Drop testing: Impacts and drops in transportation environments

A shock is a short-duration, high-intensity dynamic event caused by a sudden change in velocity. When a moving object comes to an abrupt stop, a shock occurs. This happens, for example, when a package is dropped. To perform well, packaging must withstand the shocks it encounters throughout the distribution chain. Drop and impact hazards exist at every stage of transportation, making it essential to recognize these risks and understand the transport environment.

Shock during transportation

Packages are often dropped or subjected to impacts during distribution, though most drop heights are relatively low. The majority occur during manual handling, such as loading, unloading or transferring packages between vehicles.

Handling activities like sorting, stacking, loading and vehicle transfers expose packages to numerous drop risks and potential hazards.

Mechanical handling

Drops may be accidental or intentional. They can result from human error, carelessness or slipping. Although accidental drops are less common, they are often more severe due to higher drop heights and unpredictable impact directions. Time pressure also reduces package safety, particularly during peak seasons when shipment volumes are high and staff work under heavier workloads. Shocks may also occur if proper handling equipment or facilities are lacking.

❌ In many cases, drops are not caused by negligence but by efficiency:
It is often faster to drop, toss, or kick a package into place rather than carefully set it down. As a result, packages are frequently dropped from low heights as part of routine operations. When thrown, a package may travel some distance, with the greatest effect occurring at final impact. These events can damage both packaging and contents. The impact surface also influences the force transmitted to the product inside. Packages are commonly dropped onto other packages as well. Such handling shocks are short in duration but generate high acceleration.

How can you prepare for or protect against these scenarios?

✅ Through testing. Drop testing is one of the most effective ways to evaluate packaging performance.

Drop testing and testers: Cost-effective and smart testing solutions

Drop testing is among the most widely used methods for validating packaging in transportation. Drop testers are a familiar sight in many laboratories because they are simple to operate and provide significant benefits.

They are relatively affordable, easy to use, and require minimal training or maintenance. Investing in an in-house drop tester quickly pays off, enabling virtually unlimited testing and retesting. Both proprietary procedures and established test standards can be applied.

Repeatability, reliability and accurate data

Repeatability is the foundation of meaningful testing. Without it, results cannot be compared. Quality data drives better decisions, which is why obtaining consistent and reliable test data with a purpose-built drop tester is so important.

Why manual drop testing is not suitable

Manually dropping packages is rarely accurate, controlled or repeatable. Setup takes time, and results are often inconsistent. Instead of using improvised setups with tape or string, a dedicated drop tester ensures controlled conditions.

A tester’s mechanism allows precise control of drop orientation and free fall. The platform retracts quickly so the package falls cleanly onto the test surface. Drop orientation (corner, edge or side) is usually defined by standards.

Free-fall drop testers are typically used for small and medium-sized packages, dropped onto a hard surface (usually steel), another package, or even an obstacle such as a wooden block.

Key considerations

✅ Testing packaging to standards cannot eliminate all transport risks, but it strengthens your position in potential disputes by proving that packaging has been validated against real-world hazards. Knowledge is power and testing is always a sound investment. Reliable results lead to better packaging decisions.

For more information about drop testing, please feel free to contact us.