How To Conduct A Drop Test On Packaging: A Complete Guide by Pacorr

Pacorr is a trusted name in the testing instruments industry, known for providing high-performance equipment such as the Drop Tester, Drop Test Machine, and Package Drop Tester. These instruments are essential for ensuring the durability and strength of packaging materials during handling and transportation. Packaging is the first line of defense for a product, and any failure in this protective barrier can result in damage, customer dissatisfaction, and financial loss. That is why conducting a drop test is a critical quality control step for manufacturers, especially in e-commerce, logistics, food, electronics, and pharmaceutical sectors.

This detailed blog will walk you through everything you need to know about conducting a drop test on packaging using professional equipment like Pacorr’s Drop Test Machines, ensuring you meet industry standards and improve your product's transit reliability.

What is a Drop Test in Packaging?

A drop test is a controlled method used to evaluate how a packaging system reacts to impact during free fall. The primary goal is to assess whether the packaging can protect its contents when dropped from a certain height and angle. This test simulates real-world conditions such as accidental drops during loading, unloading, or while in transit.

Using a Drop Tester such as Pacorr’s high-precision machine allows manufacturers to identify weaknesses in packaging design, material quality, and sealing methods. The results help in improving structural integrity and reducing the risk of damage.

Why is Drop Testing Important?

1. Product Protection: Ensures that the packaging can safeguard the product from breakage or malfunction during transit.
2. Compliance with Standards: Meets industry requirements like ISTA, ASTM, ISO, and other global packaging protocols.
3. Customer Satisfaction: Minimizes returns and complaints due to damaged goods.
4. Cost Efficiency: Reduces losses due to product replacement and reshipping.
5. Brand Reputation: Shows commitment to quality and reliability in product delivery.

Types of Drop Tests for Packaging

There are several types of drop tests, depending on the testing objective:

• Free Fall Drop Test: The package is dropped from a fixed height to evaluate overall impact resistance.
• Edge Drop Test: The package is dropped on its edge to check structural endurance.
• Corner Drop Test: Focuses on the corners, which are typically vulnerable to impact.
• Flat Drop Test: The package lands flat on its base, simulating falls during stacking or carrying.
• Rotational Drop Test: Simulates how a package may flip during transit and fall at an angle.

Pacorr’s Package Drop Tester is designed to perform all of these variations with adjustable height settings and a reliable drop mechanism for accurate and repeatable results.

How to Conduct a Drop Test on Packaging Step-by-Step

Let us now walk through the complete process of conducting a packaging drop test using Pacorr’s Drop Test Machine.

Step 1: Choose the Right Drop Tester

Select a Drop Testing Machine suitable for the weight, size, and type of your product packaging. Pacorr offers models with single and dual-column configurations depending on the application.

Step 2: Prepare the Test Sample

Ensure the package is prepared as it would be for actual shipping. This includes the final product, inner cushioning, external box, sealing, and labels. Consistency is key.

Step 3: Set the Drop Height

Determine the drop height based on your shipping environment or compliance standards. Common heights range between 76 cm to 122 cm for retail packaging, and up to 1.5 meters for rugged industrial packages.

Use the drop height adjustment scale provided in Pacorr’s Drop Tester to set the exact fall distance.

Step 4: Position the Package

Using the platform arms of the Drop Tester, align the package so that the intended part (flat side, edge, or corner) is facing downwards. Ensure the placement is precise for repeatable testing.

Step 5: Perform the Drop

Activate the drop mechanism. Pacorr’s machine ensures a free-fall release without any vibration or force interference, giving you an authentic simulation of accidental drops.

Step 6: Inspect the Results

After the drop, visually inspect the package and the product inside. Record any signs of:

• Surface dents or tears
• Crushed corners or edges
• Seal breakage
• Internal product displacement or damage

You may also weigh or photograph the damaged areas for documentation.

Step 7: Repeat with Variations

Conduct drops from different angles – flat base, edge, and corners. Each position reveals a unique stress point in the packaging system. Multiple tests improve reliability and statistical accuracy.

International Standards for Drop Testing

Drop tests are often conducted in accordance with several industry standards:

• ASTM D5276: Standard for drop testing of loaded containers
• ISTA 1A and 2A: Test procedures for packaged-products weighing 150 lb (68 kg) or less
• ISO 2248: International standard for impact testing during free fall
• MIL-STD-810H: Military-grade packaging and transit shock evaluation

Pacorr’s Drop Testing Equipment is designed to comply with these international protocols, allowing businesses to maintain global shipment quality.

Best Practices for Effective Drop Testing

• Always calibrate the Drop Tester before usage
• Test multiple samples for statistical consistency
• Document every result with photos and notes
• Integrate drop testing into your packaging development cycle
• Use data to revise material choice or box design

Applications of Drop Test Machines

Industries that benefit greatly from drop testing include:

• E-commerce and Logistics: Ensuring product safety during doorstep delivery
• Electronics: Preventing fragile components from cracking
• Pharmaceuticals: Maintaining integrity of medical products
• Food & Beverages: Avoiding leakage, spoilage, or deformation
• Automotive Parts: Ensuring mechanical parts arrive in perfect condition

Pacorr’s Drop Test Machine is widely used in all these sectors, offering unmatched precision, durability, and control.

Advantages of Using Pacorr Drop Tester

1. Adjustable Height for Custom Testing
2. Versatile for Different Package Sizes
3. Accurate Drop Mechanism
4. User-Friendly Design
5. Compliance with Global Standards
6. Durable Frame for Long-Term Use
7. Available in Manual and Automated Models

Conclusion

Conducting a drop test on packaging is more than a compliance task—it is a critical investment in customer satisfaction, product integrity, and brand trust. Pacorr’s advanced Drop Test Machines offer the reliability, consistency, and precision needed to simulate real-world transportation challenges. By following the step-by-step process outlined above, manufacturers can eliminate packaging flaws, reduce product damage, and build stronger logistics operations.

If you are looking for a trusted solution to test the endurance of your product packaging, Pacorr’s Drop Tester should be at the top of your list.