Packaging Testing Checklist: What to Do Before You Ship
This checklist covers every step of the packaging testing process — from selecting the right protocol to submitting your test report to a retailer or regulatory agency. Use it before every product launch, packaging redesign, or customer compliance submission.
Step 1: Define Your Testing Requirement
- ☐ Identify what your customer, retailer, or regulatory requirement specifies (ISTA series, ASTM standard, Amazon APASS)
- ☐ If no requirement is specified, select the appropriate protocol based on product weight and distribution environment (see our ISTA guide)
- ☐ Confirm whether you need ISTA certification, ASTM documentation, or Amazon APASS qualification — they are different outputs from different protocols
- ☐ Determine whether you need ISO 17025 accredited results (most major retailers and regulatory agencies require this)
Step 2: Select Your Laboratory
- ☐ Verify ISO 17025 accreditation — confirm it is current and covers your required test methods
- ☐ Verify ISTA certification if running ISTA protocols
- ☐ Verify Amazon APASS qualification if pursuing FFP or SIOC
- ☐ Confirm equipment capability — payload capacity, force capacity, temperature range
- ☐ Confirm report turnaround meets your timeline
- ☐ Request written scope confirmation before shipping samples
Step 3: Prepare Your Samples
- ☐ Use production-representative packaging — same materials, same board grade, same closure system as production
- ☐ Use production-representative product weight — fill with representative product or equivalent deadweight
- ☐ Prepare the minimum required sample quantity (confirm with lab — typically 3–6 samples)
- ☐ Label samples clearly — product name, product weight, packaging configuration
- ☐ Do not condition samples yourself — let the lab condition per protocol
Step 4: Submit and Test
- ☐ Receive and review written test scope from the lab before shipping
- ☐ Ship samples to the lab with sufficient lead time for your report deadline
- ☐ Confirm sample receipt with the lab after shipping
- ☐ Confirm test schedule and report delivery date
Step 5: Review Your Test Report
- ☐ Verify test protocol matches what was required
- ☐ Verify all test elements were completed in the correct sequence
- ☐ Review pass/fail determination for each test element
- ☐ If failed: review failure mode analysis and redesign recommendations
- ☐ If passed: retain report for customer submission and internal records
Step 6: After a Failure — Redesign and Retest
- ☐ Identify the specific failure mode from the test report
- ☐ Implement the targeted redesign (cushioning, board grade, closure, or structural)
- ☐ Prepare new samples with the redesigned packaging
- ☐ Retest — priority scheduling available at CertaPak for active redesign cycles
- ☐ Do not submit a failed test report to customers — only submit passing results
Step 7: Submit and Maintain Certification
- ☐ Submit passing test report to customer, retailer, or regulatory portal as required
- ☐ File the test report in your packaging validation documentation system
- ☐ Set a review trigger for any packaging change — material, dimension, weight, or closure changes require retesting
- ☐ Schedule periodic retesting if your distribution environment or retail requirements change
Quick Protocol Reference
| Situation | Recommended Protocol |
|---|---|
| General retail, no specific requirement | ISTA 2A |
| Major retailer requiring full simulation | ISTA 3A |
| Amazon FFP or SIOC | ISTA 6 via APASS |
| Pharmaceutical or medical device | ASTM D4169 + ISO 11607 |
| Automotive OEM supply | ASTM D4169 per OEM spec |
| Product over 150 lbs | ISTA 2B or 3B |
| Budget-constrained basic check | ISTA 1A or ASTM D5276 drop test |
Ready to start? Submit your packaging details to CertaPak — free protocol recommendation, scope confirmed in 24 hours, reports in 48.