Transport Packaging CBU Packaging

5/25/2013
Presentation Topics
Transport Packaging
CBU Packaging
Presented by
Pong Malasri, PhD, PE, CPLP Technician
Distribution Hazards & Potential Damages
Packaging Department Chair
Healthcare Packaging Consortium Director
Christian Brothers University
Memphis, TN 38104, USA
@
Pre‐shipment Lab Tests
Competitive Packaging for the U.S. Market Workshop
Dusit Thani Hotel
Bangkok, Thailand
June 5, 2013
CBU ISTA Certified Packaging Test Lab
CBU Packaging
•
•
Presented by
Pong Malasri, PhD, PE, CPLP Technician
Packaging Department Chair
Healthcare Packaging Consortium Director
Christian Brothers University
Memphis, TN 38104, USA
@
Certified by the Int’l Safe Transit Association
One of eight certified packaging labs and the only one in an academic setting within the tri‐
state area of Tennessee, Arkansas, and Mississippi
Competitive Packaging for the U.S. Market Workshop
Dusit Thani Hotel
Bangkok, Thailand
June 5, 2013
1
5/25/2013
General Support
Innovation Center Account
Engineering Students
Revenue
Up-to-date Equipment
Revenue
R&D Projects
Directions
Expertise
The
Global Lasallian
The Global Lasallian
Packaging
Consortium
Packaging Alliance
R&D Collaboration
Networking
Distribution Hazards
& Potential Damages
Presented by
Pong Malasri, PhD, PE, CPLP Technician
Packaging Department Chair
Healthcare Packaging Consortium Director
Christian Brothers University
Memphis, TN 38104, USA
@
Competitive Packaging for the U.S. Market Workshop
Dusit Thani Hotel
Bangkok, Thailand
Transport Packaging
Point of
Manufacture
Transportation
Handling
Warehousing
Atmospheric Condition
Point of
Use
Packaging helps products arrive in good condition!
June 5, 2013
2
5/25/2013
Shock
Major Hazards of Distribution
•
• Shock
•
•
Mostly from handling
Breakage
• Vibration
•
•
Mostly from transportation
Abrasion, loosening •
•
• Compression
•
•
Mostly from warehousing
Crushing
•
• Atmospheric Condition
•
•
Shock is a common phenomenon arising from dropping of a package or a unit load (pallet load) during the handling of it, such as sorting, vehicle loading/unloading, delivery, manual palletizing, stacking/un‐stacking, moving/positioning, placing in/out of racks, etc.
Short duration with high intensity
High intensity dynamic event characterized by a sudden change in velocity
Purposeful drops often occur due to efficiency
Temperature, humidity, pressure
Weakening
Free‐Fall Impact Velocity
•
Weight = Mass * g
where g = 32.2 ft/sec2 or 386.1 in/sec2 or 9.8 m/sec2
•
•
If an object is released from an at‐rest position, it picks up speed as it falls. At the end of the first second, it will be moving at 386.1 in/sec velocity (or 22 miles/hr or 35 km/hr).
Impact velocity (Vi) from a drop height (h):
Vi  2 gh
•
Vi
(fps)
11.35
Vi
(mph)
7.74
Vi
(km/hr)
12.45
3 ft
(0.91 m)
13.90
9.48
15.25
5 ft
(1.52 m)
17.94
12.23
19.69
h
2 ft
(0.61 m)
Pallet Study @ CBU
Impact Acceleration
•
Vi  2 gh
Attraction of earth’s gravity gives 1g (or 1G) of acceleration
Intensity of a shock is generally measured in terms of its peak acceleration in g or G.
50G means the peak acceleration is 50 times the acceleration that occurs naturally as a result of gravity.
Impact acceleration felt by products on pallet due to impact is around 20g‐30g.
Impact Force F = m a
3
5/25/2013
Plastic Tote Study @ CBU
Impact acceleration felt at interior bottom of plastic tote pallet due to impact is around 200g for 12‐in drop height with one layer of 5/16‐in bubble wrap cushion.
Impact acceleration felt by products on pallet due to impact is around 80g‐90g.(12‐in drop with cushion)
Vibration
B
Reference
Point
A
• Rattles in vehicles
• Turbulence in airliners
C
• For packaging, vibration is common in transport vehicles, lift trucks, conveyors, etc.
• Oscillation around a reference point, i.e., ups and downs
• Period is time to complete a cycle.
• Frequency is number of cycles in a set period of time. Period
x
B
A
A
A
t
(1 Hz = 1 cycle/sec)
1
Frequency 
Period
Period
C
Peak Acceleration
x
a
Zero-Peak
Amplitude
t
t
Period
Period
• Given a mass‐spring system, then give the mass some displacement and let the mass oscillates. The mass will vibrate at its natural frequency.
• The amplitude may vary depending on the displacement given. But the period of natural period remains the same.
Period
x
Peak-Peak
Amplitude
t
Period
4
5/25/2013
Vibration Hazards
• Of the three logistic elements (transportation, handling, and warehousing), transportation is linked with vibration the most.
Truck Vibration
• Truck vibration is worst than airplane and ship vibrations
• High frequency (more Hz)  Less amplitude
• Low frequency (less Hz)  High amplitude  more severe
• Vibration in transportation is influenced by many factors: vehicle suspension, vehicle structure, road/rail/water/air condition.
• Vibration in vehicles occurs in all directions; up/down, left/right, front/back.
• Up/down (vertical vibration) is most severe, thus is the focus of vibration test.
• Length of time makes vibration a hazard to products. A coast‐to‐coast truck trip in the U.S. is around 2,500 miles and about 50 hours of vibration. Long‐
term motion causes wear, fatigue, abrasion, loosening, etc.
• Vibration in transportation is a mixture of frequencies and amplitudes called random vibration.
• Typical frequencies are in the range from 3 – 100 Hz, but could go as low as 1 Hz and as high as 500 Hz.
• Resonance can come from suspension, tire, etc.
PSD = Power Spectral Density
Compression Hazards in Warehousing
• The logistic function of warehousing is to buffer the uncertainty of demand and production.
• Individual and unitized products are stacked in warehouses to utilize the cube of the warehouse, which includes height.
• Most warehouses are not environmental controlled.
• Time in a warehouse of a product/package could be short or long.
• Hazard due to compressive load due to stacking
•
•
Stack heights up to 12‐15 feet are common.
Some warehouses use racks, thus stack heights are often under 6 feet.
• Hazard due to atmospheric conditions
•
Humidity affects paper‐based packaging.
• Hazard due time (duration in warehouse)
5
5/25/2013
Paper Products
• Paper products are hydroscopic (the ability of a substance to attract and hold water molecules from the surrounding environment).
• They take up and give off water with the surrounding atmosphere.
• Usually 24 hrs or more is time allowed for paper products will reach an equilibrium moisture content.
• Paper products exhibit a hysteresis effect conditioning (The dependence of a system not only on its current environment but also on its past environment. This dependence arises because the system can be in more than one internal state.)
• Low  High Moisture paper products will show a different equilibrium point than from High  Low
• Compression tests are usually conducted after conditioning at 50% relative humidity and 73F – known as “standard conditions.”
www.cbu.edu/packaging
Corrugated boxes
Vehicle Stacking Compression Hazard
• Lower stack heights than in warehouses
• Loaded times are usually shorter
• Atmospheric conditions in vehicles may be wider swings and worse extremes
• Dynamic environment, road shock and vibration, increases hazard/damage potential
Pressure (mm Hg)
Some products and packaging materials are sensitive to
• Temperature
• Moisture
• Pressure
• Light (such as ultraviolet)
• Gases (such as oxygen)
Pressure (psi – absolute)
Altitude (meters above sea level)
Atmospheric Effects
Conditioning and pre‐conditioning are activities usually done prior to testing in an effort to prepare the test sample. Altitude (feet above sea level)
6
5/25/2013
Potential Damages from Pallets
Pallet Study @ CBU
Potential Damages for Bulk Content
Interior Partitions
7
5/25/2013
Recycled Corrugated Paper Study @ CBU
Tested at extreme condition: 90F & 90% RH
Cost
Damage Samples
8
5/25/2013
Pre‐shipment Lab Tests
Presented by
Pong Malasri, PhD, PE, CPLP Technician
Packaging Department Chair
Healthcare Packaging Consortium Director
Christian Brothers University
Memphis, TN 38104, USA
@
Competitive Packaging for the U.S. Market Workshop
Dusit Thani Hotel
Bangkok, Thailand
“Your package is going to be tested – one way or another. You have the option of testing it in a laboratory to find out in advance if it’s going to do the job, or shipping it to your customers and letting that be the test.” – Dennis Young
Jenevieve Blair Polin, “The Four Hazards of Distribution,” PMPNews, June 2, 2009.
June 5, 2013
9
5/25/2013
Ship Tests
“If you are not regularly using a laboratory package performance test, start now. Even a simple lab test used wisely is preferable to trial and error or total reliance on field experience” –
ISTA
•
•
•
•
Actual shipment of samples through distribution to see if they will survive.
Often time‐consuming, expensive, and non‐repeatable
Can be used to validate lab tests
Not a substitute for lab tests because they may be non‐
representative of actual condition over time.
Guidelines for Selecting and Using ISTA Test Procedures & Projects, International Safe transit Association, 2013.
www.cbu.edu/packaging
Types of Packaging Lab Tests
Reasons for Lab Tests
• Predict the outcome/performance of a package during distribution
• Pre‐shipment performance tests
Pass/fail
Does your package have what it takes to survive?
Does the package survive a sequence of tests per ISTA test procedure?
• Provide information for changing protective packaging design
• Engineering and development tests
You may be looking for ways to use less packaging… but how much less is not enough?
Specific purposes
What is the maximum compressive load this box can withstand?
Test Standard Organizations
•
Founded in 1948
ASTM International
•
•
•
•
ISTA has developed test procedures based on the most current global transport environmental data.
ISTA
International Safe Transit Association
•
•
• Use real world shipping data
Etc.
Committee D10 – Packaging
Usually focuses on how to conduct a specific tests but not on overall package performance.
Example: ASTM D5276 tells how to run a drop test, but does not specify drop heights, number of drops, or drop orientations.
International Safe Transit Association
www.ista.org
Certifies test labs
Certifies lab professionals
Hosts annual International Transport Packaging Forum
• Sets standards/protocols for distribution testing
• Certifies packaged‐products
•
•
•
•
•
10
5/25/2013
ISTA Certified Lab in Thailand
Distribution Hazards & Lab Tests
www.ista.org
Shock Test
Basic Equipment @ CBU Packaging Lab
11
5/25/2013
•
Drop Tester
•
•
•
•
Free‐fall drop machines are usually used to test small to medium size packages. They are designed to release the package cleanly for accurate control of drop orientation and repeatability.
Could also use slings around the package and use quick release hooks.
Free fall and rigid surface are important.
Simple “hand” drops (hold and release) are generally not acceptable.
•
•
•
Quick Release Hook
Drop Test Alternatives
Swing arm drop testers support the package under its center before activation. When activated, the arm swings out of the way.
Split leaf drop testers provide two synchronized supports, one under each end of the package before activation. When activated, the two supports swing out of the way quickly.
Fall away drop testers have their package support moving down ahead of the package into their pocket.
Large package is often tested by raising one bottom edge to a certain height then dropping it to the hard surface, also known as rotational flat drop.
Drop Test Specifications
•
•
Incline Impact Tester
•
•
•
•
Number of drops
Drop height distribution (how many at what heights) – usually in 6‐in increments.
Orientation of drops (corner, edge, face)
Order of drops (which is first, second, etc.)
Number of test cycles (how many times the test series is performed)
Number of specimens and any conditioning, pre‐conditioning, or other treatment
Shock Machine
Horizontal Impact Tester
12
5/25/2013
Vibration Test Equipment
Mechanical Shakers
• Driven by an electric motor and eccentric cams
• Frequency range: 2 – 5 Hz
• Fixed displacement = eccentric offset
• Rotary motion: Table moves around in a vertical‐plane circle
• Vertical linear motion: Table moves up and down in a line.
Single‐Axis Linear Vibration Systems
• Activated hydraulically, electronically, or other ways
• Used for bounce test as well as sine vibration, and random vibration.
‐
‐
In‐phase rotary motion: Table remains horizontal during the rotation
Out‐of‐phase rotary motion: Rocking component to the table movement
Compression Test Classifications
Based on test types:
• Constant deflection (apply & release)
• Common rate = 0.5 in/min
• Constant load (apply and hold)
Based on terminal conditions:
Hydraulic Vibration Systems
Compression Tables
• Test to specified level
• Test to failure
Environmental Chambers
• They allow temperature/moisture/pressure controls.
Humidity/Temp Chamber
Walk‐in Humidity/
Temp/Altitude Chamber
Altitude Chamber
13
5/25/2013
Actual vs. Dummy Products
• Actual products are normally used in a lab test.
• A dummy product are used if it is dangerous in testing an actual product.
• A dummy product, if used, must represent damage potential of the real product.
Test Objectives
• Screening
–
–
–
–
–
–
• Prediction
–
–
–
–
“Reduce to Damage”
• ISTA tests provide lower limits… Pass/fail fashion
• “Reduce to damage” or “Pass with minimum margin” means if a packaged‐product passes a test, it must be redesigned with less packaging and tested again until an optimum level is reached.
To avoid serious problems in shipment, i.e., damage to the product
Simple and inexpensive
Widely available and accepted
Use simple equipment
Accommodate known and suspected severe hazards
Not necessarily a simulation of the hazards of distribution
Foresee more subtle effects, such as minor damage
More difficult
Fine‐tune cost and environmental impact
Incremental testing reduces cost and materials
Test Categories/Types
Non‐Simulating Integrity Tests
• Best for finding potential problems
General Simulation Tests
• Handle diverse environments in complex logistic mixes
• Screening tests should be used with caution for “reduce to damage” protocol since they may not well represent actual field exposure.
Focused Simulation Tests
• Powerful in fine tuning overall costs and tradeoffs
• Better to use tests that provide a good actual simulation of the distribution hazards.
Non‐Simulating Integrity Tests
General Simulation Tests
• Provide effective screening of proposed packaging to locate potential problems
• Challenge the ruggedness or integrity of the product and its package
• Appear similar to actual shipment hazards but are often different in many significant respects
• Are not designed to simulate shipping
• Rely on historical success and common sense
• Example: ISTA 1A (the most widely used packaging test in the world)
• Attempt to simulate the hazards and sequence of shipping but only in a broad and general sense
• Consider overall characteristics of transit mode or product handling
• Cover all four hazard elements: shock, vibration, compression, and atmospheric
• Tend to envelop what probably occurs in shipment
• Place emphasis on the near‐worst conditions observed or expected
• Examples: ISTA 3‐Series and ASTM D4169
14
5/25/2013
Focused Simulation Tests
ISTA Test Series
• Link lab tests to actual measured shipment and distribution hazards
• Use instruments to measure actual field conditions such as vehicle vibration, package drops, or compressive loads, etc.
• Represent both the types of hazards and the statistically variability of the hazards as they occur in actual distribution
•
1 Series: Non‐Simulation Integrity Performance Tests
Procedures 1A, 1B, 1C, 1D, 1E, 1G, 1H
•
2 Series: Partial Simulation Performance Tests
Procedures 2A, 2B, 2C
•
3 Series: General Simulation Performance Tests
Procedures 3A, 3B, 3E, 3H; Project 3K
•
4 Series: Enhanced Simulation Performance Tests
Project 4AB •
ISTA 6 Series: Member Performance Tests
Procedures 6‐FEDEX‐A, 6‐FEDEX‐B; Project 6‐SAMSCLUB •
ISTA 7 Series: Development Tests
Projects 7D; Standard 7E
Note: CBU Test Lab is certified to perform procedures in bold.
Proc.
D
I
H
FV
RV
1A
X1
X1
X1
X2
X2
CM
LS
1B
X1
X1
X1
X2
X2
1C
X1
X1
X1
X2
1D
X1
X1
X1
X2
X2
X3
X3
X2
X3
X3
X2
X2
TH
D = drop tester
I = incline impact
H = horizontal impact
X1
X1
1G
X1
X1
X1
1H
X1
X1
X1
2A
X1
X1
X1
X2
X2
X3
X3
X
2B
X1
X1
X1
X2
X2
X3
X3
X
2C
X1
X1
X1
3A
X
1E
X
X
X
X
X1
X
3E
X1
X1
X
7D
X
CM = compression machine
LS = load spreadher
TH = temp/humidity chamber
X
X
X1
3H
FV = fixed displacement vibration table
RV = random vibration table (can also perform fixed displacement vibration)
X
3B
ISTA Test Procedures & Required Equipment
X3
X3
X3
X3
X
X1 Only one is needed
X2 Only one is needed
X3 Only one is needed
X
X
CBU Lab shown in RED
15
5/25/2013
ISTA Transit Tested Certification Mark
Shipper (product manufacturer) must be an ISTA member
Tested by an ISTA Certified Lab
Test report filed with and approved by ISTA
All samples must pass the test(s)
Must be retested after any change is made to the product, package, or the process
• Placed on the package as a proof of the highest level of credibility to the design, test, and packaged‐product performance verification process
•
•
•
•
•
ISPM‐15: Regulation of Wood Packaging Material in International Trade
• Covers all forms of wood packaging material that may contain pests, including crates, boxes, pallets, etc.
• Exemptions: Thin wood (6 mm or less thick), processed wood material (plywood, particle board, etc.)
• Treatment Methods:
• Heat treatment using a conventional heat chamber (HT)
• Heat treatment using dielectric heating (DH)
• Methyl bromide treatment (MB)
Conventional Heat Treatment (HT)
• Heat Treatment: When using conventional heat chamber technology, the fundamental requirement is to achieve a minimum temperature of 56 °C (132.8 °F) for a minimum duration of 30 continuous minutes throughout the entire profile of the wood (including its core).
16
5/25/2013
UN Hazardous Materials (Dangerous Goods) Regulations
Other Hazardous Materials (Dangerous Goods) Regulation Organizations
• Most HazMat regulations are based on the recommendations of the United Nations Committee of Experts on the Transport of Dangerous Goods. (Often called “Orange Book”)
• U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration (PHMSA)
• International Air Transport Association (IATA)
• International Civil Aviation Organization (ICAO)
• International Maritime Organization (IMO)
U.S. HazMat Regulations
49 CFR Parts 100 ‐ 185
• Title 49 of the Code of Federal Regulations (49 CFR), parts 100‐185
• Addresses key protocols for preparing, shipping, and handling dangerous goods. Any person handling dangerous goods should read, understand, and comply with all elements of the 49 CFR.
http://phmsa.dot.gov/hazmat
• Some of the highlights include:
• The description of hazardous materials by class, including explosives, gases, flammable and combustible liquids and solids, poisons, radioactive materials, and corrosive agents.
• The amount of hazardous materials permitted in certain primary containers as well as the total volume per shipped package.
• The types of packages and packaging required to safely transport hazardous materials.
• Testing requirements needed to reach specific performance standards.
• The documentation required when shipping hazardous materials.
• The markings and labels required on packaging and the placards required by the carrier.
• raining and safety plan requirements.
http://phmsa.dot.gov/regulations
17
5/25/2013
HazMats & Lab Tests
(http://www.advanced‐labs.com/un‐
hazmat‐testing.html )
Packaging Groups
Group
Danger Level
Drop Height
Pressure for Leakproof
I
Great
1.8 m
(70.9 in)
30 kPa
(4.35 psi)
II
Medium
1.2 m
(47.2 in)
20 kPa
(2.9 psi)
III
Minor
0.8 m
(31.7 in)
20 kPa
(2.9 psi)
Product
Quality
Technology
Marketing
Oriental Grocery Stores in the U.S.
U.S. Big Chains
18
5/25/2013
Walmart Packaging Scorecard
• Introduced in 2006, the scorecard included measurements for greenhouse gas emission, recycled content, and cube utilization, etc., in a simple 15‐question scorecard
• Now expanded into 100 category‐
specific scorecards in 2013
• Integrated with formal reviews of suppliers
• Suppliers who score well are recognized and rewarded
• Suppliers who do not perform well have meetings with Walmart to develop improvement plans.
19