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Compression Strength Loss Over Time in Warehouse Storage
Corrugated boxes lose a significant portion of their original compression strength during prolonged storage, especially under load. Understanding the mechanics of compression creep and the environmental factors at play allows packaging engineers to design boxes that maintain structural integrity throughout their intended shelf life.
Why Compression Strength Declines
- Material Creep: Fibers gradually deform under constant load, reducing box stiffness.
- Humidity Impact: Elevated RH accelerates creep, with potential strength losses of 40–60% in humid conditions.
- Stacking Configuration: Poor pallet patterns or uneven weight distribution compound stress points.
Testing and Standards
- ASTM D4577: Measures compressive creep over time in shipping containers.
- ASTM D642: Evaluates initial compression strength, serving as a baseline before long-term storage.
Design Strategies to Reduce Loss
- Select Higher ECT Boards: Provides a stronger starting point, delaying the drop below critical load thresholds.
- Moisture Control: Use desiccants, ventilation, or moisture-barrier coatings in high-humidity warehouses.
- Pallet Pattern Optimization: Uniform stacking prevents concentrated stress on corner posts.
Application Considerations
- Long-term storage in non-climate-controlled facilities should factor in 30–50% compression loss for safety margins.
- Double-wall or reinforced designs are advised for seasonal inventory stored for extended periods.
References
ASTM International. (2015). ASTM D4577-15: Standard test method for compressive creep of shipping containers. ASTM International. https://www.astm.org/d4577-15.html
ASTM International. (2015). ASTM D642-15: Standard test method for determining compressive resistance of shipping containers. ASTM International. https://www.astm.org/d0642-15.html
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Home » Compression Strength Loss Over Time in Warehouse Storage

The Edge Crush Test (ECT) is a critical performance metric for corrugated boxes, directly correlating to stacking strength and load-bearing capacity. In the high-stress world of e-commerce shipping, where packages face frequent handling, multi-stop routes, and varying climates, optimizing ECT values without over-engineering is essential for cost efficiency and product protection. Why ECT Matters in E-Commerce Stacking Strength: Determines how well boxes can withstand vertical loads in warehouse racking or trailer stacking. Material Efficiency: Allows engineers to achieve performance targets with lighter weight liners or mediums, reducing costs. Regulatory Alignment: Certain carriers and industry sectors specify minimum ECT ratings for compliance. Balancing ECT and Basis Weight ECT vs. Mullen Burst: ECT measures column strength; Mullen measures resistance to puncture/tearing. E-commerce often favors ECT for stacked pallet loads. Lightweighting Strategies: Use high-performance recycled fiber blends to maintain stiffness. Incorporate higher-grade outer liners for localized reinforcement. Design Variables That Influence ECT Flute Profile: B- and C-flutes offer different stiffness profiles. B-flute generally yields higher ECT for the same board weight. Adhesive Quality: Uniform glue lines prevent micro-buckling under compression. Moisture Resistance: High humidity can reduce ECT by up to 50%; moisture-resistant coatings help maintain performance. Testing and Standards ASTM D642: Measures box compression strength. TAPPI T839: Determines edgewise compressive strength of corrugated fiberboard using the clamp method. ISTA Series: Full-scale distribution simulation, including drop, vibration, and compression under varying conditions. Optimization in Practice Case Example: Switching from 44 ECT double-wall to 32 ECT single-wall with enhanced flute medium reduced material cost by 14% without increasing damage claims in a 90-day trial. Prototyping: Lab ECT data should be validated through route-specific field testing before large-scale rollout. ReferencesASTM International. (2015). ASTM D642-15: Standard test method for determining compressive resistance of shipping containers. ASTM International. https://www.astm.org/d0642-15.htmlTechnical Association of the Pulp and Paper Industry. (2018). TAPPI T839 om-18: Edgewise compressive strength of corrugated fiberboard using the clamp method. TAPPI. https://www.tappi.org/content/store/shared/T839.htmlInternational Safe Transit Association. (2018). ISTA 6-Series transit tests. ISTA. https://ista.org/ (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Corrugated Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts

In the world of packaging, ensuring the safety and integrity of products during transit is paramount. This is where the corrugated box drop test comes into play. It’s a critical evaluation method used to determine the durability and protective qualities of corrugated boxes, which are widely used in shipping various goods. This blog post delves into the details of the corrugated box drop test, its importance, and how it is conducted. The Importance of the Corrugated Box Drop Test Drop testing is an essential part of quality control in packaging. It simulates the impacts a package may endure during handling and shipping, including being dropped, knocked, or jostled. For businesses, ensuring that their product packaging can withstand such treatment is crucial to avoid damage during shipping, which can lead to financial losses and affect customer satisfaction. What is a Corrugated Box Drop Test? The corrugated box drop test is a systematic procedure where a packed corrugated box is dropped from a specific height to observe how well the packaging protects its contents. This test is typically performed under controlled conditions following standardized guidelines, such as those set by ASTM or ISTA. How is the Drop Test Conducted? Preparation of the Test Sample: The corrugated boxes are prepared with the actual product inside, or a dummy package that simulates the weight and dimensions of the real product. The boxes are sealed as they would be for normal distribution. Determination of Drop Height: The height from which the box is dropped depends on the package’s weight and the standards being followed. Typically, the higher the package’s weight, the lower the drop height. Execution of the Drop: The box is dropped onto a solid, flat surface. The drops are conducted on different faces of the box, including corners and edges, to simulate various real-world scenarios. Each drop is observed and recorded, noting any visible damage to the box and its contents. Assessment Post-Drop: After the test, the box is examined for any signs of structural failure, such as tears, ruptures, or punctures. The contents are checked for damage or breakage. Interpreting Test Results Pass/Fail Criteria: The criteria for passing the test can vary but generally include no significant damage to the box or its contents. Data Analysis: The results are analyzed to determine if the packaging design needs to be improved. This could involve enhancing the box’s material strength, adding protective cushioning inside, or altering the box design. Why is the Drop Test Crucial? Consumer Confidence: Ensuring product safety during shipping builds consumer trust and satisfaction. Cost-Effectiveness: It’s more cost-effective to invest in proper packaging than to bear the costs of damaged goods and returns. Brand Reputation: Consistently delivering products in excellent condition enhances a brand’s reputation. Technological Advances in Drop Testing Automated Drop Test Equipment: Some companies use advanced, automated equipment to conduct more precise and repeatable drop tests. Simulation Software: Technological advancements allow for computer simulations of drop tests, providing an additional layer of analysis. Conclusion The corrugated box drop test is a vital tool in the packaging industry, serving as a frontline check for packaging integrity. Regularly conducting these tests helps businesses ensure that their products are well-protected through the rigors of shipping and handling. In the end, the drop test is not just about maintaining product integrity; it’s about upholding customer satisfaction and preserving the brand’s reputation in a competitive marketplace. If you are interested in corrugated boxes and require assistance in passing a drop test, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Corrugated Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts

Choosing corrugated boxes for packaging needs is a decision that offers unparalleled benefits in terms of protection, sustainability, and cost-effectiveness. These boxes stand out for their robust design, versatility, and environmental friendliness, making them a top choice for businesses looking to optimize their packaging solutions. Superior Protection At the heart of the appeal of corrugated boxes is their exceptional ability to protect contents during shipping and storage. The secret lies in their construction: a fluted corrugated sheet sandwiched between one or two linerboards. This structure creates a sturdy yet cushioned barrier against impacts, vibrations, and compressive forces, ensuring that items inside remain secure and undamaged. The fluting also provides excellent insulation against temperature changes, which is crucial for the safe transport of sensitive products. Customization and Flexibility Corrugated boxes can be easily customized to meet the specific needs of any product, regardless of size, shape, or fragility. This flexibility ensures that every item can be packaged in a box that fits perfectly, reducing the risk of movement and damage. Additionally, these boxes can be printed with logos, branding elements, or handling instructions, enhancing brand visibility and providing valuable information to handlers and consumers alike. Environmental Sustainability In today’s eco-conscious market, the sustainability of packaging materials is more important than ever. Corrugated boxes excel in this area, as they are made from recycled paper and are fully recyclable themselves. The industry’s commitment to sustainable practices means that the majority of corrugated cardboard is produced using renewable energy sources, and the high recycling rate of these boxes reduces the need for virgin paper, conserving natural resources and minimizing environmental impact. Cost Efficiency Despite their high quality and performance, corrugated boxes are an economical packaging option. Their lightweight design lowers shipping costs, and the materials used in their production are relatively inexpensive, especially when compared to alternative packaging solutions. This cost efficiency makes corrugated boxes an attractive choice for businesses of all sizes, from small startups to large corporations. Durability for Repeated Use Corrugated boxes are not only strong but also durable enough for multiple uses, underlining their value and efficiency. When handled and stored properly, these boxes can be reused several times, further extending their lifecycle and enhancing their environmental benefits. This durability also contributes to their cost-effectiveness, as the ability to reuse boxes can significantly reduce packaging costs over time. Wide Range of Applications The versatility and adaptability of corrugated boxes make them suitable for a vast array of applications. From fragile electronics and perishable food items to bulky industrial equipment, corrugated boxes can be engineered to meet the specific requirements of virtually any product. This wide-ranging applicability ensures that businesses in diverse sectors can rely on these boxes for their packaging needs. Conclusion The choice of corrugated boxes for packaging is justified by their protective qualities, customization options, environmental sustainability, cost-efficiency, and durability. These advantages make corrugated boxes an indispensable resource for businesses seeking reliable, responsible, and effective packaging solutions. With their ability to cater to a wide range of products and their contribution to sustainable packaging practices, corrugated boxes are not just a choice but a necessity for forward-thinking businesses today. If you are interested in corrugated boxes, then partner with Brown Packaging today to get started. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Corrugated Boxes Facebook Twitter LinkedIn Pinterest Relevant Posts