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 3K
Fast Moving Consumer Goods in the 2
0
European Retail Supply Chain 1
1

ISTA 3 Series ISTA, Distributing Confidence, Worldwide™

General Simulation
Performance ISTA® 3-Series tests are advanced tests and are designed to:
 Challenge the capability of the package and product to withstand transport hazards, but
Test PROJECT*
 Utilize general simulation of actual transport hazards, and
 Do not necessarily comply with carrier packaging regulations.
When properly executed, ISTA procedures will provide tangible benefits of:
 Product to market time reduction
VERSION  Confidence in product launch
DATE  Reduction in damage and product loss
January  Balanced distribution costs
2011  Customer satisfaction contributing to increased market share
Initial Release
There are two sections to this procedure: Overview and Testing
Last  Overview provides general knowledge required before testing and
EDITORIAL  Testing presents the specific instructions to undertake laboratory testing.
Change:
Weights and measures system - Familiarity with the following units and symbols used in this document is required:
JANUARY
2017 For measuring Metric units and symbols
Weight kilograms (kg) or grams (gm)
Distance metres (m) or millimetres (mm)
Volume Cubic centimetres (cm3)
Density kilograms per cubic metre (kg/m3)
Temperature Celsius (°C)
For complete
listing of VERY IMPORTANT:
Procedure
Changes and The entire document shall be read and understood before proceeding with a test.
Version Dates
go to
www.ista.org
* Notes Regarding ISTA “Projects” and “Procedures”
 ISTA 3K is currently an ISTA “Project”, first released in January 2011. New ISTA test protocols are given the
designation "Project" during their implementation phase. After a minimum one-year period and required
evaluation, a "Project" will either be adopted as an established "Procedure", revised and kept as a "Project"
for another period of time, or be dropped. Therefore, a “Project” is potentially subject to greater and more
frequent revision than a “Procedure”.
 Comments regarding this Project and its use are encouraged and welcome. Please contact [email protected].
 ISTA members may use either Procedures or Projects for package certification.

Project History:
The testing detailed in this procedure is as per methods first developed through a multi-client research project that
was established and managed by Smithers Pira. The Smithers Pira research project examined real life supply chain
conditions and processes, and included a program of laboratory validation testing to benchmark test results against
real life packaged product performance. Smithers Pira shares these methods with ISTA in order to support the
packaging and testing communities in assessing packaging performance, and to support progression towards
greater sustainability in packaged grocery products distribution. Smithers Pira and ISTA acknowledge the co-
sponsors of the original Smithers Pira research project in allowing this test method to be published by ISTA.

ISTA 3K 2011 - Page 1 of 20

© 2017 International Safe Transit Association. All rights Reserved.
3K OVERVIEW OF PROJECT 3K
Preface Project 3K is a general simulation test for fast moving packaged consumer products shipped through the multiple-retail supply
chain environment in Europe. Project 3K is appropriate for the range of packages commonly merchandised through large retailer
stores and large retail chain convenience stores, and where retailer operations include shipment of store-specific mixed loads in
roll cages or as mixed pallets. This retail environment is common within western European countries, including (but not exclusive
to) Sweden, Norway, Denmark, UK, France, Belgium, Netherlands, Germany, Austria, Switzerland, Spain and Italy; thus the scope
of this project applies primarily to these countries. The scope also applies to similarly developed European states that are not
listed but where large multiple-retail environment infrastructure is developed. Note large multiple-retail environment infrastructure
involving shipment of mixed-loads is growing in other European countries and so this project may also apply in those cases. Many
European grocery packages are in shelf-ready format; this method applies equally to shelf ready and non-shelf ready packages.
In this procedure the term ‘package’ is used to describe a collation of primary packs. Common package formats that appear in the
retail supply chain are presented below to clarify the scope of this method (this list is not exhaustive):

Package Formats
 Small shrink wrap tray, for example
o collation of 6 or 12 deodorant aerosols
o collation of 6 glass jars of a sauce product
 Large shrink wrap trays, for example
o tray of 24 cans of a beverage product
o tray of 12 stand-up-pouches of washing detergent product
 Small corrugated cases or wraps, for example
o shelf ready corrugated case for a snack product
 Large corrugated cases or wraps, for example
o collation of 20 glass bottles of a beverage product
o tray of 12 aseptic drinks cartons
 Shrink wrap without tray, for example
o collation of 6 large bottles of mineral water
o collation of rolls of an absorbent kitchen towel product
 Bags, for example
o 10kg or 20kg bag of pellet pet food product
o Collation of 12 bags of flour or sugar product.

The following package type definitions are required for selecting specific tests where test options are detailed:
Type 1: Single hand lift/carry – closed ends
Weight  4.5kg
AND
One principal dimension  120mm
AND
No opening in the outer package materials  60 x 40mm with
flexibility or space behind so at least 3 fingers could be inserted
(i.e. the package is a closed corrugated case or carton, or is a
shrink wrap collation that can’t be lifted by inserting the hand in
to the opening in the wrap at one end of the package).

Type 2: Double hand lift/carry – closed ends

All principal dimensions  120mm
AND / OR
Weight > 4.5kg
AND
No opening in the outer package materials  60 x 40mm with
flexibility or space behind so at least 3 fingers could be inserted
(i.e. the package is a closed corrugated case or carton, or is a
shrink wrap collation that can’t be lifted by inserting the hand in
to the opening in the wrap at one end of the package).

Continued on next page

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© 2017 International Safe Transit Association. All rights Reserved.
3K OVERVIEW OF PROJECT 3K
Preface Continued from previous page
continued
Type 3: Single hand lift/carry - open ended
Weight  7kg
AND
Opening at one (or more ends)  60mm x 40mm with flexibility
or space behind so at least 3 fingers can be where there is
sufficient space to insert the hand within an opening in the wrap)
inserted for lifting (i.e. normally a shrink wrap collation).

Opening > 60mm x 40mm

Type 4: Double hand lift/carry - open ended

Weight > 7kg
AND
Opening at two opposing ends  60mm x 40mm with flexibility
or space behind so at least 3 fingers can be inserted for lifting
(i.e. normally a shrink wrap collation where there is sufficient
space to insert at least 3 fingers within an opening in the wrap at
either end of the package).

Opening > 60mm x 40mm

NOTE:
Within this procedure the term ‘sample’ is also used as a common description for the various types of packages
described above (i.e. one ‘sample’ is the same as one ‘package’, consisting of a number of primary packs in a collation).

General
 Testing can be used to evaluate the fitness for purpose of a packaged-product or the protective performance of packaging
with respect to the common hazards of the European retail supply chain.
 Tests and test levels are based on observation of various brand owner and retailer distribution and in-store systems, and
correlation between specific damage occurrences observed in the field and damage produced using laboratory testing during
a validation exercise; however the test may not represent any specific distribution system.
 The package and product are considered together and not separately.
 Some conditions of transit, such as moisture, pressure, careless handling or unusual handling may not be covered.

Other ISTA Procedures or Projects may be appropriate for different conditions or to meet different objectives.

Refer to Guidelines for Selecting and Using ISTA Test Procedures and Projects for additional information.

NOTE:
Hazardous material packaging that passes this test procedure may not meet international, national or other
regulatory requirements for the transport of dangerous goods or hazardous materials. This test is not a substitute
for United Nations and/or any other required test standards for the transport of dangerous goods or hazardous
materials, but may be used as an additional test in conjunction with them.

ISTA 3K 2011 - Page 3 of 20

© 2017 International Safe Transit Association. All rights Reserved.
 3K OVERVIEW OF PROJECT 3K
Scope Project 3K covers the testing of packaged-products prepared for sale through multiple-retail environments. From the point of
manufacture of finished packaged goods, this supply chain commonly involves unit load (full pallet) storage, unit load shipment and
unit load handling within the brand owner controlled part of the supply chain, leading to delivery of unit loads of product to a retailer
distribution centre. This is commonly followed by a series of steps controlled by the retailer, involving order picking and mixed load
building at the retailer distribution centre, mixed load delivery to store and in-store handling leading to loading of packaged-
products on to the store shelf.
This test method relates only to the retailer controlled parts of this supply chain. Separate testing should be undertaken
at the unit load level to determine fitness with respect to full pallet shipment commonly controlled by the brand owner.
Research shows that the hazards of distribution are commonly more severe in the retailer controlled parts of the supply chain
(largely due to the complex product mix); however successful performance in this test method does not eliminate the need for
evaluating packaged-product performance at the unit load level.
Specifically the test investigates the following processes occurring at the package (case or tray) level:
o Pyramid-pick/Overhang stack (representing the way a package is often partially supported on the unit load at the
pick face at retailer distribution centre, occurring as a result of the way other packages are selected from the unit
load)
o Drag (representing pulling of a package from a unit load at the pick face at retailer distribution centre)
o Carry (representing lifting and carrying of a package over short distance from the pick face to the mixed load,
including, as appropriate to the pack design/format, carrying packs without supporting the base and carrying using
openings in shrink wrap)
o Placement-drop and Drop–on impact (representing impacts occurring to packages during building of the mixed load)
o Package horizontal impacts (representing impacts occurring through automated conveyor operations at automated
retailer distribution centres) - where it is known or possible that packages will pass through a retailer distribution
centre with conveyoring/package level automated systems this test should be conducted.
Specifically the test investigates the following processes occurring for mixed loads (mixed pallets or roll cages):
o Both mixed pallet and mixed roll cages are commonly used in retailer distribution in Europe. Based on observation it
is deemed that roll cage mixed loads experience more significant hazards because packs are able to press against
the roll cage sidewalls as well as other packs (other than this, mixed load hazards are similar between the mixed
load pallet and mixed load roll cage formats); the presence of sidewalls provides a horizontal load on packs that is
less significant in mixed pallets. Because both mixed pallet and roll cage formats are used widely, the worst case of
the two formats was selected for the test.
o Horizontal impact of mixed load (representing horizontal cage to cage (or mixed pallet to mixed pallet) impacts, or
impacts between a mixed load and other fixed object, occurring during vehicle loading, road journey and handling at
store)
o Vibration of mixed load (representing the road journey segment of the mixed load life cycle, but also representing
more aggressive vibration occurring during loading/unloading where mixed loads are moved over chequer-plate
ramps or rough surfaces within receiving bay areas, normally at the store)
o Vertical impact of mixed load (representing higher level transient shocks occurring during road shipment and vertical
shocks occurring during marshalling/movement of mixed loads over rough surfaces or over door thresholds,
normally at the store).

Product Damage The shipper shall determine the following prior to testing:
Tolerance and  what constitutes damage to the product and
Package
Degradation  what damage tolerance level is allowable, if any, and
Allowance  the correct methodology to determine product condition at the conclusion of the test and
 acceptable package condition at the conclusion of the test.

For additional information on these determinations refer to Guidelines for Selecting and Using ISTA Test Procedures and Projects.

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© 2017 International Safe Transit Association. All rights Reserved.
 3K OVERVIEW OF PROJECT 3K
Samples Samples should be untested actual package and product, but if one or both are not available, the substitutes shall be as
representative as possible to actual items.

Multiple test samples are required, but they should be identical. The exact number is dependent on the size of the sample. To
provide an indication of the total number of samples needed for testing, establish the number of samples required to build a stack
measuring at least 0.8m x 0.8m x 1.6m without significant gaps in the stack. Take this number and multiply it by 2; the resultant
provides a guide to the total number of samples required. For example for a sample measuring 0.4m x 0.4m x 0.2m, 16 samples
would be required to build the stack described above, so a total of 32 samples would be required for testing.

For this procedure the samples are classified and utilized in three (3) ways:
 Test packages are used from the start through to the end of testing; when multiple identical test packages are tested, all
test packages must pass all tests.
 Dummy packages are used in various parts of the procedure to allow effective simulation of the real life hazard in the
test (so that the real life hazard is correctly applied to the test package). Specifically, dummy packages are used in Test
Blocks 1, 2, 3, 6 and 13. If a dummy package becomes degraded to the point that it does not maintain its shape or
provide resistance to test packages it should be replaced with another dummy package, but dummy packages are not
subject to inspection or pass/fail assessment as part of the test. Note: dummy packages are different from Roll Cage Fill
packages described below.
 Roll Cage Fill packages are used only in Test Blocks 8, 9 and 10 to enable building of the mixed load in the roll cage
around the test packages. Dummy packages used during Test Blocks 1- 6 should not be used as Roll Cage Fill
packages for Test Blocks 8, 9 and 10. Upon completion of Test Block 10 Roll Cage Fill packages are set aside for later
assessment (and pass/fail judgment), so should not be used as Dummy packages in Test Blocks 11-13.
To enable effective tracing of samples throughout the procedure, Test package samples should be identified with “TP”, Dummy
package samples as “DP” and Roll Cage Fill package samples with “RCF”. The exact number of each classification will vary
depending on the size and type/format of package, so this identification is to be applied to each pack during testing at the point
where a Test package, Dummy package or Roll Cage Fill package is required according to the details in the Test Block.

Refer to Guidelines for Selecting and Using ISTA Test Procedures and Projects for additional information on statistical sampling.

NOTE:
In order to ensure testing in perfect condition, products and packages shipped to an ISTA Certified Laboratory for
testing shall be:
 Adequately over-packaged for shipment or
 Repackaged in new packaging at the laboratory.

NOTE:
It is important to thoroughly document the configuration, materials, and construction of the tested product and
package. Significant variations in performance can sometimes be caused by seemingly insignificant differences.
Photo documentation is strongly recommended to supplement detailed written descriptions.

Basis Weights of Corrugated Board

Basis Weight
When the outer package is a corrugated box, it is strongly recommended that the basis weights of the papers/paperboards used to
make the box be determined and documented. If the nominal basis weights change, even if the board is rated for the same
performance, a retest is appropriate.

Refer to Guidelines for Selecting and Using ISTA Procedures and Projects for additional information on documentation and basis
weight determination.

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© 2017 International Safe Transit Association. All rights Reserved.
 3K OVERVIEW OF PROJECT 3K
Test Sequence Test sample selection and sample flow through the test sequence are detailed within the TESTING part of this PROJECT

Format Test Category Test Type Test Level For ISTA Certification
Package Atmospheric Temperature and Ambient, frozen or chilled (to Required
Preconditioning Humidity be selected as appropriate
TEST BLOCK 1 for the distribution and
merchandising channel for
the packaged product being
tested)
Package Picking Pyramid Pick 5 minute test duration Required
TEST BLOCK 2 (Overhang stack)

Package Picking Drag 900mm drag distance at Required

TEST BLOCK 3 1.0 m/s

Package Picking Carry 10 seconds static plus 5 Required

TEST BLOCK 4 cycles carry-oscillation

Package Shock Placement drop 5 impacts in various Required

TEST BLOCK 5 orientations, 150mm

Package Shock Drop-on Impacting top of lower Required

TEST BLOCK 6 package, base of upper
package, 150mm
Package Shock (OPTIONAL) Impact 8 impacts at 1.35m/s Optional
TEST BLOCK 7
Mixed load Shock Impact 4 impacts at 0.91m/s Required
TEST BLOCK 8
Mixed load Vibration Random Overall Grms level of 0.28 Required
TEST BLOCK 9 Vibration for 40 minutes followed by
0.517 for 60 seconds
Mixed load Shock Flat drop 1 drop from 60mm Required
TEST BLOCK 10
Package Shock Placement drop 4 impacts in various Required
TEST BLOCK 11 orientations, 150mm

Package Shock Drop 4 impacts in various Advised (Optional)*

(INVESTIGATIVE) orientations, 300mm
TEST BLOCK 12
Package Shock Drop-on Impacting top of lower Advised (Optional)*
(INVESTIGATIVE) package, base of upper
TEST BLOCK 13 package, 300mm

Assessment Package No testing Inspection and assessment Required

Assessment involved of test and roll cage fill
BLOCK 14 packages

* In certain situations, the 300mm drop or drop-on test may not be appropriate. 300mm drops represent 'worst of normal' handling
and should be conducted to investigate the perfromance of packages under more severe (but still within the range of normal)
conditions; not every package will experience free fall impact from 300mm, but a small quantity of packages will be exposed to this
level of hazard such that its effect should be investigated. If the drops are NOT performed, this should be shown in the test report.

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© 2017 International Safe Transit Association. All rights Reserved.
 3K EQUIPMENT REQUIRED FOR PROJECT 3K
Equipment Atmospheric Conditioning:
Required  Humidity recorder complying with of the apparatus section of ISO 2233 or ASTM D 4332.
Atmospheric
Conditioning  Temperature recorder complying with the apparatus section of ISO 2233 or ASTM D 4332 .
 Chamber and Control apparatus complying with the apparatus section of ISO 2233 or ASTM D 4332 .

In compliance with the

Equipment Type of Shock Test Type of Equipment Comments
apparatus sections of…
Required
Shock Free-Fall Drop Tests Fork-type free-fall drop ISO 2248 or ASTM D If available, use this drop
tester 5276 apparatus as the preferred option
for all package drop tests (from
150mm and 300mm) and for the
60mm mixed load drop test.
Some drop tester designs do not
allow for drops as low as 150mm
or 60mm – in this case use
alternative apparatus described
below.
Free-Fall Drop Tests Drop by hand using a N/A Preferred alternative option for
(Alternate) reference measure to 150mm package drop tests
maximise repeatability of
drop height
Free-Fall Drop Tests Slings and Quick-Release ISO 2248 or ASTM D Preferred alternative option for
(Alternate) mechanism 5276 60mm mixed load drop test
X

Impact Tests Incline ISO 2244 or ASTM D 880

or ASTM D 4003

Horizontal

Equipment Random Vibration:

Required  Vertical Random Vibration Test System complying with the apparatus section of ISO 13355 or ASTM D 4728 .
Vibration
 Means must be provided to prevent the test item from moving off the vibration system’s platform, without restricting the
vertical motion of the test item.

Equipment Mixed Load:

Required  A four wheeled metal roll-cage measuring approximately 800mm X 700mm in the horizontal
Mixed Load axes and 1800mm in height (from the underside of the wheels to the top of the metal cage).
A mid-shelf in the roll cage may be required – see bottom of page 11 for further details.
 Cage to have three fixed sides and one open side, plus two elastic or fabric straps
to contain product on the open side face.

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© 2017 International Safe Transit Association. All rights Reserved.
3K EQUIPMENT REQUIRED FOR PROJECT 3K
Equipment
Type of
Required Type of Equipment Drawing/Detail Comments
Package/Carry
Picking
Picking Drag Wedge A wedge approximately 70 mm Ensures the front edge of top
wide, 150mm long, with one end package is supported by the test
2 mm high and the other end package
20 mm high.
Single hand One single-dummy hand Dimensions = mm It is most suitable to construct this
lift/carry packages required dummy hand in mild or stainless
(Type 3 package, steel. To undertake the oscillation
as defined in the part of the lift/carry tests using the
Preface) single dummy hand, secure the
single hand to a rigid frame or
assembly (described below in “For
the oscillatory part of the carry
test”. Drill a hole at the top of the
single dummy hand to enable the
dummy hand to be hung freely on
the rigid frame/assembly.

Double hand A pair of double-dummy Dimensions = mm It is most suitable to construct this

lift/carry packages hands required dummy hand in hardwood timber
(Type 4 package, or in aluminium or stainless steel.
as defined in the To undertake the oscillation part
Preface) of the lift/carry tests using the
double dummy hands, secure the
dummy hands to a rigid frame or
assembly (described below in “For
the oscillatory part of the carry
test”). Drill a hole at the top of
each dummy hand to enable the
dummy hand to be hung freely on
the rigid frame/assembly.
For the oscillatory Oscillation may be Complying with the apparatus Will require displacement and
part of the carry effected using a vibration section of ISO 13355 or ASTM D frequency to achieve peak
test table with fixed frequency 4728 would be suitable – other acceleration of 0.2g, delivered
sinusoidal control, and smaller scale sinusoidal with peak to peak displacement of
with the package oscillation producing apparatus no less than 40mm and no more
supported on a rigid frame may also be suitable than 80 mm (corresponds to
or assembly such that the frequency no more than 1.6Hz
test item hangs clear of and no less than 1.1Hz)
the table platform during
the test. The rigid
frame/assembly can be of
any construction as long
as there is no flex in the
construction as a result of
the oscillation during test,
and as long as the frame
and vibration table
platform do not interfere
with the test package
during oscillation.

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© 2017 International Safe Transit Association. All rights Reserved.