According to Packaging Digest, up to 11% of unit loads arriving at distribution centers show some level of case damage. The average sits around 2%, often caused by: mishandling, improper stowage, vibrations or shock during transit, or even weather conditions, such as temperature or humidity.
That is why packaging testing is essential. Whether launching a new product or optimizing an existing design, it ensures that the packaging protects what matters most - the shipped goods.
What is Packaging Testing?
Packaging testing helps validate that a product can survive in real-world shipping conditions. There are two main options:
- Standard In-Lab Testing - physical
- Virtual testing labs - digital simulation using Finite Element Analysis (FEA)
Each approach offers unique advantages depending on the end goals, timeline, and available budget.
Standard In-Lab Testing = Real-World Validation
This traditional approach uses physical prototypes and lab simulations to replicate real-world shipping and handling conditions, helping assess how well the packaging performs.
How does it work?
A special machines mimic what happens during shipping and storage:
- Vibration Test : Think of a package shaking constantly in a truck. This test checks if the contents stay safe.
- Drop Test : If the packaging gets dropped, does it hold up, or does something break?
- Compression Test: What if your package is at the bottom of a tall stack? This test checks if it can handle the pressure.
- Incline Impact Text1: This test replicates scenarios where packages might slide during loading, unloading, or transportation.
- Environment test: An environmental test checks if packaging can handle tough conditions like heat, cold or humidity during storage and transport2.
When is this a good idea?
When laws require it: some products, such as lithium-ion batteries, require UN Dangerous Goods testing to ensure safe transport and compliance with international regulations.
When you want real-world proof: like testing packaging in hot, cold, or super humid conditions to see if it holds up (ISTA, ASTM D4332, ISO 22333).
When your product is fragile or oddly shaped: this is determined by the product's fragility and its shape.
Virtual Testing Labs: Fast, Cost-Effective and Scalable
As packaging development moves faster and becomes more complex, virtual testing using Finite Element Analysis (FEA) has emerged as a powerful alternative or complement to physical testing.
How does it work?
FEA allows engineers to simulate how packaging performs under a wide range of conditions, without the need to build a physical prototype. Digital models can replicate shock from drops during transportation, or pressure from stacking. The ability to test this in a virtual environment makes this approach ideal for early-stage development.
If you’re under tight deadlines, when live testing isn’t possible or want to avoid costly tooling corrections, virtual testing is an excellent solution that offers speed, flexibility, and data-driven insight.
When is this a good idea?
Virtual testing is particularly useful when dealing with oversized, heavy, or expensive products, scenarios where physical testing may not be feasible or cost-effective. It allows packaging engineers to quickly adjust a design, test it, and optimize performance in real time.
What is it best for?
- Speed and savings: great for fast design changes and cutting prototype costs.
- Early-stage testing: try out different ideas before anything is built.
- Mass testing made easy: run hundreds of test scenarios in a short time.
- Ultimate flexibility: tweak the design and test it again instantly.
Does Packaging Testing Really Make a Difference?
Absolutely.
Take the case of a medical device manufacturer Nefab worked with. Their old, legacy standard required packaging to withstand 25G shock levels - a strict requirement meant to prevent damage during transport. But this made the packaging bulky, over-designed, and more expensive to ship.
Nefab’s engineering team stepped in and ran a series of packaging tests. The results showed that the product could actually handle up to 50G. With that insight, the team redesigned the packaging, making it smaller, just as protective, all of that without wasting packaging material.
The outcome? A leaner, smarter solution that cuts shipping costs without compromising safety.
Choosing the Right Method: What to Consider
When selecting a packaging testing method, several factors can guide the decision:
- Does the product require regulatory certification? If so, in-lab testing may be the go-to option.
- Is the project timeline tight? Virtual testing can significantly shorten development cycles.
- Is the project budget tight? Digital simulations help explore options without building multiple prototypes.
- What stage is the project in? Early development favors virtual testing; final approval may require lab-based validation.
- Is the product large or heavy? FEA-based virtual testing is ideal for oversized or heavy equipment that is difficult to test physically.
Nefab operates 6 ISTA-certified labs and over 30 engineering centers dedicated to helping their customers optimize protection levels, minimize damages, and reduce costs through rigorous testing and analysis.
Testing with Nefab: Global Expertise, Local Support
Nefab operates six ISTA-certified packaging labs and more than 30 engineering centers worldwide. This infrastructure enables the company to support global customers with tailored packaging validation, cost-reduction strategies, and damage prevention across diverse industries.
From early design to final certification, Nefab combines physical testing with digital simulations to deliver packaging solutions that are resilient, compliant, and cost-effective.
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