform they are placed mechanical parts in the middle, having
their own natural frequencies, as a result, vibrations are not totally Random but
pseudo-Random.
Furthermore, since on the roads some steps or damaged portions are present, on some
point of the route impact waves must be added. For this reason, it can be said – strictly
speaking – that the vibrations on loading platform are Random oscillations plus impact
waves added, which can be named as “Shock on Random Vibrations”
However, in order to input these “Shock on Random Vibrations” on the vibration test
apparatus the conditions become very complex, and additionally, the phenomena analysis
are difficult and moreover, the mechanical load on the test equipment is becoming too high.
For these reasons, for general vibration tests they are applied the Random test for one
side and the impact test by other side, in separate way.
This Standard applies the same concept, so that both tests have been specified
separately. On the Annex B Fig.1 a) it is indicated a typical Random wave. As it can be
observed on the diagram, the general type of Random waves has a totally irregular shape,
where it cannot be seen any periodical signals, as observed in sinusoidal waves. The
Random waves have some statistical characteristics, so that when the data are processed
by using statistics tools, it can be determined the actual characteristics of the wave.
Using a common expression, the aspects related to frequencies are measured by the
PSD, and the vibration amplitude by means of the amplitude occurrence density.
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When the acceleration signal is passing through a narrow band filter, having an center
frequency of 5Hz, only a portion of the signal pass through the filter on a band around 5Hz,
as indicated in the curve b). This filtered signal apparently has a sinusoidal shape but it
contains not only a pure 5Hz signal but also other components waves close to 5Hz,
depending on the filter, and their intensity on the band width.
Furthermore, the signal level is not fixed, as it is in sinusoidal waves, but variable by
Random way.
The signal indicated in b), can not be used for statistical calculations since it includes
values below zero. Consequently, this signal is transformed to a square parameter.
The signals of d) are the square of the b) signals and all the values now are positive.
The signal of c) is a filtered signal, previously set with a center frequency of 15Hz, and
the signal e) is the square signal of the last one.
The band width of the filtered signal will depend on the filter resolution, so that it is
necessary to determine that resolution to a value near to 1Hz.
The term of “density” used on the naming of the PSD of acceleration is referred to the
process, indicating that the signal has been passed all these calculations. Furthermore,
since this signal also is varying on the time, it is necessary to process them by calculating
the averages in the time axis.
As result of passing through all this process within the measuring frequency range, finally
the PSD curve of acceleration (broken line) is obtained.
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1 t1
2
Arms= ―― A (t)dt ........................(1)
T
t2
Where:
Arms:Effective acceleration
A(t): Acceleration through time
t1 : Initial time of the calculation
t2: End time of the calculation
T: Time period between t1 and t2
The effective acceleration can be calculated from the PSD of acceleration, according to the
formula (2).
f1
Arms= φ(f)df
........................(2)
f2
Where:
φ(f): PSD function of frequency f
f1 : Frequency low limit
f2: Frequency upper limit
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Since the PSD is input data to the Random vibration tests, it is possible to calculate the
effective accelerations required, by the formula (2). Normally, on the test apparatus they
are provided the function for doing these calculations automatically.
Also, this value is indicating by the area covered by the PSD curve (broken line).
5. Effective Speed
From the power spectrum acceleration, it can be determined the speed spectrum, so that
by replacing φ(f) in formula (2), the calculation is very simple.
However, this value is applied only for the selection of the test apparatus, which are using
them, but it is not required for the execution of the test itself.
6. Effective Displacement
The effective displacement is calculated on a simple way, starting from the spectrum
acceleration, so, it is determined the spectrum displacement and this is replaced in the
formula (2). In general, this value is used only for the selection of test equipment, and it
is not required for the execution of the vibration tests.
However, it is quite significant since it is the origin of the faults on the products due to
displacements caused by vibrations, analyzed in the tests of “Pattern B” of this Standard.
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
1. Introduction
This Standard specifies the testing methods for evaluating the degree of resistance of
packaged freights to vibrations during the transportation within the MERCOSUR region.
This Standard has been prepared based on JIS and ISO standards as a reference.
However, regarding to the ANNEX A of this Standard, the test conditions indicated have
been configured based on the results of vibrations measured during the transportation
route surveys, taken on loading platforms of loaded vehicles, as a part of studies carried out
in cooperation with the JICA on year 2005 and 2006, independently from the standards
mentioned above. (1)
Therefore, in the case of routes which are not surveyed at that time, or routes
constructed or repaired after the survey, it is possible to find some vibration conditions other
than those specified in this Standard. Also, there are some cases of routes remarkably
out of the normal conditions, due to the degradation of the surface at the moment of the
survey.
In order to cope with all these cases, it is recommended to continue the measuring of
vibrations on the routes which are not surveyed yet, and determine the test conditions by
comparing with already analyzed routes.
Also, in the case of Argentina, the National Traffic Office (Direccion Nacional de Vialidad)
is publishing every year the Road Index of the national routes (a factor indicating the road
surface irregularities) of almost all the country, indicating a factor value per each
segment.(2)
If a comparison study is made between this information and the data of the JICA Study, it
would be possible an objective evaluation of routes.
Similar information can be found in the others 3 countries of the region.
On the other hand, this Standard has been prepared mainly based on JIS Z0232
standard as a reference.(3)
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expensive. Also, almost all the institutes of the counterparts of MERCOSUR are
not furnished with this type of equipment.
b) The vibrations on the loading platform of transportation vehicles show remarkably high
values on vertical direction compared to the others directions.(4) On the other hand, in
the field, it was proved that almost all packaged freights passing the vertical vibration
tests have the necessary characteristics to resist the actual transportation conditions.
3. Test Apparatus
The specifications of the test apparatus, indicated in the related clauses, can be covered
by standard apparatus, such as inductive electric type or hydraulic-electric controlled
equipment. However, the moving parts of the equipment are deteriorated due to the
repetition of tests, and the aging of non-movable parts along the time.
Furthermore, the measuring instruments and control systems are suffering aging
phenomena also. For these reasons, it is necessary to take measures in order to ensure a
proper functionality and accuracy, by carrying out a calibration at least once a year.
The vibration test apparatus have their own limits, according to the frequency range,
accelerations and speeds.
Regarding the displacements, the apparatus are provided with a device for limiting the
oscillations (limiter). Based on these restrictions, the test conditions limits are determined.
The limits of the test conditions are indicated through a broken line in chart of
acceleration, speeds and displacement. The figure of Narrative-Fig. 1 shows an example
of the chart indicating the limitations of a test.
In this example, the allowable frequency range is 3Hz to 200Hz, the maximum speed of
200cm/s, and maximum displacement of 50.8 mm (2 inches), and maximum acceleration
without load of 980 m/s2 {100G}.
It must be noted that maximum accelerations can varies, depending on the mass of the
specimen placed on the test apparatus.
Note 1): The maximum allowable acceleration is the result of dividing the electrical output of
vibration equipment by gross mass of the movable parts. The gross mass of movable
parts is the sum of mass of the shaker, vibration table, the specimen, and fittings.
For example, if the output of the vibration equipment is 2500 kg-G, the mass of movable
part 25 kg, the vibration table with accessories 500kg, the mass of the specimen 75 kg, the
total of fittings 8 kg, then the gross mass of all movable parts is 608 kg. So, the maximum
allowable acceleration will be 40.3 m/s2 {4,11G}.
Also, if protection devices are placed on the vibration table, to avoid fallings, the mass of
these devices must be added to the total mass of movable parts, and then the maximum
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allowable acceleration will consequently decrease. For this reason, necessary care must
be taken.
Shaker
only
Vibration table
Specimen of 60kg on
table
4. Test Method
4.1 Vibration driving methods
According to actually applied methods of vibration tests on packaged freights, there are 3
types of tests: with fixed frequency, variable frequency by sweeping, and random
frequency. The method by fixed frequency includes the case of oscillations produced by a
determined frequency (i.e. 10 Hz) and the others where the impulse is given by the natural
frequency of the specimen.
The vibration tests by fixed frequency are normally carried out for investigate the sliding
of palletized cargoes. Also, considering the transportation and packaging conditions in
MERCOSUR region, it is not necessary of an immediate action to implement a Standard for
this matter. However, since it is very difficult for the full reproduction of the transportation
conditions on the MERCOSUR routes by using Random tests, the “Shim Test” has been
introduced as replacing method in this Standard in order to cover this gap, as indicated on
next pages (See details in Clause 4.3).
The vibration test by natural frequency is applied normally to replace the Random tests.
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
It is often used to supplement other tests to investigate the resistance of industrial products.
Since this Standard is basically to specify the Random tests, it is not stated any
specification for methods for replacing them. Also, since the standards related to the
verification of resistance of products are specified by others standards, they are not
included in this Standard.
Pattern A
The Pattern A is the case for reproducing the process which leads to a fault of
components, particularly the weak ones, due to fatigue through a repetitive force. It is
based on the concept of S-N curves applied for metallic pieces. (see Narrative Fig. 2)
This pattern is applied to the packages covering the following conditions.
1) In case that the content of the package is an industrial product: Considering that
the fault is reached due to the application of repetitive forces on the weak portion,
the use of Pattern A is the most adequate.
2) For the case of the target is a container for food product: This is the case when
the fault is reached by the exfoliation of the films of containers placed in the lower
part of a cargo, and produced due to the weight of upper portion.
Also, in the case of packaged freights with contents other than industrial products, and if
the origin of the faults are assumed due to weights or repetitive loads, it is recommended to
define the test conditions analyzing the collapse characteristics as Pattern A.
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
Pattern B
The Pattern B is the case to reproduce the fault conditions such as product leaks due to
pin holes in the container bags, originated by the friction caused by vibrations. It is applied
particularly for packages influenced by some frequency band and number of oscillations.
The applicable packaging conditions are indicated below, and it is not applied to industrial
products.
1) Packaging of food products, where the fault appears as product leak due to generation
of pin holes on a portion of the container bags, originated by friction.
Regarding the divisions of each condition, they are described in the items 1 to 4 of the
main part of this Standard.
2) Since the Pattern A has an objective the products in which the fault is produced due to
repetitive loads, as indicated in Clause 4.2, where big accelerations or low frequencies are
not present, it will be enough reproducing frequencies around 5Hz.
3) Regarding to the Pattern B, since the purpose is to reproduce frictions stemmed from
displacements, the necessary condition is the reproduction at low frequencies. Therefore,
it was fixed as test range the frequency of 3Hz, which are present in the load platforms of
transportation vehicles.
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But the high frequencies are not totally transmitted, depending on the packaging materials.
This phenomenon is especially remarkable in the case of packaging using expanded
plastics as cushioning material. The reason is because the expanded plastics have the
characteristics of decrease suddenly the vibration response once exceed their own natural
frequency (see Narrative Fig. 3).
Up to now, a frequency of 50Hz as upper frequency limit was considered enough, but
according to the last tendencies of packaging, originated on environmental aspects, there is
an increasing utilization of cushioning materials made by paper cellulose, so that it can be
said that the adequate upper frequency limits are slightly higher than those applied up to
now.
Taking into consideration all these aspects, the upper frequency limit has been fixed as 100
Hz.
2) The Pattern B is the test case where the main parameter is the vibration amplitude. For
oscillations of 50Hz and 1G, the half wave is no more than 100µm (see Narrative Fig. 4).
So, for a vibration of higher frequencies, there is no influence to producing a friction, since
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the vibrations will be absorbed for almost all the usual packaging materials. Taking into
consideration this fact, the upper frequency limit has been fixed to 50Hz.
A =( 2πf ) 2 d 、 V= (2 πf ) d
Where A: Oscillation acceleration (cm/sec2)、
V: Oscillation speed(cm/sec)
f:frequency(Hz) d: displacement(half wave)
(cm)
Narrative Fig. 4 Vibration Chart of Multiple Parameters
The multiple parameter chart of Narrative Fig. 4 is the element linking the 4 parameters of
a sinusoidal wave, this means, frequency, acceleration, speed and displacements. The
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relationship can be seen directly on the chart; for this reason this chart is useful and
appreciated.
Regarding to the chart mentioned above, the other chart including frequency,
acceleration and displacements is also widely used. The displacement data are
abbreviated since this is no so much used. The charts for 3 parameters are shown in
Narrative Fig. 5.
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6.3.3.5 Packed Freights-Method of Vibration Test MERCIS E203:2006
Therefore, this test is not carried out independently but it must be combined with Random
tests. Depending on the test levels, there are some cases where this test is not carried
out.
Furthermore, since this test implies the application of oscillating loads on the equipment
table by bouncing of the sample, it is highly probably that vibration overloads are generated
on the machine. Consequently, in case that the number of bounce is very high, it can be
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Chap 6 Establishment of the "Reference Guidelines for Packaging Tests" / 6.3.3 MERCOSUR Standard
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Bibliography:
1) JICA cooperation Study – Final Report- (March 2007 )
2) Argentina Traffic Office (Dirección Nacional de Vialidad) – Road Status Report
3) JIS Z 0232- Packaged freights - Method of Vibration Test (2004)
4) K. Hasegawa -“Determination of Packaging Test Standards, based on Transportation
Environment Survey data–Japan Packaging Association MagazineVol.13 Nro.2.(April
2004)
5) ISTA – “Package Testing” Test Procedure 1-A.
(6.3.3.5) - 25
Chap 6 Establishment of the "Reference Guidelines for Packaging Tests"
6.4 Reference Guideline for Packaging Tests, for Evaluation: Data Input into the
Database (DB)
Based on the data classification for the DB discussed and mutually agreed on February 16,
2006, at the time of the Joint Meeting of 4 member countries for the presentation of the Progress
Report of this Study done on May 2006 (Campinas, Brazil), - starting point of the 3rd year of
activities, the whole data have been transferred to each counterpart institute through a hard disk
(HDD).
This DB is prepared by all the gathered information up today, and based on the data
classification system indicated above.
On the other hand, the following documents and supplementary information will be added
to the DB: a) document of "Reference Guideline for Packaging Tests, for Evaluation", b)
background information of route classification based on “grades”, c) others support information.
The details of criteria and validation related to this topic are all described in the Chapter 5
of this report.
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Chapter 7 Packaging Design and Testing
Chap 7 Packaging Design and Testing
The following paragraphs describe the steps required to maintain the quality of products
and packaging, in respect of the household appliances selected as target products for this Study.
The five steps for packaging design are: (1) transportation conditions, (2) product resistance
control, (3) the study of the packaging material, (4) the packaging design techniques and (5) the
packaging evaluation tests. In this case, it is mainly referred to refrigerators.
In this chapter, item (2) will be considered in respect of household appliances.
The main issue to be taken into account in order to develop a product is its outstanding
quality and functions; lately, the sum of the product plus its packaging is being considered.
Therefore, factors beyond the external aspect of the packaging should be taken into account,
considering the life cycle of the product and the distribution process.
In case of industrial products, packaging is determined by the specific life cycle of the
product (product characteristics, production, distribution and consumption), and taking into
account how consumers accept the packaging and the transportation conditions of the product.
Based on that, processes should be reorganized by analyzing feasibility in order to minimize
costs, including the product. In this respect, the items to be taken into account when designing
packaging, in furtherance of an effective development of the product, packaging and distribution,
are described in Table 7.1.1-1.
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Chap 7 Packaging Design and Testing
The following is an example of common household refrigerators, the target product of the
Study. In this design, the color was selected to combine with the walls of the house.
bottom
Design:
As seen in the photograph, the door can be bilaterally opened, to the left or to the right, as
required. The design has taken into account drainage details. Since this model opens to both
sides, the design is restricted and has specific characteristics since it does not have a handle.
Structure:
The back side of the refrigerator, painted white, is a very thick wall. The appliance is
basically a metal box with isolating material adhered to it. However, since the radiator
serpentines are exposed, the packaging should protect them.
Compressor:
The compressor is fixed with a clinch, which has a rubber cap to reduce vibrations and ends
in a plate stamped protuberance on the tray that supports the compressor.
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Chap 7 Packaging Design and Testing
Door:
The door is placed on hinges. One of the parts of the door is mechanically weak.
The number of refrigerators sold is relatively high and their price is low, so the impact of
transportation costs is low as well. In case of long distance transportation, trucks have to carry
as many refrigerators as possible, so usually a line of refrigerators is loaded in vertical position
plus two lines of refrigerators in horizontal position, or alternatively, 6 horizontal lines.
However, when placed horizontally, the compressor could be subject to additional
mechanical efforts. To avoid this, the trucks should be loaded very carefully.
In serious cases, the base or the clinches that hold the compressor could be damaged.
Five years ago, these refrigerators were packed in cardboard boxes. Then, cardboard was
replaced for EPS due to price increases. At present, EPS is used under the current specifications.
The different aspects of packaging improvement were analyzed taking into account the
latest packaging trends and transportation conditions.
a. Packaging design improvements, taking into account the fragility of the product
b. Packaging design improvements taking into account the “3R”
c. Packaging design improvements to comply with the Reference Guidelines for the
Transportation Environment Surveys
To perform the stress test of the conditions of distribution of the products, the distribution
process itself should be analyzed first. This analysis should include the organizational structure
of distribution, storage, transportation and distribution centers, stage by stage. Detailed records
of the working methods and the equipment used are maintained. Based on this analysis, the
number of times the product has been handled can be determined, as well as the conditions of
the loading/unloading equipment, the impacts due to dropping, static compression on the boxes,
dynamic compression, vibrations during transportation, etc., obtaining a general overview that
can be used to plan the packaging design.
In case of new products, the results of the actual transportation /distribution routes test
should be analyzed.
Table 7.1.2-1 shows the results of surveys performed in Japan on household refrigerators.
Besides, to supplement this information, Table 7.1.2-2 shows the results of surveys performed
on refrigerators in Brazil.
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Chap 7 Packaging Design and Testing
7-4
Chap 7 Packaging Design and Testing
Transportation Cycle
Loading / Unloading Condition Ana lysis of Tra nsporta tion Environment Survey
Drop/impact Static compr T&H.
Factory Joinville Vibr.on Tr Dynamic comp
Install sensor Packing Molded EPS + shrinkable plastic
Warehouse Low WH, piled refrig x 4 - w ithout pallets ○
Delivery Clamp f ork 12 unid/operation. Side press. Pi l ing test ○ ○ ○
Loading Displacement 50 a 100m
Manual (on truck) 1st raw pulled ○
2nd raw :moved on products ○
Transport Rented trailer Distance: 1300km ○ ○
Remove sensor
Custom Uruguaiana Custom 2 days Outdoor 2 days w aiting Temp variat
install sensor Opening Opening time M easuring Temp variat
Transport Rented trailer Distance: 1000km aprox. ○ ○ M easuring
Custom Mendoza Opening Horario apertura Temp variat
Transport Rented trailer Distance: 700km Temp variat
7-5
○ ○
Running through mountains High Lvl cond
Storage ○
Max load
Secondary transportation
Max load Load x nbr Load x time Load x times
Load x time
Testing Packaging
Source: JICA Study Team
Chap 7 Packaging Design and Tests
Packaging of large products, such as refrigerators, is limited from the point of view of the
production line.
(1) Assembly line: The packaging material may not be adequately transported on the conveyor
belt (especially soft materials or those easy to bend). They should be considered in the
product assembly stage.
(2) Problems related to the packaging equipment: The production line platforms should have
a hole at the bottom to allow the passing of air during the shrinking process when using
shrink type material.
(3) Packaging of accessories: this allows for the reduction of steps (the method used to pack
the accessories should be defined).
The following is a summary of the tasks required for the design of packaging for dairy
products as well as the specific details corresponding to milk pouches, aluminum foil lids for
yogurt pots and milk jam pots.
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Chap 7 Packaging Design and Tests
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Chap 7 Packaging Design and Tests
7-8
Chap 7 Packaging Design and Tests
Within the range of flexible packaging, the most major one is pouch packaging.
1
Source: Ohsuga, Hiroshi. “New Food Packaging Film – Flexible Package / Theory and Application”. Nippo Co.,
Ltd.
7-9
Chap 7 Packaging Design and Tests
7 - 10
Chap 7 Packaging Design and Tests
7 - 11
Chap 7 Packaging Design and Tests
LDPE L-LDPE
Iono EVA
MI MI Met. Met. T CPP
-mer VA5%
Low High infated die
Cold Approx. 0ºC ◎ ◎ ◎ ◎ ◎ ◎ △
Resist
Approx. -20ºC ○ ○ ◎ ◎ ○ ◎ ×
7 - 12
Chap 7 Packaging Design and Tests
Fig. 7.2.1-2 shows the relationship between hot sealing temperature and seal strength.
Lately, some L-LDPE-like materials, polymerized with metallocene catalysts have been
introduced.
Molecular distribution is very tight, and co-monomers are uniformly distributed, when
compared to traditional Ziegler-Natta catalyzed product. Consequently, its mechanical
properties are outstanding.
7 - 13
Chap 7 Packaging Design and Tests
(2) Double layered film with base film and sealant layer
Example: PET/LDPE vacuum containers, ONY/LDPE food containers for cooling,
OPP/LDPE containers for dry food, ONY/LDPE containers for fluid food and PET/CPP retort
food containers.
(3) Triple layered film with base film, intermediate sheet and sealant layer.
When the film required qualities cannot be achieved with only a base film and a sealant
layer, there are some options for quality improvement. Example: a film made of OPP/gas
vaporized Al/PET/CPP can be used for light blocking improvement, as in potato chips
containers. Films made of OPP/EVOH/CPP are used for oxygen gas barrier containers.
1
7.2.2 Aluminum Foil
1
Source: Ohsuga, Hiroshi. “New Food Packaging Film – Flexible Package / Theory and Application. Nippo Co.,
Ltd.
7 - 14
Chap 7 Packaging Design and Tests
Aluminum foil below 20~25µm is well known to have pinholes. Single foils are oxygen
permeable, therefore plastic laminating or lacquer coating shall be used.
7 - 15
Chap 7 Packaging Design and Tests
Friction pinholes are directly correlated to material wear. It is defined as the accumulated
pressure value due friction displacement in a unit area. In practice, friction pinholes appear
because of the sharp edges of the container’s folds. Taking a sheet of laminated film, folding it
twice, and placing a fingertip just in the pointed corner obtained anybody can prove that the
level of pain varies with the film material and its thickness. For a given load: the lesser the
supporting area for the load the higher the pressure value per unit area. Consequently, the
sharper the contacts end the higher the pressure as well as the wear, leading to the outcome of
pinholes.
For the bending or flexing fatigue pinholes the breakage is similar to that of repetitively
bending a piece of wire. The same happens in plastic films. Fatigue is provoked by the
application of repetitive loads, and when it leads to a breakage it is called fatigue breakage.
Material bending fatigue pinholes are an example of fatigue breakage.
The most reliable method to test flexing fatigue is the GELBO Tester under ASTMF 392
standard that evaluates the number of repeated folds and the resulting quantity of pinholes for
each type of plastic film.
There are no significant expectations regarding the aluminum foil strength. Therefore, it
has to be bond to either a paper or a plastic film for packaging manufacturing. Notwithstanding
that, even a PAPER/Al/ LDPE film shows clear pinholes after being repetitively folded (10
times) in the GELBO test. On the other hand, there is no pinhole generation after repetitive load
testing (250 times) performed on simple materials as aluminum deposition PET, and it is scarce
after bending tests.
1
7.2.3 Plastic film with vacuum metal deposition
Metal vapor deposition (metallizing) is a vacuum metal vaporizing process that lays a very
thin metal layer on plastic film or paper surfaces. Aluminum is the most frequently vaporized
metal, among others like gold, silver, copper, chromium, nickel, cobalt and their alloys.
Deposition is a metal vaporizing technique that takes advantage of the fact that vaporizing
temperature falls when vacuum increases. For example: aluminum vaporizing point is 2,060ºC;
when submitted to 10-2 or 10-4 torr vacuum it lowers to 1,148ºC and 927ºC respectively.
Vacuum deposition equipment is usually furnished with two vacuum chambers. The upper
chamber bears the feeding reel and the final reel, at a vacuum level of 1.3 Pa (10-2 torr). The
lower chamber has the vaporizing and heating devices, with a vacuum level set at 0.013 Pa (10-4
torr). The vaporized metal reaches the base paper or plastic material and it is cooled by the
refrigerating rod, and the film is rolled on reels.
1
Source: Ohsuga, Hiroshi. “New Food Packaging Film – Flexible Package / Theory and Application. Nippo Co.,
Ltd.
7 - 16
Chap 7 Packaging Design and Tests
Aluminum deposition film is the most popular one for containers manufacturing.
The case indicated in this clause is the material of corrugated cardboard manufactured in
Brazil. KLABIN Embalagens is one of the biggest paper companies in Brazil. The company
7 - 17
Chap 7 Packaging Design and Tests
possesses 9 factories is Brazil, and the mission focused the visit on the Jundai factory, which
works since 1992. A number of different classes of cardboard are produced at this factory (see
grades E to A as described below).
Thicker Thinner
A B C D E F G H
t=2mm t=1mm
Source: JICA Study Team
Fig. 7.2.4-1 Range of Manufacturing of Corrugated Cardboard
Corrugated Grade H thickness is less than 1 mm, and it is not manufactured by this
company yet. In Japan, the material of this grade was considered as “common carton” (due to
external appearance). In recent years, due to the influence of the application of “Packaging
1
Recycle Law” the actual tendency is that, even for so thin materials, to be considered as
2
“corrugated cardboard”. This material of small thickness is known as “microflute” in Japan.
Cardboard
Paper
Storage
Cardboard boxes fabrication facility production 100m
Area (1 line)
(6 lines)
1
NT: According this Law, the manufacturers which are using “recyclable common materials” must pay a tax per ton, for
subsidize the recycling program. But the corrugated cardboard is exempted to pay this tax.
2
NT: The recycling of corrugated cardboard is widely implemented in the recent years in Japan, showing high recycling index
rates.
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Chap 7 Packaging Design and Tests
In the stage of packaging design by using corrugated cardboard, the most important point
for verification of their resistance is the compression resistance. The cans or glass containers do
not have major problems on this sense, since the container itself can withstand the external loads.
On the contrary, in the cases of carton pots or plastic pots, part of the loads must be withstood
by the product itself. Also, in the case of pouch or fresh fruits, the total of the loads must be
withstood by the carton box. From this point, the necessity shall be paid attention in the design.
The corrugated carton boxes circulating in the region apparently are relatively of low
quality compared with those in Japan, particularly under the material resistance point of view.
Consequently, in order to ensure the prevention against damages on the products, resistance
calculations must be carefully developed during the design process of corrugated carton boxes,
particularly for packaging destined for food products or household appliances.
As a reference, examples of “Calculations of resistance of corrugated cardboard boxes
against compression forces” are shown, and the “Selection of materials for corrugated carton
boxes”, based on available specifications of Japanese material suppliers of liner paper and wave
papers.
It can be mentioned here that recently, the JIS standards related to corrugated cardboard
papers have been revised dated September 2005.
On the following tables, they are shown the resistance values of papers for liner (Table
7.2.4-1) and waves (Table 7.2.4-2).
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Chap 7 Packaging Design and Tests
As next step, it is indicated an example of packaging design for food products verifying
their resistance, as a part of design procedure by using corrugated cardboard.
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Chap 7 Packaging Design and Tests
where:
Furthermore, the conditions varies depending if the corrugated cardboard are of one layer
or multilayer, as indicated above in clause 7.2.1. Regarding to the types of corrugated
cardboard, they are indicated on Table 7.2.4-3.
Example No.1:
Calculate the compression for a box having following internal dimensions:
360L×300W×250H (mm), and the materials to be utilized is LB220×MB125×LB220 with
Wave A type.
Response 1:
First, it is calculated Rx.
The compression resistance of Liner LB220 will be:
PL = 2.17kN/m× 1,000/k ×0.1524m=331 N
Compression resistance of the wave MB125 is:
PO = 0.94 kN/m ×1000/k ×0.1524m=143 N
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Chap 7 Packaging Design and Tests
(2) Selection of the materials for the corrugated cardboard box (example)
The procedure of the selection of materials for the box is as follows:
[1] Calculate the load applied on the bottom end box of a pilling on storage.
[2] Calculate the compression resistance required for the box, considering a safety factor
due to others aspects such as material aging.
[3] It is selected the wave type, and based on reverse calculation from Kellicut formula, it
is calculated the required resistance of the paper.
[4] Finally it is selected the material which covers the compression requirements, both for
the liner and for wave.
Example No 2
Select the required material for a box Model 0201 (JIS) under the following conditions.
‣Box internal dimensions : 450L×350W×250H( mm )
‣Total weight of the box: 12kg
‣Number of boxes pilled vertically: 10 boxes
‣Safety Factor: 3 Response 2:
(1) The required resistance is calculated.
P=12×( 10-1 )×3×9.81=3,178 N
(2) The reverse calculation by Kellicut is made:
Rx=P/(0.748×Z1/3)
(3) The value of cubic root is calculated (Z)1/3
The perimeter of the box is: ( 45+35 )×2=160( cm )
(Z)1/3=5.43
(4) The value of Rx is calculated
Rx =3178N/( 0.748×5.43 )=782N
(5) The material is selected:
Considering to use the material LB180 for the external and internal liner, the compression
is calculated.
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Chap 7 Packaging Design and Tests
(1.59kN/m×1000/k×0.1524m) = 242 N
Thus, the compression resistance will be the double: 484 N.
The compression resistance of the wave will be:
(782N-484N)/1.6 ≒ 185N
Compression resistance as per ISO is:
(185N÷1000/k÷0.1524m)=1.21kN/m
From material various, the one which covers this condition is: MC100.
Consequently, the materials for the box, covering the mentioned conditions are:
LB180×MC160×LB180 and with Wave-A.
The specifications of materials indicated above, have been taken as reference from the
training program texts of the XXXI Training Course for Packaging Design with Corrugated
Cardboard, of the Japan Packaging Association Inc. (JPI).
1
7.2.5 Shrink type film
1
Source: Ohsuga, Hiroshi. “New Food Packaging Film – Flexible Package / Theory and Application”. Nippo Co.,
Ltd.
7 - 23
Chap 7 Packaging Design and Tests
Fig. 7.2.5-1 shows the curves that relate the heating temperature of the shrink type film to
the pertinent shrinking ratio. Table 7.2.5-1 shows the types of films and their characteristics.
7 - 24
Chap 7 Packaging Design and Tests
1
7.2.6 “Stretching” and “Wrapping” films
“Stretching” packaging is obtained by stretching the film. “Wrapping” film is also stretched
– mainly for commercial applications – so it is frequently used as internal layer of a “stretching”
film.
Table 7.2.6-1 describes the classification of these films.
“Stretching” films for packaging should have the following features.
‣High resistance to pin-holes under stress traction conditions
‣Good elastic recovery properties to remain stretched
‣No yield point
‣High traction resistance
‣Sufficient self adherence properties
‣Good transparency properties
1
Source: Ohsuga, Hiroshi. “New Food Packaging Film – Flexible Package / Theory and Application”. Nippo Co.,
Ltd.
7 - 25
Chap 7 Packaging Design and Tests
The EPS has a variety of functions and properties such as: cushioning support, suitability
for primary packaging and for external packaging. Some examples are as follows:
(1) Pots and trays for food products, manufactured by continuous extrusion process and molded
in vacuum condition
(2) Packs, pots, cushioning material (i.e. for fish), trays manufactured from expanded material
from chips raw material
However, this material is not fully the ideal material, since it is made by a fragile styrene
resin. But thanks to their expansion during the fabrication, the material is light and relatively
low cost, so that it is widely applied as packaging material, specially for household appliances.
In the case of refrigerators produced in Latin America, they are used an average of 1 kg of
material per unit, as cushioning material and external protection element as well. This is due to
the good use of their advantages to allow the protection of the product for long distances
transportation and their low weight, and the ausence of compression creep phenomena. This
means, this material allows a design covering two aspects: a) to have an enough area so that the
product can be piled 3 units vertically, and 4 units in horizontal position for transportation (the
surface is enough for not creating creep due to compression), b) to allow a cushioning design to
resist the impact requirements for the product.
The information of properties of the materials for the design can be obtained from the EPS
material manufacturers, through Internet etc so that the only point required it to make an
appropriate selection of the materials, according to the design needs.
Table 7.2.7-1 EPS Volume Used for Refrigerators in Latin America (example)
Brazil Æ 872gr Argentina Æ 782gr
Component Bottom Top Col*B Col *F Bottom Top Col*B Col *F
Nbr pieces 1 1 2 2 1 1 2 2
Mass gr 366 242 108 156 255 231 181 115
Lenght mm 692 691 1425 1425 622 622 1525 1505
Wide mm 642 642 140 160 620 620 205 150
Thick. mm 105 127 70 80 120 120 85 65
Source: JICA Study Team
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Chap 7 Packaging Design and Tests
The "Reference Guideline for Packaging Tests, for Evaluation" is described in the Chapter
6 of this report. In this section, it will be explained the procedures for the design control to
accomplish the requirements of that reference guideline.
(1) The general check of the packaging design is prepared, considering the steps of the design
of the product, during engineering process. In Table 7.3-1, it is shown an example of the
determination of the reference values, taking into account the (allowable) errors during the
manufacturing of the product.
Table 7.3-1 Development Steps and Reference Values for the Evaluation and
Design of the Product (guideline)
General Criteria
Validation Step Ref. Value for Vibration Ref. Value for Compression
Ref. Value for Drop Tests
Tests Test
Prototype tests 100% 105% 105%
Trial tests for mass production 100% 100% 100%
Mass production tests 90% 90% 90%
Source: JICA Study Team
This table is showing the reference values only, with the purpose to explain the works
criteria. For defined products, it is possible to determine the values case by case, according to
particular needs.
(2) The reference guideline for packaging are applied, based on the existence of the control of
distribution process. In other words, the companies which do not have those controls, the
reliability factor will be zero. In order to make feasible the validation of the packaging
design for a defined product, it is strictly necessary to establish a strict control system.
Depending on the type of problems to be solved, this matter is of a high level, so that it can
be treated as top management issue, including as company to company issue.
Next, it is showed the process in order to cover the design quality requirements, based on
the reference guideline and according to the type of product. The external view of the
improved packaging (pilot cargo) is shown in Fig. 7.3-1
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Chap 7 Packaging Design and Tests
*: The sum of 300km between Bs.As./Rosario and 1,200km between Bs.As./Mendoza are considered.
7 - 28
Chap 7 Packaging Design and Tests
7 - 29
Chap 7 Packaging Design and Tests
(1) Working plan for improvement of refrigerators: Packaging design quality evaluation
tests
The test contents of packaging design quality evaluation, developed in Brazil are shown
below.
Vibration Test
Product Prod+Packaging Sample Necessary Equip.
Vibrac. Random
(Vert./Horizontal)
Vibrac. Random
- Vibration Sensor
(Vert./Horizontal)
- Vibration Sensor
Compression Test
Product Prod+Packaging Sample Necessary Equip.
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Chap 7 Packaging Design and Tests
Drop Test
Product Prod.+Packaging Sample Necessary Equip.
PU defor
Impact Test
Product Prod.+Packaging Sample Necessary Equip.
(to verify as per Products: 2 Vibration Test Eq.
requirements) PU
Defor Caliper
PU aceler Dial gage
Drop impact
◎acceleration
◎deformation
◎damages
Sample quantity indicated are minimum required →products 2, packed units 5, frames 2.
If possible, the availability of one additional packed unit as spare would be convenient.
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Chap 7 Packaging Design and Tests
2) EPS
Bottom Top Pillar*B Pillar*F
Source: JICA Study Team
quantity 1 1 2 2 Fig. 7.3.1-1 Product external
Mass g 366 242 108 156 view
Long side mm 692 692 1,425 1,425
short side mm 642 642 140 160
thickness mm 105 124 70 80
3) Shrinkable film
Thickness μ
Film opened surface
total used m2
4) Adhesive tapes
Adhesive tape is used for fixing the internal
components to the refrigerator. Source: JICA Study Team
Fig. 7.3.1-2 Component Fixing
View
5) Packaging design remarks
1. EPS density
Size 50 x 50 x 50 mm
Mass : 2.637 gr
Density: 21 Kg/ m3
2. Cushining properties
EPS support face and thickness have been measured.
Support face: 1129cm2
Avg thickness: 6.3cm
Cushining properties have been calculated and it was detemined the Fig. 7.3.1-3.
Drop height: 8 cm→Generated acceleration 30g’s but EPS was deformed for approx.
6%.
7 - 32
Chap 7 Packaging Design and Tests
Gmax-H
50
40
Acceleration g’s
30
20
10
0
0 5 10 15 20
Droop Height cm
7 - 33
Chap 7 Packaging Design and Tests
Reference: in Fig. 7.3.1-4, it is shown the cushioning calculated value based on Fig 7.3.1-3,
by applying a density of 30 kg/m3.
Gm-H
22kg/m3 30kg/m3
50
40
g's
30
Acceleration
20
10
0
0 5 10 15 20
Drop Height cm
Source: JICA Study Team
Fig. 7.3.1-4 Cushioning Value by Applying Density = 30 kg/m3
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Chap 7 Packaging Design and Tests
The resistance tests are executed based on the conditions of item (1) indicated above, and
doing calculations based on the criteria table which depends on the type of the product.
In the case where the information of the product and the distribution route are available,
they can be used as reference the information of the Transportation Environment Surveys of this
Study.
Next, it is detailed as an example, the case of the refrigerators.
The works related to the improvement of the packaging of refrigerators could be developed
thanks to the availability of reliable data of the commercial network system.
The steps for the evaluation of the resistance of packed products have been carry out based
on that information.
For determining the reference values for the Random Vibration tests, they were taken the
steps indicated in Clause 6.1.(4), Chapter 6.
In here, it is indicated the tests by PSD curves which reflects the oscillations of the actual
distribution route, based on the evaluation PSD of each route type, gathered from recorded data.
Based on this method, it is possible to calculate the PSD for 4 routes in Brazil, and 1 route
of Argentina. At this step, it can be observed a difference on the reference values, between
results of actual routes and the conventional method as per ASTM standard.
The main points are detailed below.
(1) Method of integration of PSD data from 4 transportation routes
Since the 4 routes to be analyzed were completely different each others, even due to
distances or due transportation durations, it was decided reordering the PSD information by
taking the most representative curves per each route.
• The data measured per each day / each route have been integrated.
• The four days data have been integrated. The PSD representative of each route has been
calculated.
• The PSD Curve for Test is calculated, by converting to a reference distance of 500km, and
a duration of test of 1 hour.
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Chap 7 Packaging Design and Tests
Furthermore, regarding to the refrigerator of Argentina, tests have been developed (3 hours
tests) by using integrated data of stretches of Rosario-Buenos Aires and Buenos Aires- Mendoza
totalizing 1300km.
As a part of the activities performed during the second year of this study, the tightness test
equipment was purchased, given that there was no equipment of this kind in any of the four
1
counterparts’ laboratories of the four participating countries. Additionally, a vacuum dryer
was supplied during the first part of the third year of this study. Here follows the detailed
information about above mentioned equipment.
1
NdT: Vacuum dryer equipment to be used for tightness tests.
7 - 36
Chap 7 Packaging Design and Tests
This test is also called Leak Test. Vacuum dryer equipment is used (vacuum chamber). The
package to be tested is placed into the vacuum chamber, which is filled with water. Vacuum is
applied, and air bubbles coming out from the submerged package into the water are measured as
air leakage indicators. Vacuum increases during a 30 seconds to 1 minute period and has to be
maintained still during at least 30 seconds.
This is an adequate method to be applied on relatively high air content samples, and several
samples can be tested at a time. Vacuum levels are set according to the sample features, and by
parties’ mutual agreement. It can also be applied to leak detection on samples that have
undergone drop testing or compression testing.
Here follows detailed information on the study performed on milk pouches and yogurt
containers.
7 - 37
Chap 7 Packaging Design and Tests
2
There are two sealing designs for pouch manufacturing: a) pillow type sealing and b)
3
three side type sealing. Most market products use pillow type sealing, while only one brand
uses the three side type one.
Pouches manufacturing process produces vertical pillow type containers that are sealed
closed once they have been filled with product. The first sealing process involves one side
heating (Fig. 7.3.3-3 and Fig. 7.3.3-5) while the second one requires two side heating (Fig.
7.3.3-4 and Fig. 7.3.3-6).
2
NdT: In Japanese “envelope type”;
3
NdT: In Japanese “praying hands”
7 - 38
Chap 7 Packaging Design and Tests
Upper and lower end sealing of the pouch are performed by material fusion, using a
simultaneous heating and cutting procedure, with a piano chord from heater. Therefore, the
sealed band with is very narrow, leading to a low sealing strength. On the other hand,
commercial pouches used for other purposes have a 5 mm seal width, with high seal strength.
Most milk pouches are pillow type sealed, and leakage can be detected on its main body
and on both upper and lower end seals. Therefore, we can see clients placing milk pouches into
plastic polyethylene bags to carry them home safely.
7 - 39
Chap 7 Packaging Design and Tests
When both temperature and pressure are increased, melted material flows along the sealing
area leading to bead formation. These are ripping and pinhole generating points, despite high
seal strength.
3 layer 3-side A 0 0 0 0 0 0 0 0
1 layer Pillow A 0 1 0 1 1 0 0 1
1 layer Pillow B 1 1 0 1 2 0 1 0
1 layer Pillow B - - 1 4 3 2 0 0
1 layer Pillow C 0 2 1 0 0 2 1 0
1 layer Pillow D 0 0 1 1 0 0 1 1
1 layer Pillow E 2 1 1 1 1 2 2 0
1 layer Pillow F 1 0 0 1 0 1 0 1
Source: JICA Study Team
7 - 40
Chap 7 Packaging Design and Tests
Container’s body flaws were detected, due to excessive temperature and to defective
temperature as well. Leaks were originated by seal thickness reduction due to a slight
temperature excess, in upper and lower ends’ seals as well.
(5) Seal test of improved film for wet sealing (Fig. 7.3.3-8)
The low density polyethylene (LDPE) are structured by branched molecules located at
Random, and it is used as sealant film from long time ago.
7 - 41
Chap 7 Packaging Design and Tests
The linear type L-LDPE has linear chains; same as the LDPE as indicated above in clause
7.2.1.3, but in this case the chains are short and linear type. Compared with the LDPE, this
material has excellent properties of seal resistance, good seal ability under impurities, and a
good property for Hot Tack.
For example, it can be described the case of liquid milk pouches. This product has a
surface tension of 50 to 60 dyn/cm for a 20℃ temperature, lower than of the water which is
72.75 dyn/cm, and it has a little tendency to generate an interface.
Furthermore, the viscosity is 1.5 to 2.0 cP which is relatively higher than the water (1.0 cP
0.01 g/cm-sec) due to the content of oily component, molecules and proteins under colloidal
condition, all soluble in water. This means, this substance has viscosity and physical activity
for generating an interface, so physically tends to create foam.
Consequently, when the product is filled in the pouch, the liquid tends to be adhered in the
surface to be sealed, so that the seal ability is decreased.
As result of this analysis, it was decided to modify the design by using another material
having a higher content of L-LDPE, in order to improve the stability of the sealing, since the
surface always is impregnated with milk during the filling process.
Regarding to he cost aspects, the L-LDPE material is 1 to 2 % cheaper than conventional
LDPE. The melting point varies depending on the density of the material. As reference, for
LDPE of density 0.92 the value is 100℃ approximately, but for the L-LDPE this value is
increasing 10 to 15℃. On the same way, the sealing temperatures are: 130℃ for LDPE, and
more than 150℃ for L-LDPE.
Regarding to the manufacturing equipment of L-LDPE film, there are some difficulties in
the case of using existing machines of models of few years ago, since the melting temperature
of this material is higher than LDPE temperature. On the other hand, regarding to the packing
machine by using L-LDPE also has difficulties in the case that the seal bars have not enough
capacity to cover the requirements.
The improved material used for the study was a LDPE film having a 15% increased content
of L-LDPE.
This film showed a better elongation property than the conventional material, during the
tensile strength test, so that it can be observed the effect of the change of chemical composition
(more L-LDPE) of the improved material.
After that, the seal test has been carried out, with milk impregnated surface. Small band
shaped samples of 20 mm wide have been cut, locating the seal line in the center portion.
The seal test method consisted on sealing samples per each temperature, varying 1℃ each,
and the exfoliation has been checked manually.
7 - 42
Chap 7 Packaging Design and Tests
The temperature of those samples not showing exfoliation but showing breaks have been
recorded, for the total of 5 samples, as shown in following table.
Table 7.3.3-2 Hot Seal Test for Improved Film under Wet Condition (milk)
2
(seal: 2kg/cm , 2 sec)
(Wetted with milk)
Film type Exfoliation Remarks
YES NO
Vapor and foam generation.
Conventional Film 180ºC 183ºC
Film shrinks when temperature rises.
As shown in above table, neither vapor nor foam generation or film shrinkage occurred
with the improved material, even when it was soaked with milk. Additionally, the work
temperature range proved to be wider.
During the fifth stage of this study, it is planned to manufacture this material on line
production, and to check its performance as well.
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Chap 7 Packaging Design and Tests
The sample in Fig. 7.3.3-9 is a cylindrical plastic pot with an aluminum foil lid. The sample
on the right (Fig. 7.3.3-10) has a square lid (in line type) made of PET/aluminum film. Sensory
evaluation was performed on these samples by 25 people of the INTN staff. Evaluators shacked
the pots at first, opened them and drank the product directly from the pot. Results were as
follows:
Half the evaluators recalled that the opening was difficult for the first product, and it has to
be improved. Three evaluators detected lid tearing defects. When considering previous
experiences on this problem, the percentage of detection increases to 40% of the evaluators.
Ninety per cent of the evaluators recalled an easy opening for the second product. No
further problems were found. Nevertheless, 10% of the evaluators said that the easy opening
feature gave them an uncertainty feeling. On the other hand, almost 40% of the evaluators
7 - 44
Chap 7 Packaging Design and Tests
recalled that the square-shaped container was not easy to drink from, and the aluminum lid
curled touching one’s nose while drinking.
One relevant aspect to be considered is the aluminum foil lid tearing, as children could
accidentally swallow aluminum debris. Therefore, the lid tearing issue has to be worked out as a
priority. One option could be to lower the lid sealability in order to improve the opening process
and avoid the lid tearing. Even though, it would be very difficult to improve both aspects. Using
laminated aluminum film would solve the tearing problem, but there are technical problems
(curling) to be solved to use this film on present production line equipment. Actually,
multilayer aluminum/plastic film should be used in order to work out the tearing problem.
7 - 45
Chap 7 Packaging Design and Tests
The following conclusions were driven from the drop tests (see Table 7.3.4-1) :
1. Pillow type sealed samples from the Company A showed 4 to 5 leak points whenever
dropped with the seal laterally or downwards. Leaks were located in the container’s body,
and they were provoked by excessive sealing temperature. On the other hand, in Paraguay,
three-side type sealed products from the Company A showed no flaws in the drop test. This
means that the seal defects observed in Uruguay, even in three-side type sealed products,
7 - 46
Chap 7 Packaging Design and Tests
appeared because there had been no accurate control of the hot sealing process. Therefore,
the implementation of a severe quality control program was recommended.
2. Three-side type sealed samples from the Company B showed leak flaws whenever dropped
with the seal laterally or downwards. For pillow type sealed products of the same company,
there were no flaws in fresh milk pouches and 2 flaws in the upper seal plus zero defects in
the container’s body for liquid yogurt pouches.
Body flaws appeared due to an excessive sealing temperature, even in three-side type sealed
containers, while there were no body flaws in pillow-type sealed ones. Therefore, we can
say that body flaws can be reduced by means of a thorough quality control.
3. Four out of five samples of pillow-type sealed containers from the Company C failed the
drop test (drop height= 1m) due to body leakages, and one body flaw was detected in the the
Company D samples. Hot sealing control improvement was recommended for the body
seals, as well as for upper and lower seals (cut seals).
7 - 47
Chap 7 Packaging Design and Tests
A ○ ○ ○ ○
Ultra Flat ○ ○ ○ ○
Three-side type
○ ○ ○ ○
B ○ ○ ○ ○
Fresh Transversely ○ ○ ○ ○
Pillow type
○ ○ ×× Exc. Temp body
1
NdT See Paraguay case, pinhole resistance (7.3.3.1 (4)).
7 - 48
Chap 7 Packaging Design and Tests
We came to know that the material for fresh milk containers from the Company B has been
improved by means of a slight increase in its L-LDPE content and a decrease in film thickness.
As a consequence, sealing time shortened, and the work line productivity changed. L-LDPE is
stronger than LDPE, and its elongation is higher, too.
Table 7.3.4-3 shows that for fresh milk containers from the Company B, an extremely low
thickness value (73.2µ) corresponds to a considerably high body elongation value (959 %).
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Chap 7 Packaging Design and Tests
On the other hand, fresh milk containers from the Company C were considered as “good
sample” B, due to their low failure rate in the drop and in the compression tests.
Ten samples from the Companies B and C,
respectively, were placed in a basket and then
submitted to a vibration test at 5 Hz, with 25mm
displacement during 15 minutes. As there was no
failure record, the test continued for 15 minutes
more, and no failures were detected even then.
Additional tests were carried out during 60
minutes more, but there was no failure detection
Source: JICA Study Team
Fig. 7.3.4-4 Vibration Tests for either.
Pouches
For pouches, we can infer that even low seal
strength materials show almost no vibration damage. It may be due to the fact that pouches
behave as flexible elements, and vibration loads distribute throughout the container.
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The pots have to be placed upside-down because air trapping occurs during the container
filling process. When this air trapped appears as bubbles, the product’s visual aspect is
disgusting to consumers. Bubble transference to the bottom of the pot is difficult because of the
product’s high viscosity.
For product transportation to Chile boxes are placed as follows: 8 boxes x 5 layers piled up
like bricks, per pallet. Inside the trailer, they place 2 longitudinal rows of 13 pallets each (total=
26 pallets).
The route from Buenos Aires to Mendoza city (nearby Chile) is plain and 1,000 km long,
while the one from Mendoza to Santiago crosses the Andean ridge at 3,200 m ASL, and is 380
km long.
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Chap 7 Packaging Design and Tests
(2) The aluminum lid is subject to repeated deformation (it blows up and flattens) by vertical
vibrations, with the subsequent material fatigue. Material bending fatigue could be
responsible for the faults.
(3) The product freezes during the Andean ridge crossing, and frozen product’s sharp edges
stab across the aluminum lid. Punching pinholes could be responsible for the faults.
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Chap 7 Packaging Design and Tests
Test No. 4 in Table 7.3.5-1). Vibration tests with different packing style combinations didn’t
show remarkable improvements on product damage records. Notwithstanding that, the number
of fault points increased with the test duration, and they concentrated along the lid perimeter,
close to the seal. On the other hand, leaks occurred with horizontal vibrations as well (See Test
No. 8 in Table 7.3.5-1).
Therefore, they stated the hypothesis under which the faults were due to the friction
between the peripheral area of the aluminum lid and the plastic cap (See Fig. 7.3.5-6).
(3) Transportation simulation test (See Test 10, 11, and 13 in Table 7.3.5-1)
Further vibration tests were performed simulating product transportation from Buenos
Aires to Mendoza (1,000 km), and from Mendoza to Santiago de Chile crossing the Andean
ridge (380 km). Simulation setup was based upon the data compiled during the Transportation
Environment Study.
They were random tests (5~150Hz, Grms:0,4 vertical wave) performed in two stages: the
first one for 1 hour and 45 minutes, and the second one for 1 hour. Horizontal vibrations were
determined to be not significant from Buenos Aires to Mendoza, despite the long way. On the
other hand they were significant from Mendoza to Santiago, crossing the Andean ridge, due to
the great number of turns, and despite the short way.
Therefore, horizontal vibration simulation tests were performed with random waves in two
stages: the first one during 30 minutes and the second one one during 60 minutes (so as were the
vertical vibration tests). Fault conditions were also reproducible after horizontal vibration tests,
too.
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15min 3 Bott3
2 201-224 10 3
30min 6 Bott1,Upp5
15min 2 Upp2
4 401-424 6 2
30min 5 Bott2,Upp3
15min 2 Bott1,Upp1
5 601-624 2 0
30min 0 0
2 Upp2
10 BUE-MDZ 101-124 8 3
Vert 105min 5 Bott3,Upp2
Simulation MDZ-SCL
2 Bott2
11 60min 6001-6024 21 9
13 Bott6,Upp7
BUE-MDZ
0 0
Horiz 30min
13 2301-2324 2 1
Simulation MDZ-SCL
2 Upp2
45min
15min 0 0
6 801-824 0 0
Vert 30min 0 0
5Hz,1G
15min 0 0
7 5001-5024 1 0
30min 1 Upp1
Horiz 15min 0 0
9 2101-2124 0 0
5Hz,1G
30min 0 0
Vert BUE-MDZ 0 0
12 2201-2224 0 0
Simulation
MDZ-SCL 0 0
Horiz BUE-MDZ 0 0
14 2401-2424 0 1
Simulation
MDZ-SCL 1 Upp1
Source: JICA Study Team
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Chap 7 Packaging Design and Tests
7.3.5.4 Material fatigue and microscopical view of the aluminum foil lid
(1) Microscopical view of the aluminum foil lid (Fig. 7.3.5-5)
The thickness of the raw material for the aluminum lid is 35 to 40µm. It is embossed in
order to improve its properties such as printing, mechanical handling, and safety (Fig. 7.3.5-9).
After this, its thickness increases 100 - 110µm, while its mechanical strength lowers.
The aluminum lids were examined under a stereomicroscope (10 X). Microscopical cuts
were observed, some of which paralleled the emboss lines, but were not related to them.
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(2) Relationship between material fatigue in the aluminum lid and natural frequencies of the
pot
The tests performed using the ring-type plastic cap showed that pinholes appeared
regardless mechanical contact between the aluminum lid and the plastic cap. Moreover, the size
of the pinholes increases along the test performance.
Further tests were performed removing the plastic cap. Vibration of the aluminum lid was
detected with a stroboscopic light (Fig. 7.3.5-10), between 20 and 40 Hz, at 1G acceleration.
Pinhole formation was detected after 1 hour at 40 Hz, and leaks occurred thereafter.
Leakage was detected during horizontal and vertical vibration tests as well, and at similar
frequencies in both cases.
PSD curves built along the Transportation Environment Study in MERCOSUR countries
showed three typical peaks at 3~4Hz, 15Hz and 30Hz. Therefore, we can say that the
pinholes detected on the aluminum lids at 30Hz can be due to natural frequencies of the pot.
Finally, in order to fix the leak faults the aluminum lid has to be replaced for either an
aluminum-laminated plastic one or for an aluminum-deposited plastic lid.
7.3.5.5 Investigation: Product freezing due to low temperature and low pressure by the
Andean ridge crossing
Temperature decreases during the Andean ridge crossing, compared to the base plain lands,
because the crossing is performed 3,200m above sea level. According to the US Standard
Atmosphere studies (1976), there is a 0.65ºC decrease every 100m higher above sea level (up to
11,000m height). The study also shows the corresponding atmospheric pressure variations in a
table. The table values indicate that taking a 15ºC temperature for the plain base land, the
temperature at 3,200m height should be -5.8ºC, and the pressure 983.4 mBar (513 mmHg).
Should the temperature at the base plain land be 0ºC, the temperature at 3,200m height will be
-20.8ºC.
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The milk caramel was taken to -12ºC for 18 hours during the test, but it didn’t freeze.
Moreover, the temperature was lowered to -18ºC for 66 hours and then to -27ºC and it didn’t
freeze either. The product’s texture was kept like an ice cream’s.
Therefore, it has to be considered that there is no product freezing during the crossing of the
Andean ridge. The hypothesis under which sharp ice portions tapered the lid, generating
pinholes shall be discarded.
The milk caramel pot is filled with product at high temperature. The aluminum lid curves
down when the product cools to room temperature, because of volumetric contraction of the
product and of the air chamber above it (Fig. 7.3.5-11). The atmospheric pressure during the
Andean ridge crossing is 510 mmHg. A test was performed placing the pots in a vacuum
chamber and lowering the pressure to 250 mmHg only, and the aluminum lid turned to a flat
position (Fig. 7.3.5-12). Should this pot now be submitted to continuous vibration, pinholes will
be likely to appear in the central part of the aluminum lids.
Mastellone Company stated that they will make some improvements on the plastic cap
geometry (between 1-2 mm).
The use of an aluminum foil laminated plastic lid is recommended for a complete solution
of this problem.
A lot of improved samples will be prepared in order to perform vibration tests. Should these
tests be positive, transportation tests will be performed during the fifth stage of the study.
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the plastic lid material has also been modified making it more resistant to avoid contact with
the internal lid.
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Chap 7 Packaging Design and Tests
As regards sample 3), tests were performed applying 5 Hz vertical vibrations and 1G
accelerations during 15 and 30 minute periods. As a result, pin holes were found in the
aluminum lids, 3 cases in the upper layer and 1 case in the bottom layer. But due to the
protection provided by the PET film, no leaks were found (Fig. 7.3.5-15 and Fig. 7.3.5-16).
Besides, the aluminum lids of the products placed in the upper layer had circular marks
caused by contact with the bottom of the pots in the bottom layer. This happened with all the
samples and can be solved by using separators, so it is not considered critical.
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Notwithstanding the difference in the volume of air injected, in both cases lids were almost
flat. Besides, no separators were used between the two layers of pots. In addition, since there
were no new pots available with improved Aluminum lids, samples used in other tests were
used.
Vibration testing conditions were only those corresponding to the Mendoza- Santiago
stretch and the testing times were 50% of the actual duration of the trip because the test was
carried out under the assumption that “flat” lids only occur when crossing the Andes at 3,200m
SNM. During actual transportation, the shape of the Aluminum lids changes from concave to
flat during the ascent from the valleys to the mountains.
In fact, during the tests, 30 minutes of vertical oscillation and 22.5 minutes of horizontal
oscillation were applied.
As a result, no failures were found in the currently used pots subjected to horizontal
vibrations while some were found in 3 pots on the upper layer.
In the case of pots with improved Aluminum lids, no leaks were found although the pots
used in this test had already been used in 2 or 3 vibration tests.
7.3.5.8 Steps taken to avoid the increased costs of improved aluminum lids
Pin holes can be found on aluminum lids due to the chemical effects of the product
contained in the pot. Tearing can also occur when opening the lid. Besides, pin holes may be
due to friction or material fatigue during transportation. An alternative to solve these issues is
the use of plastic laminated materials (specifically 12µPET). In this case, if the current
Aluminum base material is used not modifying its thickness adding a PET-12 film costs would
increase. To avoid this, the thickness of the aluminum foil should be reduced.
Besides, when reducing the thickness of the aluminum, the laminated film “curls”
becoming mechanically unfit. To avoid this, the material is embossed, such as the currently used
material, thus increasing its apparent thickness. For example, the original aluminum foil used in
milk jam pots is 50µ thick but after the embossing process its thickness increases up to 110 to
130µ.
The costs of cases (1) and (3) can be analyzed based on the following specifications.
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Taking into account that the diameter of the aluminum lids of milk jam pots is 100 mm, it
can be estimated that 100 lids can be obtained from 1 m2 of material.
Once the 100 lids are obtained, the subsequent processing costs can be calculated as
follows: in case (1) < Current material: 50µaluminum foil /Lacquer > and (3) < improved
material-2:40µ aluminum foil /PET12µ/ Lacquer > respectively, pursuant to the following
formulae.
Result: the increased costs of laminating the current material with PET12µ can be set off by
reducing the thickness of the aluminum by 10 microns. If it could be further reduced, costs
would also be lower.
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As shown in the table, when elapsed 30 minutes, failures were observed for the Company B,
and at 45 minutes for the Company A. The leakages were located in the upper side seal and on
the body of pouch, respectively. Also, pin holes were found in other parts of the pouch, in the
plastic film. The origin of the pin holes are not well known, but the possible origin could
include the puncture due to edges in the basket, friction against the basket wall, friction between
pouches, etc. This phenomenon can be analyzed through deeper studies and tests of these
products.
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Chapter 8 Transportation Tests (Model Project)