Fast Mving Cnsumer Gds in the Eurpean Retail Supply Chain 3K2 011 ISTA 3 Series General Simulatin Perfrmance Test PROJECT* VERSION DATE January 2011 Initial Release Last EDITORIAL Change: JANUARY 2013 Fr cmplete listing f Prcedure Changes and Versin Dates g t www.ista.rg ISTA, Distributing Cnfidence, Wrldwide ISTA 3-Series tests are advanced tests and are designed t: Challenge the capability f the package and prduct t withstand transprt hazards, but Utilize general simulatin f actual transprt hazards, and D nt necessarily cmply with carrier packaging regulatins. When prperly executed, ISTA prcedures will prvide tangible benefits f: Prduct t market time reductin Cnfidence in prduct launch Reductin in damage and prduct lss Balanced distributin csts Custmer satisfactin cntributing t increased market share There are tw sectins t this prcedure: Overview and Testing Overview prvides general knwledge required befre testing and Testing presents the specific instructins t undertake labratry testing. Weights and measures system - Familiarity with the fllwing units and symbls used in this dcument is required: Fr measuring Metric units and symbls Weight kilgrams (kg) r grams (gm) Distance metres (m) r millimetres (mm) Vlume Cubic centimetres (cm 3 ) Density kilgrams per cubic metre (kg/m 3 ) Temperature Celsius ( C) VERY IMPORTANT: The entire dcument shall be read and understd befre prceeding with a test. * Ntes Regarding ISTA Prjects and Prcedures ISTA 3K is currently an ISTA Prject, first released in January 2011. New ISTA test prtcls are given the designatin "Prject" during their implementatin phase. After a minimum ne-year perid and required evaluatin, a "Prject" will either be adpted as an established "Prcedure", revised and kept as a "Prject" fr anther perid f time, r be drpped. Therefre, a Prject is ptentially subject t greater and mre frequent revisin than a Prcedure. Cmments regarding this Prject and its use are encuraged and welcme. Please cntact ista@ista.rg. ISTA members may use either Prcedures r Prjects fr package certificatin. Prject Histry: The testing detailed in this prcedure is as per methds first develped thrugh a multi-client research prject that was established and managed by Smithers Pira. The Smithers Pira research prject examined real life supply chain cnditins and prcesses, and included a prgram f labratry validatin testing t benchmark test results against real life packaged prduct perfrmance. Smithers Pira shares these methds with ISTA in rder t supprt the packaging and testing cmmunities in assessing packaging perfrmance, and t supprt prgressin twards greater sustainability in packaged grcery prducts distributin. Smithers Pira and ISTA acknwledge the cspnsrs f the riginal Smithers Pira research prject in allwing this test methd t be published by ISTA. ISTA 3K 2011 - Page 1 f 20 2016 Internatinal Safe Transit Assciatin. All rights Reserved.
Preface Prject 3K is a general simulatin test fr fast mving packaged cnsumer prducts shipped thrugh the multiple-retail supply chain envirnment in Eurpe. Prject 3K is apprpriate fr the range f packages cmmnly merchandised thrugh large retailer stres and large retail chain cnvenience stres, and where retailer peratins include shipment f stre-specific mixed lads in rll cages r as mixed pallets. This retail envirnment is cmmn within western Eurpean cuntries, including (but nt exclusive t) Sweden, Nrway, Denmark, UK, France, Belgium, Netherlands, Germany, Austria, Switzerland, Spain and Italy; thus the scpe f this prject applies primarily t these cuntries. The scpe als applies t similarly develped Eurpean states that are nt listed but where large multiple-retail envirnment infrastructure is develped. Nte large multiple-retail envirnment infrastructure invlving shipment f mixed-lads is grwing in ther Eurpean cuntries and s this prject may als apply in thse cases. Many Eurpean grcery packages are in shelf-ready frmat; this methd applies equally t shelf ready and nn-shelf ready packages. In this prcedure the term package is used t describe a cllatin f primary packs. Cmmn package frmats that appear in the retail supply chain are presented belw t clarify the scpe f this methd (this list is nt exhaustive): Frmats Small shrink wrap tray, fr example cllatin f 6 r 12 dedrant aersls cllatin f 6 glass jars f a sauce prduct Large shrink wrap trays, fr example tray f 24 cans f a beverage prduct tray f 12 stand-up-puches f washing detergent prduct Small crrugated cases r wraps, fr example shelf ready crrugated case fr a snack prduct Large crrugated cases r wraps, fr example cllatin f 20 glass bttles f a beverage prduct tray f 12 aseptic drinks cartns Shrink wrap withut tray, fr example cllatin f 6 large bttles f mineral water cllatin f rlls f an absrbent kitchen twel prduct Bags, fr example 10kg r 20kg bag f pellet pet fd prduct Cllatin f 12 bags f flur r sugar prduct. The fllwing package type definitins are required fr selecting specific tests where test ptins are detailed: Type 1: Single hand lift/carry clsed ends Weight 4.5kg One principal dimensin 120mm N pening in the uter package materials 60 x 40mm with flexibility r space behind s at least 3 fingers culd be inserted (i.e. the package is a clsed crrugated case r cartn, r is a shrink wrap cllatin that can t be lifted by inserting the hand in t the pening in the wrap at ne end f the package). Type 2: Duble hand lift/carry clsed ends All principal dimensins 120mm / OR Weight > 4.5kg N pening in the uter package materials 60 x 40mm with flexibility r space behind s at least 3 fingers culd be inserted (i.e. the package is a clsed crrugated case r cartn, r is a shrink wrap cllatin that can t be lifted by inserting the hand in t the pening in the wrap at ne end f the package). Cntinued n next page ISTA 3K 2011 - Page 2 f 20 2015 Internatinal Safe Transit Assciatin. All rights Reserved.
Preface cntinued Cntinued frm previus page Type 3: Single hand lift/carry - pen ended Weight 7kg Opening at ne (r mre ends) 60mm x 40mm with flexibility r space behind s at least 3 fingers can be where there is sufficient space t insert the hand within an pening in the wrap) inserted fr lifting (i.e. nrmally a shrink wrap cllatin). Opening > 60mm x 40mm Type 4: Duble hand lift/carry - pen ended Weight > 7kg Opening at tw ppsing ends 60mm x 40mm with flexibility r space behind s at least 3 fingers can be inserted fr lifting (i.e. nrmally a shrink wrap cllatin where there is sufficient space t insert at least 3 fingers within an pening in the wrap at either end f the package). Opening > 60mm x 40mm NOTE: Within this prcedure the term sample is als used as a cmmn descriptin fr the varius types f packages described abve (i.e. ne sample is the same as ne package, cnsisting f a number f primary packs in a cllatin). General Testing can be used t evaluate the fitness fr purpse f a packaged-prduct r the prtective perfrmance f packaging with respect t the cmmn hazards f the Eurpean retail supply chain. Tests and test levels are based n bservatin f varius brand wner and retailer distributin and in-stre systems, and crrelatin between specific damage ccurrences bserved in the field and damage prduced using labratry testing during a validatin exercise; hwever the test may nt represent any specific distributin system. The package and prduct are cnsidered tgether and nt separately. Sme cnditins f transit, such as misture, pressure, careless handling r unusual handling may nt be cvered. Other ISTA Prcedures r Prjects may be apprpriate fr different cnditins r t meet different bjectives. Refer t Guidelines fr Selecting and Using ISTA Test Prcedures and Prjects fr additinal infrmatin. NOTE: Hazardus material packaging that passes this test prcedure may nt meet internatinal, natinal r ther regulatry requirements fr the transprt f dangerus gds r hazardus materials. This test is nt a substitute fr United Natins and/r any ther required test standards fr the transprt f dangerus gds r hazardus materials, but may be used as an additinal test in cnjunctin with them. ISTA 3K 2011 - Page 3 f 20 2015 Internatinal Safe Transit Assciatin. All rights Reserved.
Scpe Prject 3K cvers the testing f packaged-prducts prepared fr sale thrugh multiple-retail envirnments. Frm the pint f manufacture f finished packaged gds, this supply chain cmmnly invlves unit lad (full pallet) strage, unit lad shipment and unit lad handling within the brand wner cntrlled part f the supply chain, leading t delivery f unit lads f prduct t a retailer distributin centre. This is cmmnly fllwed by a series f steps cntrlled by the retailer, invlving rder picking and mixed lad building at the retailer distributin centre, mixed lad delivery t stre and in-stre handling leading t lading f packagedprducts n t the stre shelf. This test methd relates nly t the retailer cntrlled parts f this supply chain. Separate testing shuld be undertaken at the unit lad level t determine fitness with respect t full pallet shipment cmmnly cntrlled by the brand wner. Research shws that the hazards f distributin are cmmnly mre severe in the retailer cntrlled parts f the supply chain (largely due t the cmplex prduct mix); hwever successful perfrmance in this test methd des nt eliminate the need fr evaluating packaged-prduct perfrmance at the unit lad level. Specifically the test investigates the fllwing prcesses ccurring at the package (case r tray) level: Pyramid-pick/Overhang stack (representing the way a package is ften partially supprted n the unit lad at the pick face at retailer distributin centre, ccurring as a result f the way ther packages are selected frm the unit lad) Drag (representing pulling f a package frm a unit lad at the pick face at retailer distributin centre) Carry (rep resenting lifting and carrying f a package ver shrt distance frm the pick face t the mixed lad, including, as apprpriate t the pack design/frmat, carrying packs withut supprting the base and carrying using penings in shrink wrap) Placement-drp and Drp n impact (representing impacts ccurring t packages during building f the mixed lad) hrizntal impacts (representing impacts ccurring thrugh autmated cnveyr peratins at autmated retailer distributin centres) - where it is knwn r pssible that packages will pass thrugh a retailer distributin centre with cnveyring/package level autmated systems this test shuld be cnducted. Specifically the test investigates the fllwing prcesses ccurring fr mixed lads (mixed pallets r rll cages): Bth mixed pallet and mixed rll cages are cmmnly used in retailer distributin in Eurpe. Based n bservatin it is deemed that rll cage mixed lads experience mre significant hazards because packs are able t press against the rll cage sidewalls as well as ther packs (ther than this, mixed lad hazards are similar between the mixed lad pallet and mixed lad rll cage frmats); the presence f sidewalls prvides a hrizntal lad n packs that is less significant in mixed pallets. Because bth mixed pallet and rll cage frmats are used widely, the wrst case f the tw frmats was selected fr the test. Hrizntal impact f mixed lad (representing hrizntal cage t cage (r mixed pallet t mixed pallet) impacts, r impacts between a mixed lad and ther fixed bject, ccurring during vehicle lading, rad jurney and handling at stre) Vibratin f mixed lad (representing the rad jurney segment f the mixed lad life cycle, but als representing mre aggressive vibratin ccurring during lading/unlading where mixed lads are mved ver chequer-plate ramps r rugh surfaces within receiving bay areas, nrmally at the stre) Vertical impact f mixed lad (representing higher level transient shcks ccurring during rad shipment and vertical shcks ccurring during marshalling/mvement f mixed lads ver rugh surfaces r ver dr threshlds, nrmally at the stre). Prduct Damage Tlerance and Degradatin Allwance The shipper shall determine the fllwing prir t testing: what cnstitutes damage t the prduct and what damage tlerance level is allwable, if any, and the crrect methdlgy t determine prduct cnditin at the cnclusin f the test and acceptable package cnditin at the cnclusin f the test. Fr additinal infrmatin n these determinatins refer t Guidelines fr Selecting and Using ISTA Test Prcedures and Prjects. ISTA 3K 2011 - Page 4 f 20 2015 Internatinal Safe Transit Assciatin. All rights Reserved.
Samples Samples shuld be untested actual package and prduct, but if ne r bth are nt available, the substitutes shall be as representative as pssible t actual items. Multiple test samples are required, but they shuld be identical. The exact number is dependent n the size f the sample. T prvide an indicatin f the ttal number f samples needed fr testing, establish the number f samples required t build a stack measuring at least 0.8m x 0.8m x 1.6m withut significant gaps in the stack. Take this number and multiply it by 2; the resultant prvides a guide t the ttal number f samples required. Fr example fr a sample measuring 0.4m x 0.4m x 0.2m, 16 samples wuld be required t build the stack described abve, s a ttal f 32 samples wuld be required fr testing. Fr this prcedure the samples are classified and utilized in three (3) ways: Test packages are used frm the start thrugh t the end f testing; when multiple identical test packages are tested, all test packages must pass all tests. Dummy packages are used in varius parts f the prcedure t allw effective simulatin f the real life hazard in the test (s that the real life hazard is crrectly applied t the test package). Specifically, dummy packages are used in Test Blcks 1, 2, 3, 6 and 13. If a dummy package becmes degraded t the pint that it des nt maintain its shape r prvide resistance t test packages it shuld be replaced with anther dummy package, but dummy packages are nt subject t inspectin r pass/fail assessment as part f the test. Nte: dummy packages are different frm Rll Cage Fill packages described belw. Rll Cage Fill packages are used nly in Test Blcks 8, 9 and 10 t enable building f the mixed lad in the rll cage arund the test packages. Dummy packages used during Test Blcks 1-6 shuld nt be used as Rll Cage Fill packages fr Test Blcks 8, 9 and 10. Upn cmpletin f Test Blck 10 Rll Cage Fill packages are set aside fr later assessment (and pass/fail judgment), s shuld nt be used as Dummy packages in Test Blcks 11-13. T enable effective tracing f samples thrughut the prcedure, Test package samples shuld be identified with TP, Dummy package samples as DP and Rll Cage Fill package samples with RCF. The exact number f each classificatin will vary depending n the size and type/frmat f package, s this identificatin is t be applied t each pack during testing at the pint where a Test package, Dummy package r Rll Cage Fill package is required accrding t the details in the Test Blck. Refer t Guidelines fr Selecting and Using ISTA Test Prcedures and Prjects fr additinal infrmatin n statistical sampling. NOTE: In rder t ensure testing in perfect cnditin, prducts and packages shipped t an ISTA Certified Labratry fr testing shall be: Adequately ver-packaged fr shipment r Repackaged in new packaging at the labratry. NOTE: It is imprtant t thrughly dcument the cnfiguratin, materials, and cnstructin f the tested prduct and package. Significant variatins in perfrmance can smetimes be caused by seemingly insignificant differences. Pht dcumentatin is strngly recmmended t supplement detailed written descriptins. Basis Weight Basis Weights f Crrugated Bard When the uter package is a crrugated bx, it is strngly recmmended that the basis weights f the papers/paperbards used t make the bx be determined and dcumented. If the nminal basis weights change, even if the bard is rated fr the same perfrmance, a retest is apprpriate. Refer t Guidelines fr Selecting and Using ISTA Prcedures and Prjects fr additinal infrmatin n dcumentatin and basis weight determinatin. ISTA 3K 2011 - Page 5 f 20 2015 Internatinal Safe Transit Assciatin. All rights Reserved.
Test Sequence Test sample selectin and sample flw thrugh the test sequence are detailed within the TESTING part f this PROJECT Frmat Test Categry Test Type Test Level Fr ISTA Certificatin Atmspheric Precnditining TEST BLOCK 1 Temperature and Humidity Ambient, frzen r chilled (t be selected as apprpriate fr the distributin and merchandising channel fr the packaged prduct being tested) Picking TEST BLOCK 2 Pyramid Pick (Overhang stack) 5 minute test duratin Picking TEST BLOCK 3 Drag 900mm drag distance at 1.0 m/s Picking TEST BLOCK 4 Carry 10 secnds static plus 5 cycles carry-scillatin Shck TEST BLOCK 5 Placement drp 5 impacts in varius rientatins, 150mm Shck TEST BLOCK 6 Drp-n Impacting tp f lwer package, base f upper package, 150mm Mixed lad Shck (OPTIONAL) TEST BLOCK 7 Shck TEST BLOCK 8 Impact 8 impacts at 1.35m/s Optinal Impact 4 impacts at 0.91m/s Mixed lad Vibratin TEST BLOCK 9 Randm Vibratin Overall Grms level f 0.28 fr 40 minutes fllwed by 0.517 fr 60 secnds Mixed lad Shck TEST BLOCK 10 Flat drp 1 drp frm 60mm Shck TEST BLOCK 11 Placement drp 4 impacts in varius rientatins, 150mm Shck (INVESTIGATIVE) TEST BLOCK 12 Drp 4 impacts in varius rientatins, 300mm Advised (Optinal)* Shck (INVESTIGATIVE) TEST BLOCK 13 Drp-n Impacting tp f lwer package, base f upper package, 300mm Advised (Optinal)* Assessment Assessment BLOCK 14 N testing invlved Inspectin and assessment f test and rll cage fill packages * In certain situatins, the 300mm drp r drp-n test may nt be apprpriate. 300mm drps represent 'wrst f nrmal' handling and shuld be cnducted t investigate the perfrmance f packages under mre severe (but still within the range f nrmal) cnditins; nt every package will experience free fall impact frm 300mm, but a small quantity f packages will be expsed t this level f hazard such that its effect shuld be investigated. If the drps are NOT perfrmed, this shuld be shwn in the test reprt. ISTA 3K 2011 - Page 6 f 20 2015 Internatinal Safe Transit Assciatin. All rights Reserved.
Atmspheric Cnditining EQUIPMENT REQUIRED FOR PROJECT 3K Atmspheric Cnditining: Humidity recrder cmplying with f the apparatus sectin f ISO 2233 r ASTM D 4332. Temperature recrder cmplying with the apparatus sectin f ISO 2233 r ASTM D 4332. Chamber and Cntrl apparatus cmplying with the apparatus sectin f ISO 2233 r ASTM D 4332. Shck Type f Shck Test Free-Fall Drp Tests Type f Frk-type free-fall drp tester In cmpliance with the apparatus sectins f ISO 2248 r ASTM D 5276 Cmments If available, use this drp apparatus as the preferred ptin fr all package drp tests (frm 150mm and 300mm) and fr the 60mm mixed lad drp test. Sme drp tester designs d nt allw fr drps as lw as 150mm r 60mm in this case use alternative apparatus described belw. Free-Fall Drp Tests (Alternate) Drp by hand using a reference measure t maximise repeatability f drp height N/A Preferred alternative ptin fr 150mm package drp tests Free-Fall Drp Tests (Alternate) Slings and Quick-Release mechanism X ISO 2248 r ASTM D 5276 Preferred alternative ptin fr 60mm mixed lad drp test Impact Tests Incline ISO 2244 r ASTM D 880 r ASTM D 4003 Hrizntal Vibratin Mixed Lad Randm Vibratin: Vertical Randm Vibratin Test System cmplying with the apparatus sectin f ISO 13355 r ASTM D 4728. Means must be prvided t prevent the test item frm mving ff the vibratin system s platfrm, withut restricting the vertical mtin f the test item. Mixed Lad: A fur wheeled metal rll-cage measuring apprximately 800mm X 700mm in the hrizntal axes and 1800mm in height (frm the underside f the wheels t the tp f the metal cage). A mid-shelf in the rll cage may be required see bttm f page 11 fr further details. Cage t have three fixed sides and ne pen side, plus tw elastic r fabric straps t cntain prduct n the pen side face. ISTA 3K 2011 - Page 7 f 20 2015 Internatinal Safe Transit Assciatin. All rights Reserved.
Picking Type f /Carry EQUIPMENT REQUIRED FOR PROJECT 3K Type f Drawing/Detail Cmments Picking Drag Wedge A wedge apprximately 70 mm wide, 150mm lng, with ne end 2 mm high and the ther end 20 mm high. Ensures the frnt edge f tp package is supprted by the test package Single hand lift/carry packages (Type 3 package, as defined in the Preface) One single-dummy hand required Dimensins = mm It is mst suitable t cnstruct this dummy hand in mild r stainless steel. T undertake the scillatin part f the lift/carry tests using the single dummy hand, secure the single hand t a rigid frame r assembly (described belw in Fr the scillatry part f the carry test. Drill a hle at the tp f the single dummy hand t enable the dummy hand t be hung freely n the rigid frame/assembly. Duble hand lift/carry packages (Type 4 package, as defined in the Preface) A pair f duble-dummy hands required Dimensins = mm It is mst suitable t cnstruct this dummy hand in hardwd timber r in aluminium r stainless steel. T undertake the scillatin part f the lift/carry tests using the duble dummy hands, secure the dummy hands t a rigid frame r assembly (described belw in Fr the scillatry part f the carry test ). Drill a hle at the tp f each dummy hand t enable the dummy hand t be hung freely n the rigid frame/assembly. Fr the scillatry part f the carry test Oscillatin may be effected using a vibratin table with fixed frequency sinusidal cntrl, and with the package supprted n a rigid frame r assembly such that the test item hangs clear f the table platfrm during the test. The rigid frame/assembly can be f any cnstructin as lng as there is n flex in the cnstructin as a result f the scillatin during test, and as lng as the frame and vibratin table platfrm d nt interfere with the test package during scillatin. Cmplying with the apparatus sectin f ISO 13355 r ASTM D 4728 wuld be suitable ther smaller scale sinusidal scillatin prducing apparatus may als be suitable Will require displacement and frequency t achieve peak acceleratin f 0.2g, delivered with peak t peak displacement f n less than 40mm and n mre than 80 mm (crrespnds t frequency n mre than 1.6Hz and n less than 1.1Hz) ISTA 3K 2011 - Page 8 f 20 2015 Internatinal Safe Transit Assciatin. All rights Reserved.