ISTA P3A Distribution Simulation Test Report APTCO, LLC S1 · 2013. 8. 21. · ISTA P3A...

www.testedandproven.com

ISTA P3A

Distribution Simulation Test Report for the

APTCO, LLC S1

Report Number: R1306156-03-00

PO Number: 48592

21 August 2013

Client: APTCO, LLC

Contact: Scott Hakl

31318 Pond Road # 2

McFarland, CA 93250

Test Performed by:

DDL, West

17371 Mt. Wynne Circle, Suite A Fountain Valley, CA 92708

tel: 714.979.1712 | 800.229.4235 fax: 714.979.1721

DDL, Inc.

10200 Valley View Road, Suite 101 Eden Prairie, MN 55344

tel: 952.941.9226 | 800.229.4235 fax: 952.941.9318

Report No. R1306156-03-00 Customer: APTCO, LLC Page 1 of 17

DDL, Inc. ▪ 10200 Valley View Road, Suite 101 ▪ Eden Prairie, MN 55344 ▪ Tel: 952-941-9226 ▪ Fax: 952-941-9318

DDL West ▪ 17371 Mount Wynne Circle, Suite A ▪ Fountain Valley, CA 92708 ▪ Tel: 714-979-1712 ▪ Fax: 714-979-1721

TABLE OF CONTENTS

Revision Record .................................................................................................. 2

Introduction ......................................................................................................... 2

Objective .................................................................................................................................... 2 Scope ......................................................................................................................................... 2

Summary of Tested Specimens ......................................................................... 2

Packaging System .............................................................................................. 3

Protective Package .................................................................................................................... 3 Shipping Units ..................................................................................................................... 3

Product ................................................................................................................ 4

Results Summary ................................................................................................ 4

Acceptance Criteria ................................................................................................................... 4 Environmental Pre-Conditioning ................................................................................................ 4 Distribution Simulation Testing .................................................................................................. 4 Visual Inspection ........................................................................................................................ 5

Related Documents ............................................................................................. 6

Logistics .............................................................................................................. 6

Equipment/Materials ........................................................................................... 7

Test Procedure .................................................................................................... 7

Environmental Pre-Conditioning ................................................................................................ 7 ISTA Procedure 3A Distribution/Shipping Simulation (Stress Tests) ........................................ 7

Drop Test (1st Sequence) .................................................................................................... 8

Vibration Test ...................................................................................................................... 9 Drop Test (2

nd Sequence) ................................................................................................. 12

Visual Inspection ...................................................................................................................... 13

Disclaimer of Warranties .................................................................................. 13

Statement of Conformity .................................................................................. 14

Appendix A: Pre-Conditioning Data ................................................................ 15

Appendix B: Distribution Simulation Data ...................................................... 16

Appendix C: Visual Inspection Data ................................................................ 17




REVISION RECORD

Report Revision Date Author Description of Change

R1306156-03-00 21-Aug-13 Long Pham Initial Release

Table 1: Revision Record

INTRODUCTION

Objective The objective of this project was to perform testing on the S1 package designs for APTCO, LLC as stated in DDL, Inc. quote number Q1306156-02.

Scope This report documents distribution simulation and visual inspection on DDL, Inc. specimen numbers 244034 - 244035. Testing was done under controlled laboratory conditions with equipment qualified to perform these tests.

SUMMARY OF TESTED SPECIMENS

Specimen Numbers Quantity Tested Testing Performed

244034-244035

2 Shippers Environmental Preconditioning

2 Shippers Distribution Simulation (ISTA P3A) – Post

Environmental Preconditioning

2 Shippers Visual Inspection – Post Environmental Preconditioning / Distribution Simulation

Table 2: Summary of Tested Specimens




PACKAGING SYSTEM

Protective Package

Shipping Units

The shipping units consisted of corrugated containers. Specimen 244034 was a brown corrugated shipper with 29 ECT that contained two EPS foam pieces with 12 wine bottles. Specimen 244035 was a white corrugated shipper with 200 psi Mullen burst that contained two EPS foam pieces and 12 wine bottles. The approximate weights and outside dimensions were as follows:

Specimen Numbers

Weight (lbs.)

Length (in.) Width (in.) Height (in.) Corrugated Type

244034 39.84 17.50 14.50 13.25 Single Wall 29 ECT

244035 39.98 17.50 14.50 13.25 Single Wall 200 psi

Table 3: Shipping Unit Description

Figure 1: The S1 Shipping Unit, Brown (Foam Post Distribution Testing)

Figure 2: The S1 Shipping Unit, White, (Foam Post Distribution Testing)




PRODUCT

S1

RESULTS SUMMARY

Acceptance Criteria APTCO, LLC personnel are responsible for determining the acceptance criteria for the package and product.

Environmental Pre-Conditioning Atmospheric preconditioning was performed on specimens 244034 - 244035 per ISTA P3A (2008) prior to distribution simulation. The following table describes the conditions and durations for environmental conditioning:

Test Interval Specimen Numbers Condition Duration (hrs.)

Preconditioning 244034-244035 Laboratory Ambient 12 (Minimum)

Table 4: Atmospheric Pre-Conditioning Cycle

The data for the environmental conditioning is located in Appendix A of this test report.

Distribution Simulation Testing Distribution simulation testing was performed on two shippers per ISTA P3A (2008). The distribution simulation cycle is outlined in the table below:

Test Interval Specimen Numbers

Condition

Post Atmospheric Pre-Conditioning

244034-244035 Test Block 1, 3, 4, 7, & 9

Table 5: Distribution Simulation Cycle Summary

Upon completion of the distribution simulation testing some minor damage was observed on the shippers, such as scuffing and creasing. This type of damage is common within the distribution environment and may not be considered a critical defect.

The data for the distribution simulation testing is located in Appendix B of this test report.




Visual Inspection Visual inspection on two shippers and their contents was performed per APTCO, LLC specifications. The results are shown below:

Test Interval Specimen Numbers

Number of Samples Inspected

Observation

Post Pre-Conditioning / Distribution Simulation

244034

1 Shipper & Foam Insert

8 Dented Corners and 3 Dented Edges Observed on Shipper; 13 Cracks on Top and 5 Cracks on

Bottom Observed on Foam Insert

12 Bottles No Observations

244035

1 Shipper & Foam Insert

4 Dented Corners Observed on Shipper; 16 Cracks on Top and 5 Cracks on Bottom Observed on

Foam Insert

12 Bottles No Observations

Table 6: Seal Integrity Visual Inspection Results

The data for the visual inspection is located in Appendix C of this test report.

Figure 3: The S1 Shipping Unit, Brown (Foam Post Distribution Testing)

Figure 4: The S1 Shipping Unit, White, (Foam Post Distribution Testing)




RELATED DOCUMENTS

Standards

ISTA P3A (2008); Packaged-Products for Parcel Delivery System Shipment 150 lb. or Less

References

DDL, Inc. Quote # Q1306156-02

DDL, Inc. Amendment # DC130504

DDL, Inc. S.O.P. # 2006-12: Environmental Chamber Test Activities

DDL, Inc. S.O.P. # 6011-08: Distribution Simulation Tests

DDL, Inc. S.O.P. # 6024-03: Inspection of Customer Materials

Table 7: Standards and References

LOGISTICS

Specimens 244034 - 244035 were received on 12 August 2013.

Lab Ambient Pre Conditioning (Pre-Distribution):

Started: 12 August 2013

Completed: 13 August 2013

Distribution Simulation Testing:



Visual Inspection:



Specimens 244034 - 244035 are retained at DDL, Inc. at the time of this test report.




EQUIPMENT/MATERIALS

The following equipment was used to complete these tests:

Equipment Name (Gage ID) Asset No. Calibration Due

Shipping Digital Scale 001368 22-Jul-14

L.A.B. Accudrop 160 Drop Tester 001304

Height verified with Scale 48 Inch 001478

Scale 48 Inch 001478 12-Dec-14

L.A.B. Vibration Test System 001483 11-Dec-13

Equipment Name (Gage ID) Serial No. Calibration Due

ATP-Mirador Logger (95) TH000011FE 2-Oct-13

Table 8: Equipment/Materials List

TEST PROCEDURE

Environmental Pre-Conditioning Atmospheric pre-conditioning was performed on specimens 244034 - 244035, pre-distribution, per ISTA P3A (2008) and DDL, Inc. S.O.P. number 2006-12. The test conditions were as follows:

Laboratory ambient for 12 hours minimum

A summary of the environmental conditioning is presented in the results portion of this test report and the data is located in Appendix A.

ISTA Procedure 3A Distribution/Shipping Simulation (Stress Tests) Distribution simulation testing was performed per ISTA P3A (2008) and DDL, Inc. S.O.P. number 6011-08. The packaged product, as described previously, was subjected to the following schedules.

Each schedule is described in the order that it was performed during the test. A summary of the distribution simulation testing is presented in the results portion of this test report and the data is located in Appendix B.




Drop Test (1st Sequence)

The test levels and method for this schedule of the distribution cycle were intended to determine the ability of the shipping units to withstand the hazards occurring during manual handling such as loading, unloading, stacking, sorting, or palletizing. The main hazards from these operations were the impacts caused by dropping or throwing. Size, weight, and shape of the shipping units will affect the intensity of these hazards.

The drop heights, the number of drops and the shipping units’ orientations at impact performed on the packages are presented in the table below.

Drop Height Orientation

18 inches 3-4 Edge

3-6 Edge

4-6 Edge

3-4-6 Corner

2-3-5 Corner

2-3 Edge

1-2 Edge

36 inches Face 3 Bottom


Table 9: Test Method ISTA P3A First Drop Sequence.

This procedure was performed using a drop tester.

Figure 5: The Drop Test Set-up.




Vibration Test

The test levels and method for this schedule of the distribution environment were intended to determine the ability of the shipping units to withstand the compressive loads that occur during vehicle vibration. The required loading must consider, in addition to the overload, the effects of length of time in storage, vibration, the alignment or stacking pattern of the container, variability in container strength, moisture content, temperature, previous handling, and method of load support. To satisfy the stacked portion of the schedule, the shippers had the following load applied to it in each of the orientations stated in the table below.

Dwell Time Orientation Load Applied lbs. (Rounded)

60 minutes Face 3 Bottom 85

30 minutes Face 4 Side 80

30 minuets Face 6 End 65

Table 10: Test Method ISTA P3A Vibration Test Dwell Time

TL = (108-13.25) x 17.50 x 14.50 x 0.0035 = 85 lbs.

108 stack height in. 17.50 l = length of one package in.

14.50 w = width of one package in. 13.25 h = height of one package in.

0.0035 Constant

Table 11: ISTA P3A Top Load Calculation for Face 3.

TL = (108-14.50) x 17.50 x 13.25 x 0.0035 = 76 lbs.



0.0035 Constant


TL = (108-17.50) x 14.50 x 13.25 x 0.0035 = 61 lbs.



0.0035 constant





Vibration under Dynamic Load (Over-The-Road Trailer Simulation)

Overall acceleration levels were 0.53 grms with a total test duration of two hours. The packages were constrained but not secured to the table for this element of the test. The table below denotes the PSD level for Over-The-Road Trailer Simulation.

Frequency (Hz) PSD (g2/Hz) Frequency (Hz) PSD (g

2/Hz)

1 0.0007 24 0.004

3 0.02 28 0.001

5 0.02 36 0.001

7 0.001 42 0.003

12 0.001 75 0.003

15 0.004 200 0.000004

Over-all grms: 0.53

Duration: 120 minutes (60 minutes Face 3, 30 minutes Face 4, 30 minutes Face 6)

Table 14: ISTA P3A Frequency Power Spectral Density Level Over-The Road Trailer Simulation.

This procedure was performed using a vertical linear vibration test system.

Figure 6: Vibration Under Dynamic Load Set-up.




Random Vibration (Pick-Up and Delivery Vehicle Simulation)

Overall acceleration levels were 0.46 grms with a total test duration of thirty minutes. The packages were constrained but not secured to the table for this element of the test. The table below denotes the PDS level for Pick-Up and Delivery Vehicle Simulation.

Frequency (Hz) PSD (g2/Hz) Frequency (Hz) PSD (g

2/Hz)

1 0.001 24 0.001

3 0.035 29 0.0001

4 0.035 50 0.0001

7 0.0003 70 0.002

13 0.0003 100 0.002

15 0.001 200 0.00005

Over-all grms: 0.46

Duration: 30 minutes, Face 3

Table 15: ISTA P3A Frequency Power Spectral Density Level Pick-Up and Delivery Vehicle Simulation.

This procedure was performed using a vertical linear vibration test system.

Figure 7: Vibration without Top Load Set-up.




Drop Test (2nd Sequence)

This test schedule has been described previously and was repeated on the test specimens.

The drop heights, the number of drops and the shipping units’ orientations at impact performed on the packages is presented below in the table below.

Drop Height Orientation

18 inches 3-4 Edge

3-6 Edge

1-5 Edge

3-4-6 Corner

1-2-6 Corner

1-4-5 Corner


18 inches Face 3 Bottom on Hazard

Table 16: Test Method ISTA P3A Second Drop Sequence.

This procedure was performed using a drop tester.

Figure 8: Drop Test Set-up (18” Bottom on Hazard).




Visual Inspection Visual inspection was performed per APTCO, LLC specifications and DDL, Inc. S.O.P. number 6024-03.

The shipper and foam inserts were inspected for the following:

Gross damage to shipper and foam inserts.

The wine bottles were inspected for the following:

Note rubbing or water damage on bottle labels and broken bottles.

A summary of the visual inspection is presented in the results portion of this test report and the data is located in Appendix C.

DISCLAIMER OF WARRANTIES

ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY THAT THE PRODUCT OR PACKAGING TESTED IS MERCHANTABLE, FIT FOR A PARTICULAR PURPOSE, OR IN COMPLIANCE WITH ANY FEDERAL, STATE OR LOCAL REGULATIONS, ARE DISCLAIMED. In no event shall DDL, Inc. liability exceed the total amount paid by APTCO, LLC for services rendered.

A Quality Assurance program should be in place to ensure that the manufacturing process produces products/packages of equivalent performance to those tested here. This is solely the responsibility of the manufacturer. DDL, Inc. takes no responsibility for the quality of products/packages produced hereafter, other than to certify the design of those physical test systems actually tested by DDL, Inc. DDL, Inc. takes no responsibility for the use, acceptance or non-acceptance of this data by government regulatory agencies.

In the event of future changes to the referenced test procedure(s), it is the responsibility of APTCO, LLC to determine whether additional testing is necessary to verify that the product and/or packaging certified here remains in compliance with requirements.




STATEMENT OF CONFORMITY

DDL, Inc. has completed the above stated testing services performed in accordance to applicable standard good laboratory practices and/or standards identified within this report. Testing has been completed as described herein.

The following list of exceptions occurred during testing performed at DDL, Inc.:

None

All materials, equipment, methods, and processes used to perform the described testing have been standardized, calibrated, and monitored in accordance with prescribed guidelines, standard operating procedures, and the supervision requirements of DDL, Inc. All raw data obtained from this testing by DDL, Inc. personnel is archived at DDL, Inc.

The signatures below are in compliance with 21 CFR Part 11.

Testing performed by: Larry E. Wilson & Long Pham

Project Manager:

Long Pham

Project Manager

Technical Approval:

John R. Koch

Lab Manager

Quality Approval:

Tammy J. Nelson

Quality Specialist




APPENDIX A: PRE-CONDITIONING DATA

http://ddl-115/...C%2FTABLE%3E&btn_submit=%3CTABLE+cellSpacing%3D0+cellPadding%3D2+width%3D%22100%25%22%3E%0D%0A%3CTBODY%3E%0D%0A%3CTR%3E%0D%0A%3CTD+align%3Dright%3E%3CIM[8/13/2013 10:33:56 AM]




APPENDIX B: DISTRIBUTION SIMULATION DATA

2001 10 100

-61x10

-51x10

-41x10

-31x10

-21x10

Frequency (Hz)

Acc

eler

atio

n (G

²/Hz)

Acceleration Profile

Demand

Control

Aug 13, 2013 12:36:25

Demand: 0.5285 G RMS

Control: 0.534 G RMS

Level 1) 100 %

Level Time: 1:00:00

Total Time: 1:00:53

Output: 0 Vrms

Ch1=0.001422 G RMS

End of Test

ISTA 3A (Stacked)

APTCO- 1306156

Spec. #244034- 244035 (Face 3)

2001 10 100

-61x10

-51x10

-41x10

-31x10

-21x10

Frequency (Hz)

Acc

eler

atio

n (G

²/Hz)


Demand

Control

Aug 13, 2013 15:28:08



Level 1) 100 %

Level Time: 0:30:00

Total Time: 0:30:49

Output: 0 Vrms

Ch1=0.01726 G RMS

End of Test

ISTA 3A (Stacked)

APTCO- 1306156

Spec. #244034- 244035 (Face 4)

2001 10 100

-61x10

-51x10

-41x10

-31x10

-21x10

Frequency (Hz)

Acc

eler

atio

n (G

²/Hz)


Demand

Control

Aug 14, 2013 09:45:07



Level 1) 100 %

Level Time: 0:30:00

Total Time: 0:30:53

Output: 0 Vrms

Ch1=0.02806 G RMS

End of Test

ISTA 3A (Stacked)

APTCO- 1306156

Spec. #244034- 244035 (Face 6)

2001 10 100-51x10

-41x10

-31x10

-21x10

-11x10

Frequency (Hz)

Acc

eler

atio

n (G

²/Hz)


Demand

Control

Aug 14, 2013 10:27:53



Level 1) 100 %

Level Time: 0:30:00

Total Time: 0:30:50

Output: 0 Vrms

Ch1=0.0221 G RMS

End of Test

ISTA 3A (Nonstacked)

APTCO- 1306156

Spec. #244034- 244035 (Face 3)




APPENDIX C: VISUAL INSPECTION DATA

www.testedandproven.com

Vision Statement DDL will become the preferred worldwide supplier of professional services in its chosen

areas of product, package and material testing, design and consulting.

Mission Statement To continually strive to exceed our customer satisfaction by providing accurate data,

attention to detail and quick turn-around times by using DDL's quality system, responsive project management and exceptional customer service.

DDL, West

17371 Mt. Wynne Circle, Suite A Fountain Valley, CA 92708

tel: 714.979.1712 | 800.229.4235 fax: 714.979.1721

DDL, Inc.

10200 Valley View Road, Suite 101 Eden Prairie, MN 55344

tel: 952.941.9226 | 800.229.4235 fax: 952.941.9318

ISTA P3A Distribution Simulation Test Report APTCO, LLC S1 · 2013. 8. 21. · ISTA P3A...

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