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Table of Contents

Introduction: Why packaging inspection is essential for your shipment ..........................3

Chapter 1: General process for packaging inspection ........................................................4
1.1 Shipping carton inspection ..........................................................................................5
1.2 Inner carton inspection ................................................................................................7
1.3 Retail packaging inspection .........................................................................................8
1.4 Compliance to Amazon FBA and retailer-specific requirements ..................................10
1.5 Polybag inspection ....................................................................................................12
Chapter 2: Legal requirements or regulations regarding packaging ................................14
2.1 Polybag suffocation warning regulations ...................................................................15
2.2 Toxics in packaging regulations .................................................................................17
Chapter 3: On-site testing for packaging ...........................................................................19
3.1 Carton drop test ........................................................................................................20
3.2 Barcode scan test ......................................................................................................23
3.3 Heat-sealed blister packaging impact test .................................................................23
3.4 Hang tag fatigue test .................................................................................................24
3.5 Retail box gluing check ..............................................................................................25
3.6 Tying strength test for twist ties ................................................................................25
Chapter 4: Lab testing for packaging .................................................................................26
4.1 Edge strength test (EST) ............................................................................................27
4.2 Burst strength test (BST) ...........................................................................................28
4.3 Puncture resistance test ............................................................................................28
4.4 Climate conditioning ..................................................................................................28
4.5 Vibration test .............................................................................................................29
4.6 Compression test ......................................................................................................29
4.7 Shock test .................................................................................................................30
4.8 Reduced pressure test ...............................................................................................30
4.9 Toxics in packaging test ............................................................................................30
Chapter 5: Defect classification .........................................................................................31
5.1 Critical defect ............................................................................................................32
5.2 Major defect ..............................................................................................................32
5.3 Minor defect ..............................................................................................................33

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INTRODUCTION
Why packaging inspection is essential for your shipment

Almost all products involve some sort of packaging, whether you’re manufacturing
children’s toys or smartphones. But as packaging is one of the last steps of the
production process, it’s easy to overlook issues in packaging. And if you neglect to
conduct packaging inspection, you may be throwing away all of your efforts to obtain
a high quality product from your supplier. Packaging inspection ensures your product
is suitably packaged to arrive at its final destination in the same condition it left the
factory.

Skipping packaging inspection might result in new defects in your product if it’s
damaged during shipment. Or if you fail to properly label your shipment, your order might
be refused by your distributor, or even be seized at customs. In 2016, U.S. Customs
seized nearly 60 tons of illegally imported Chinese honey that was mislabeled as
originating from Vietnam to evade anti-dumping duties.

The factory in Asia that manufactures your

product itself often won’t also make its
corresponding packaging. Rather, they’ll
outsource the job to one of their sub-
suppliers. And when you’re dealing with
sub-suppliers, it’s even more essential to
conduct product inspection to manage
product quality and ensure conformance to
your specifications.

Packaging inspection is one of the main

benefits of conducting final inspection,
as packaging inspection usually occurs
only after all goods are packed and ready
for shipment. Each packaging inspection
will vary slightly based upon your product
type, shipping methods and retailer. This
guideline will provide general procedures
for inspecting packaging, including shipping
cartons, inner cartons, retail packaging
and polybags, as applicable for checking
conformance to your specifications.

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Chapter 1

GENERAL
PROCESS FOR
PACKAGING
INSPECTION

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1.1 Shipping carton inspection

Shipper cartons are the outermost packaging for products. Below is an excerpt from a
QC checklist showing common checks and tolerances for shipper carton packaging.

Section 1: Shipper Carton Packaging

Check-
No. Pcs Checkpoint Instruction Tolerance Result
point

Shipper
Measure the shipper carton gross weight and compare against the As per client-provided
1.1 Dimen- 1*
given values; otherwise, report actual. spec; otherwise, +/-5%
sions

Shipper Measure the shipper carton gross weight and compare against the As per client-provided
1.2 3*
Weight given values; otherwise, report actual. spec; otherwise, +/-5%

Shipper
Markings
1.3 ASD As per client spec. N/A
/ Label-
ling

Material  Br. Cardboard  White Cardboard  Color Export Box

Layers  Single  Double  Triple

Shipper
1.4 ASD Sealing  Transparent Tape  Opaque Tape  Paper Tape
Details
Strapping  Nylon Band  Metal Band  None

Binding  Glue  Staples  None

1.1.1 Carton measurement

ľľ Provision of equipment
»» A supplier should have an industrial
scale on site for weighing shipping
cartons.
»» A QC inspector can generally carry
small tools and measuring equipment
with them to the factory, such as a
tape measure or Pantone swatches.
The factory is expected to provide
other any other relevant equipment
that is costly or difficult to transport.
ľľ There should be no extra space within
the shipping carton as this can cause
excess movement during shipping and
potentially damage products.

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1.1.2 Carton markings/labeling

ľľ Markings should be permanent, clearly

legible and conform to customer
specifications.
ľľ Check for retailer-specific markings
and labeling, where applicable. This is
important for large orders and orders
shipped directly to a large retailer,
as warehouse personnel use carton
markings to organize shipments. Your
retailer might fine or otherwise penalize
you for not meeting their standards.
ľľ PO number and items, as well as bar
codes (or even RFID tags) should be
clear and conform to specifications.
ľľ Carton markings should specify country of origin, or where the item was
manufactured or underwent the most significant manufacturing process. This is
important for customs processing and duties, which might vary based on special
trade programs between countries.

1.1.3 Carton material colors

ľľ Check for the use of a brown, white or color export box.

1.1.4 Carton no. of ply cardboard

ľľ Check for use of single, double or triple-ply cardboard.

1.1.5 Carton sealing method

ľľ Check for use of transparent, opaque or paper tape.

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1.1.6 Carton sealing method

ľľ Check for use of glue or staples.

1.1.7 Carton strapping method

ľľ Check for use of nylon or metal band.

1.2 Inner carton inspection

Inner cartons refer to any additional cartons within the outermost shipping carton
that contain stock keeping units (SKUs). Not all shipments will include inner cartons.
Some products might instead be packaged only in blister packs or polybags within
shipping cartons. Below is an excerpt from a QC checklist showing common checks and
tolerances for inner carton packaging.

Section 1: Inner Carton Packaging

Check-
No. Pcs Checkpoint Instruction Tolerance Result
point

Inner
Carton
2.1 ASD As per client spec. N/A
Markings /
Labeling

Material  Br. Cardboard  White Cardboard  Color Export Box

Layers  Single  Double  Triple

Inner
2.2 Carton ASD Sealing  Transparent Tape  Opaque Tape  Paper Tape
Details
Strapping  Nylon Band  Metal Band  None

Binding  Glue  Staples  None

Packaging
Method &
3* As per the client-given spec. Conforms
Assort-
ment
2.3
1 set includes: Assortment Details:
Actual
Findings Packaging Set/pc per per
Breakdown per per Shipper Carton

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1.2.1 Inner carton packaging method and assortment

ľľ Confirm your specifications for number of units per carton and assortment within
each carton.
ľľ Check for appropriate package cushioning, such as paper, corrugated fiberboard,
foam structures, polystyrene foam, packing peanuts or inflated air cushions.
ľľ If you’re packing similar SKUs within the same carton, check that the quantity and
proportion of each SKU is matches specifications.
»» For garments and footwear with sizing requirements, check that the quantity of each
size and proportion of size of total units meets specifications.

1.3 Retail packaging inspection

1.3.1 Retail packaging methods

ľľ Check mass produced retail packaging

against any approved or “golden” retail
packaging sample and your specifications
for appropriate packaging materials,
construction, color, logo and labeling.
ľľ Measure retail package dimensions for
proper fitting of product within packaging.
ľľ Verify that all associated components,
accessories, instruction manuals, assembly
hardware and tools are assorted correctly
within retail packaging.

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ľľ Check that retail boxes are folded
correctly for all labeling and artwork to
be correctly aligned.
ľľ Ensure any instruction manual included
with the product is written in proper
language for target market and printed
in the required color and styling.

1.3.2 Retail packaging printings, artwork and labeling

ľľ Compare printing on retail packaging to

approved sample or digital art file.
ľľ Ensure logo accurately represents your
branding.
ľľ All markings should be clear and legible.
ľľ Check for associated barcodes and price
tags.
ľľ Check for relevant warning symbols for
applicable products, such as lighters and
electronics.
ľľ Use Pantone swatches to compare artwork
to your color specifications.

1.3.3 Retail packaging condition

ľľ Check for any defects in visual appearance of retail packaging, like dirt marks, dents
and scratches.
ľľ Check for rough edges in blister packaging.

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ľľ Packaging should be free from dust, moisture and foreign materials, such as animal
hair, insects or needles and other sharp objects (see below photo for reference).
Product should be packaged with silica gels where necessary to absorb excess
moisture.

1.4 Compliance to Amazon FBA and retailer-specific

requirements

1.4.1 Amazon Fulfillment by Amazon (FBA)

ľľ Amazon may refuse,

return or repackage any
product delivered to an
Amazon fulfillment center
with inadequate or non-
compliant packaging at
the seller’s expense and
reserves the right to impose
noncompliance fees.

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ľľ Each unit must have an exterior FBA
shipment scannable barcode or label, in
addition to any carrier shipment labels.
The original manufacturer’s label should
be covered.
»» Packaging must include the
appropriate FNSKU, the identifier used
by Amazon fulfillment centers. Each
FNSKU must be unique and must
correspond to one unique product. For
example, each assortment type, such
as size or color, will have a different
FNSKU.
ľľ Amazon will not serve as the “Importer of Record” for any shipment of FBA inventory
and will not be responsible for any applied customs duties.
»» Amazon can be listed as the “Ultimate Consignee”, but only if your customs broker
contacts Amazon in advance of shipping any inventory to obtain the EIN or Tax ID #
required for customs clearance.
»» Each unit must be pre-assembled and contained within a single, secure package.
Loose products should be bagged, or secured with a non-adhesive band or
removable tape.
ľľ Units that are sets must be marked as sets on packaging and sealed so they cannot
be separated.
ľľ For boxed units:
»» Boxes must be six-sided.
»» If the boxed unit has perforated sides or openings, the product must pass a drop test
from 3 feet high.
»» Openings should not easily open on their own.
ľľ For poly-bagged units:
»» Suffocation warnings must be printed on or attached to bags with a 5 inch or larger
opening (see section 3.1.1 of this guideline for appropriate language and placement).
»» Bag must be 1.5 mils thick and polybag must not protrude more than 3 inches past
the dimensions of the product.
»» Bag must be transparent and completely sealed, with no vent holes.
»» Bag must have scannable barcode that is either scannable through the bag or
attached to the outside of the bag.

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ľľ For case-packed products:
»» All products in the box should have matching SKUs and condition and will have been
previously packaged together by the manufacturer.
»» All boxes containing the same product should contain equal quantities of that
product in each box. For example, a case-pack of 12 units must always contain 12
units.
»» For case-packed Items, you must remove or cover any scannable barcode from the
case itself. Only the units within the case can have scannable barcodes.
ľľ Products that expire must include the
expiration date in MM-DD-YYYY format on
the master carton in 36+ point font and on
the individual units. Lot numbers alone are
insufficient.
ľľ Refer to specific requirements for liquid
products, pellets and powders, sharp units,
fragile units, batteries, plush units, baby
products, apparel and textiles, jewelry, small
products, Plexiglas and adult products.

1.4.2 Other retailers

ľľ Refer to other retail-provided guides, like for Walmart, Target and Costco

1.5 Polybag inspection

1.5.1 Polybag packaging/sealing methods

ľľ Check for use of tape or heat sealing to completely seal polybag and protect item
from dust, moisture and damage.
ľľ Measure polybag for appropriate size
»» Using a polybag that’s too large might result in excessive product movement during
shipment and lead to damaging the product.
»» Using a polybag that’s too small might cause excessive wrinkling in garment
products or cause the polybag to tear during shipment.

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 »» For garments, generally allow for no more than 1 inch of space between the edge of
the product and the polybag.
»» Amazon requires polybags not to protrude more than 3 inches past the dimensions
of the product.

ľľ Check for conformance to retailer requirements and customer specifications for item
labeling and barcodes on the polybag itself.
ľľ Check for universal recycling markings and labeling where specified.

1.5.2 Polybag warnings and vent holes

ľľ See legal requirements

for suffocation warnings
in Chapter 3 of this
guideline.
ľľ Vent holes might cause
soiling and are not
permitted by some
retailers.

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Chapter 2

LEGAL
REQUIREMENTS
OR REGULATIONS
REGARDING
PACKAGING

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2.1 Polybag suffocation warning regulations

2.1.1 U.S. state regulations

ľľ There are no U.S. federal legal requirements for suffocation warning labels on
polybags. However, Massachusetts, New York, Rhode Island, Chicago and New York
City have all implemented requirements for suffocation warnings on plastic (poly)
bags for household use. Failure to comply could result in a misdemeanor or fine.
ľľ Regulated bags
»» All regulations apply for plastic bags with a thickness of less than one mil (1/1000)
inch. There are no state legal requirements for thicker bags, but retailers might have
their own requirements. Suffocation warnings are required for polybags with a 5 inch
or larger opening distributed through Amazon FBA and must be 1.5 mils thick.

State/City Bag Size Scope Exclusions

Any bag sold or delivered
Opening > 25 sq. inches or Bags used solely for
California or used to package articles
a capacity 125 cu. inches industrial purposes
delivered to purchasers

Plastic bag or partial

Length and width totals 25
plastic bag intended for
inches or more and open-
Massachusetts domestic use or designed N/A
ing has diameter of at least
or decorated to encourage
7 inches
use as toy

Plastic bag, partial plastic

Length and width totals 25
bag or packaging articles
inches or more and open-
New York intended for domestic use N/A
ing has diameter of at least
or designed or decorated
7 inches
to encourage use as toy

Polyethylene bags or pack-

Opening > 5 inches in Bags intended for food
Rhode Island aging articles that are used
diameter products < 5 lbs.
in or around household

Opening > 7 inches in Polyethylene bags for Bags intended for food
Chicago, IL
diameter household use products < 5 lbs.

Plastic bag, partial plastic

Length and width totals 25
bag or packaging articles
inches or more and open-
New York, NY intended for domestic use N/A
ing has diameter of at least
or designed or decorated
7 inches
to encourage use as toy

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ľľ Warning requirements
»» Regulations vary slightly in the specific language suggested or required for the label,
but the following language complies with all regulations:
»» “Warning: To avoid danger of suffocation, keep this plastic bag away from babies
and children. Do not use this bag in cribs, beds, carriages, or playpens. This bag
is not a toy.”
»» Minimum type size of warning also varies by locality, but adherence to the standards
shown in the following table will meet all requirements:

Total Length and Width

Minimum Type Size
of Bag Combined

Less than 25 inches 10 point

25-39 inches 14 point

40-59 inches 18 point

60 inches or more 24 point

ľľ For Massachusetts, the warning must appear on both sides of the bag and be
repeated at 20-inch intervals for bags whose length and width are more than 40
inches.
ľľ Warning should be clear, distinct and conspicuous in color, layout and contrast.

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2.1.2 Canada suffocation warning regulations for toys

ľľ Canada requires suffocation warnings for all flexible plastic film bags and flexible
plastic sheets used as packaging materials for shelf packages or used with or as
part of toys.
ľľ Bags must be at least 0.00150 in. in average thickness, but the actual thickness of
any individual measure must never be less than 0.00125 in. Alternatively, sheeting
with an average thickness of less than 0.00150 in. must be perforated with defined
holes so that a minimum of 1 % of the area has been removed over any area of 1.18
in. x 1.18 in.. This requirement does not apply to the following:
»» Shrink film in the form of an over
wrap that would normally be
destroyed when the package is
opened by a consumer.
»» Bags or plastic film with a minor
dimension of 3.94 in. (100 mm)
or less. Bag dimensions must be
measured while in the form of a
bag, not cut open into a single
thickness sheet.
ľľ The warning must be printed in
English and French.

2.2 Toxics in packaging regulations

ľľ The Model Toxics in Packaging Legislation establishes consistent requirements

for the reduction/elimination of four specific toxics (lead, mercury, cadmium and
hexavalent chromium) in packaging sold or distributed in the U.S. The European
Union also uses the Model for the basis of its packaging requirements. Nineteen U.S.
states have laws against toxics in packaging with the same basic requirements:
»» No intentional use of any amount of the 4 restricted metals (lead, mercury,
cadmium and hexavalent chromium).
»» A threshold level of 100 ppm by weight for incidental use of the total of the four
metals combined.

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ľľ Applies to any package or packaging component offered for sale or for promotional
purposes by its manufacturer or distributor.
»» “Package” refers to a container providing a means of marketing, protection or
handling of a product and must include a unit package, an intermediate package and
a shipping container.
»» “Packaging component” means any individual assembled part of a package,
such as but not limited to, any interior or exterior blocking, bracing, cushioning,
weatherproofing, exterior strapping, coatings, closures, inks and labels.
»» Applies to inks, dyes, pigments, adhesives, stabilizers and any additives.

» All manufacturers and suppliers of packaging and packaging components, as well

as product manufacturers or distributers who use packaging are held accountable
to these requirements. The manufacturer, supplier and distributor to the purchaser
must be able to submit a Certificate of Compliance. There are some exemptions in
application, which vary by state laws.
» Lab testing of packaging can reliably measure heavy metals and demonstrate
compliance to toxics in packaging requirements.

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Chapter 3

ON-SITE TESTING
FOR PACKAGING

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3.1 Carton drop test

ľľ The carton drop test, in accordance with ISTA 1A, simulates shipping conditions,
including any falling, swinging or shaking that might occur during transit. For fragile
products, this can help forecast any potential damages that might occur from
improper packaging.
ľľ If inspecting multiple SKUs of items that are similar (differing only in color/artwork)
and the packaging method is identical across SKUs, it’s acceptable to predict the
results of carton drop tests will be the same across SKUs. The QC inspector should
conduct the carton drop test on 2-3 SKUs first and record the results. If the results
are similar (both cartons PASS or both FAIL), it’s unnecessary to continue testing the
remaining SKUs. But the QC inspector should still note in their inspection report on
which SKUs the test was conducted for reference.

3.1.1 Procedure

ľľ Step 1: Select a packaged carton from total

cartons available as a testing sample. If you’re
carrying out testing in a factory, it’s important
to choose a carton at random. Ensure that the
products inside the carton have already been
inspected for defects, both in visual appearance
and function.
ľľ Step 2: Select a testing area that is large enough
for the carton to free-fall completely on a flat
and hard floor, with no interference.
ľľ Step 3: Drop the carton from a selected height
10 times, changing the orientation of the carton
for each drop.
»» The standard for drop height for the test varies
based on carton weight.

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 Drop Height

English Metric

Package Weight Drop Height Package Weight Drop Height

1-20 lb 30 in 1-9 kg 76 cm

21-40 lb 24 in 10-18 kg 61 cmt

41-60 lb 18 in 19-27 kg 46 cm

60-100 lb 12 in 28-45 kg 30 cm

101-150 lb 8 in 46-68 kg 20 cm

»» Turn the packaged-product so that you are looking directly at a face with the
manufacturer’s joint (or the part of the package where the carton is adhered together
by gluing, stitching or taping) on your right. If the manufactured joint is not known,
position one of the smallest width faces of the packaged-product directly in front of
you.

Identify faces
according
to the diagram
on the right

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 Drop
Carton
Sequence Specific face, edge or corner
Orientation
Number
Most fragile face-3 corner. If not known, test corner formed
1 Corner
by face 2, face 3, and face 5 of the packaged product
2 Face Shortest edge radiating from the corner tested
3 Face Next longest edge radiating from the corner tested
4 Face Longest edge radiating from the corner tested
5 Face One of the smallest faces
6 Face Opposite small face
7 Face One of the medium faces
8 Face Opposite medium face
9 Face One of the largest faces
10 Face Opposite large face

ľľ Step 4: Open the carton and check the

condition of products and packaging
inside the carton for any damage
resulting from the test. Separate any
damaged packaging and record results.
»» A pass result is indicated by the
presence of only normal deformation
and puckering of the shipping
carton. There is no damage to
inner packaging or the products
themselves.

»» A failed test is the result of:

»» Significant damage to export carton.
»» Significant damage to inner/retail boxes.
»» Damage to products, including
deformation, scratches, dents and
problems with product functionality.
»» Safety hazards with product and packaging
resulting from the carton drop.

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ľľ Step 5: Adjust the carton drop test
if necessary. Depending on product
type and packaging method, dropping
cartons from alternate heights or
angles might be appropriate.
ľľ Carton drop tests can also be
performed in certified third-party labs
by machines designed to test the
structural integrity of the box.

3.2 Barcode scan check

ľľ Use a standard barcode scanner to test all

barcodes on retail packaging, polybags and
shipping cartons.
ľľ Barcodes should reflect proper product
and distribution identification tracking
information in accordance with your
specifications.
ľľ Typically, a third-party inspection company
is capable of providing a barcode scanner
for testing, as it’s small and portable.

3.3 Heat-sealed blister packaging impact test

ľľ For heat-sealed blister packaging, hit the back card on each of its edges onto a flat
surface, like a table, with reasonable force.
ľľ Ensure the blister is fully attached to the back card and cannot be easily detached.
There should be no open seals at any of the connection areas between the blister
and back card after testing.

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ľľ Blister packs are commonly used for pharmaceuticals and small consumer
goods like hardware products, electrical items and toys. Blister testing is typically
conducted on the full sample size during product inspection. Testing will usually
destroy the packaging. Factory staff may not permit this testing if conducted at the
supplier’s facility. It may be necessary to test only the greatest number of units the
factory staff will allow.

3.4 Hang-tag fatigue test

ľľ For any item with a hang-tag hole, hang

the item using the peg hole for 2 hours
to confirm it can hold the item securely.
ľľ Tug on the item gently to test the
strength of the packaging.
ľľ A professional third-party inspector will
often also photograph the item as it
hangs to show the customer how the
item will appear on the shelf.

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3.5 Retail box gluing check

ľľ Pull slightly on each of the glued areas

of the box to verify packaging is glued
securely.
ľľ Temperature and humidity changes can
weaken gluing, so it’s essential to ensure
the retail box is strongly affixed together.

3.6 Tying strength check for twist ties

ľľ Any item attached to a back card

with a twist tie should be checked for
sturdiness.
ľľ Items should be well affixed to the card
with the twist tie fixed tightly using at
least 3-4 rotations.
ľľ After checking the twist tie, shake the
packaged item 3-5 times to check
for any sliding of the item within the
packaging.
ľľ Sliding indicates that the twist tie is
not tight enough. The product could be
damaged if it moves freely within the
packaging during transit.

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Chapter 4

LAB TESTING FOR

PACKAGING

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Lab testing for packaging typically requires specialized equipment, such as mechanized
shock machines and environmental test chambers, which is typically not available on-
site at the factory. Samples of your product and packaging can be pulled on-site and
sent to an accredited laboratory for more rigorous testing.

Certified third-party labs use internationally recognized standards and procedures to

measure packaging durability and performance. For general products, the International
Safe Transit Association (ISTA) 1A standards are an effective and efficient way to
evaluate the performance and strength of product packaging.

4.1 Edge crush test (ECT)

The edge crust test is based on TAPPI (Technical Association of the Pulp and Paper
Industry) 811 standard. This is the most commonly used test to evaluate the physical
strength of carton boards. It measures the stacking strength of corrugated cardboard
boxes or fiberboard in its vertical or loading direction to simulate conditions during
transportation and distribution.

A finished box’s compression strength is defined by the amount of force needed to crush
a section of cardboard when standing on its edge. Generally, this test is conducted on a
small sample of the box with a load applied to its edge when standing on end.

Strength is measured in pounds per square inch. For example, a box with an ECT
result of 32 pounds per square inch indicates that the board, standing on its edge, can
withstand a force of 32 pounds per square inch before it crushes under the weight. The
minimum required strength depends on product type.

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4.2 Bursting strength test (BST)

The bursting strength test is based on TAPPI/ANSI T 810 om-11. Like the edge crush
test, this test also measures the physical strength of carton boards. But force is applied
on its flat side, rather than at the edge, like the edge crush test. The bursting strength
test measures the box’s ability to withstand external or internal forces to simulate how
the box will contain its contents during rough handling.
A finished box’s bursting strength is defined by the force required to rupture, or burst, the
flat side of a corrugated box.

Strength is measured in pounds per square inch. For example, a box with a burst
strength of 200 pounds per square inch indicates that the box can withstand 200 pounds
of pressure per square inch before it bursts or ruptures. The minimum required strength
depends on product type.

4.3 Puncture resistance test

The puncture resistance test is based on ISO 3036:1975. A puncture tester produces an
impact by means of a pendulum to measure the force necessary to puncture and tear
open the board.

4.4 Climate conditioning

Climate conditioning testing is based

on ASTM D4332. This class of testing
includes elevated temperature, cold/
sub-zero and elevated humidity
testing using environmental test
chambers at a certified lab. Testing
is designed to provide assurance that
the structural integrity of packaging is
not compromised by temperature and
humidity changes.

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4.5 Vibration test

The vibration test is based on ASTM D999. This test includes machine-based shaking
and vibration with varying intensity and duration to simulate rough handling of packages
over long shipping routes.

4.6 Compression test

Compression testing is based on ASTM D642 - 15. Testing uses a machine to apply
pressure to different parts of the package with varying time periods and strength, based
on product requirements.

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4.7 Shock test

The shock test is based on ASTM D 5487. This test verifies what damage, if any,
packaging will sustain when subjected to sudden shock. Machines can test vertical,
horizontal and rotary shock factors at different G force levels.

4.8 Reduced pressure test

The reduced pressure test is based on ASTM D4991 - 07(2015). This test examines
packaging for its ability to withstand low pressures, including strength of seals and
tendency for leakage. A vacuum adjusts air levels in the package or around the package
and tests whether the box remains sealed. This test is important for products where
leakage would be hazardous or sterility of the product is essential and when the product
will be transported by air at high altitudes.

4.9 Toxins in packaging tests

Toxins in packaging tests consist of chemical analysis for detection and measurement
of lead, cadmium, hexavalent chromium, mercury and other hazardous chemicals per
toxins in packaging regulation (see 2.2 of this guideline).

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Chapter 5

DEFECT
CLASSIFICATIONS

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5.1 Critical defect

Nonconformance that causes a reasonable

probability that the product is unsafe to the
user, which could cause injury or harm to,
property damage to, or otherwise endangering
the life or safety of, the customer or end user
of the product. Packaging defects that prevent
the traceability of a product may also be
considered critical defects. Some examples of
critical defects in packaging are:

ľľ Mold
ľľ Markings/labelling does not comply with
legal requirements
ľľ Infestation of insects
ľľ Presence of needles, razors or any other
non-intended metal objects
ľľ Incorrect barcode no.

5.2 Major defect

Nonconformance that reduces the value or

usability of the product. The product would
not be considered unsafe to the user, but it
does not meet specifications and may affect
the salability or result in a customer return.
Major defects in product packaging may
include:

ľľ Incorrect packing assortment

ľľ Missing user manual, warranty card or
other packaging component
ľľ Obvious damage to polybag
ľľ Obvious color deviation from sample or
specification

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5.3 Minor defect

This is a defect which would not normally be

identified by the customer or affect usability
or salability of the product, but nevertheless
is less than the agreed upon quality standard.
Some examples of minor defects in packaging
include:

ľľ Illegible graphics or shipping marks

ľľ Slight damage to carton with product
secured inside
ľľ Mild odor dissipating upon opening
packaging

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 8.1 Shipper Carton & Retail Packaging Critical Major Minor

1 Missing bar code X

2 Wrong barcode printed X

3 Mislabeled carton sticker X

Incorrect shipping mark/shipping mark color/color box or bag

4 X X
graphics/wording (critical if persistent throughout sample)

5 Illegible graphics or shipping mark X

6 Carton broken and product inside exposed, and/or damaged X

7 Carton damaged or taped poorly, but product still secure X

Incorrect packing method (i.e. wrong package used, missing

8 X
plug/paperboard upside down)
Missing user manual, warranty card, color card or other packag-
9 X X
ing

10 Incorrect hangtag X X

11 Wrong spelling, wording or graphics on hangtag X X

12 Broken/damaged polybag X X

13 Color does not match the approved sample X X

14 Foreign matter (safety issue e.g. blade, rodent, etc.) X

15 Foreign matter (non-safety issue e.g. hair, insects…) X

16 Color deviation within the packaging X

17 Stain/crack/damage on the individual package X X

18 Ventilation holes in polybag missing (if applicable) X

Polybag not closed/sealed properly (if applicable)

19 Polybag opening ≥ 50%: Major X X
50% ≤ Polybag opening ≥ 10%: Minor

20 Broken/damaged polybag X X

21 No cautionary labeling (if applicable) X

22 Retail box poorly glued (too little glue and/or poor adhesion) X

23 Received product has odor, which dissipates upon opening X

Received product has odor, which does not dissipate upon

24 X
opening
Other instances of poor packaging
25 X
(poorly applied static label, etc.)

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About AQF
Asia Quality Focus (AQF) is a leading quality control service provider, serving global
brands, importers and retailers from more than 135 countries since 2007.

With expertise in hardlines, softlines, consumer electronics, electrical products and

industrial goods, AQF delivers quality control services in 12 countries throughout Asia.

Interested in more great quality control content?

Check out our other eBook by clicking below!

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