NOTICE: This standard has either been superseded and replaced by a new version or discontinued.

Contact ASTM International (www.astm.org) for the latest information.

Desi
Design
gnat
atio
ion:
n: D 6198
6198 – 01

Stan
Standa
dard
rd Guid
Guide
e for
for
Transpo
ransport
rt Packag
Packaging
ing Design1
Design
This standard is issued under the fixed designation D 6198; the number immediately following the designation indicates the year of 
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript
superscript epsilon
epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope
Scope D 1974
1974 Practice
Practice for Method
Methodss of Closin
Closing,
g, Sealin
Sealing,
g, and
1.1 This guide covers
covers an approach
approach to design of packaging
packaging Reinforcing Fiberboard Boxes 2
for distributing goods through the hazards of handling, storage, D 3332 Test Methods
Methods for Mechanica
Mechanical-Sh
l-Shock
ock Fragility
Fragility of 
2
and transportation. Products, Using Shock Machines
1.2 The principal
principal content of this guide is the identificat
identification
ion D 3580 TestTest Method for Vibration (Vertical
(Vertical Linear Motion)
2
of the key steps involved in development of transport pack- Test of Products
ages, including shipping containers, interior protective pack- D 4003 TestTest Methods for Programmable Horizontal
Horizontal Impact
aging, and unit loads. It is recognized that actual usage and Test for Shipping Containers and Systems 2
application to individual design projects may vary appreciably D 4169 Practice for Performance Testing Testing of Shipping Con-
2
without diminishing the value of the process. Consult with a tainers and Systems
packaging professional whenever needed. D 4728
4728 Test Method
Method for Random
Random Vibrati
ibration
on Testing
esting of 
2
1.3 This guide is not intended
intended for design of primary pack- Shipping Containers
aging
aging unless
unless the primar
primaryy packag
packagee is planne
planned d for use as a D 4919 Specificat
Specification
ion for Testing
esting of Hazardous
Hazardous Material
Materialss
2
shipping container. Packagings
1.4 The user of this guide
guide must be aware of the carrier
carrier rules D 5276 TestTest Method for Drop TestTest of Loaded Containers by
2
regarding packaging for shipment via each mode of transpor- Free Fall
tation in which the transport package may move, such as the D 5487
5487 Test Method for Simulated
Simulated Drop of LoadedLoaded Con-
2
National Motor Freight Classification (less-than truckload) and tainers by Shock Machines
the Uniform
Uniform Freight
Freight Classifica
Classification
tion (railroa
(railroad).
d). For hazardous
hazardous D 6055 TestTest Methods for Mechanical Handling of Unitized
material
materialss packaging,
packaging, the packaging
packaging must perform
perform to the re- Loads and Large Shipping Cases and Crates 2
quirements of the applicable modal regulations listed in Sec- D 6179
6179 Test Method
Methodss for Rough
Rough Handli
Handlingng of Unitiz
Unitized
ed
2
tion 2. Loads and Large Shipping Cases and Crates
1.5   This standar
standard d does
does not purpor
purportt to addre
address
ss all of the D 6344 TestTest Method for Concentrated Impacts to Transport
Transport
2
safe
safety
ty conc
concer
erns
ns,, if any
any, asso
associ
ciat
ated
ed with
with its
its use.
use. It is the
the Packages
responsibility of the user of this standard to establish appro- D 6537
6537 Practice
Practice for Instrume
Instrumented
nted Package
Package Shock Testing
Testing
2
 priate safety and health practices and determine the applica- for Determination of Package Performance
bility of regulatory limitations prior to use. 2.2 ISO Standard:
Standard:
ISO 4180 Complete Filled Filled Transpor
Transportt Packages—G
Packages—Gener eneral
al
2. Referenced Documents Rules for the Compilation of Performance Test Schedules 3
2.1   ASTM Standards: 2.3 Other Documents:
D 642 Test Method
Method for Determini
Determining
ng Compressi
Compressive ve Resis-
Resis- National Motor Freight Classification 4
tance
tance of Shippi
Shipping
ng Contai
Container
ners,
s, Compon
Componentents,
s, and Unit
Unit Uniform Freight Classification, Rail Publication Service 5
Loads2 International Civil Aviation Organization Technical Instruc-
D 880 Test
Test Method for Impact Testing
Testing of Shipping Contain- tions for the Safe Transport of Dangerous Goods by Air 6
ers and Systems 2 IMDG
IMDG Code,Code, Intern
Internati
ationa
onall Mariti
Maritime
me Danger
Dangerousous Goods
Goods
7
D 996 Terminology
Terminology of Packaging
Packaging and Distribution Environ-
Environ- Code
ments2
D 999 Test
Test Method
Methodss for Vibrati
ibration
on Testing
esting of Shippi
Shipping
ng
Containers2 3
Available
Available from American National Standards Institute, 25 W. 43rd St., 4th
Floor, New York, NY 10036.
4
Available
Available from National
National Motor Freight
Freight Traffic
Traffic Association,
Association, Inc., American
1
This guide is under the jurisdiction of ASTM Committee D10 on Packaging and Trucking Associations, 2200 Mill Road, Alexandria, VA 22314.
5
is the direct responsibility of Subcommittee D10.21 on Application of Performance Available
Available from 151 Ellis Street NE, Suite 200, Atlanta,
Atlanta, GA, 33035-6021.
33035-6021.
6
Test Methods. Available from ICAO, Suite 400, 1000 Sherbrooke St. W., Montreal, Quebec,
Current
Current edition
edition approved
approved Oct. 10, 2001.
2001. Published
Published December 2001.
2001. Originally
Originally H3A 2R2 Canada.
7
published
published as D 6198 – 98. Last previous
previous edition D 6198 – 00. Available
Available from International
International Marine Organization
Organization,, 4 Albert Embankment,
Embankment,
2
Standards,, Vol 15.09.
 Annual Book of ASTM Standards London,
London, Ontario 5E1 7SR Canada.
Canada.

Copyright © ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.

1
 D 6198
IATA Dangerous Goods Regulations 8 packaging that will eventually be required. The user of this
United States Code of Federal Regulations Title 49, Trans- guide is encouraged to examine each particular situation and
portation (CFR-49) 9 decide the best order in which to proceed, without omitting any
International Safe Transit Association Procedures 10 of the basic steps that follow.
5.2 Iden
Identif
tifyy Phys
Physica
icall Char
Charactacteris
eristic
ticss of the Pack Package age
3. Terminology Contents—It is imp import
ortant
ant to kno
know w mor
moree aboabout
ut the package
package
3.1   Definitions— GenGenera
erall defi
definit
nition
ionss for pac
packag
kaging
ing and contents (goods) than simply its dimensions and weight. The
distribution environments are found in Terminology D 996. packag
pac kagee des
design
ignerer mus
mustt be awa awarere of phyphysicsical
al and chechemicmicalal
3.2   Definitions of Terms Specific to This Standard: characteristics and hazardous properties so proper packaging
3.2.1  interior protective packaging —packaging materials or can be devel
developed.
oped. These incl include:
ude: susceptibili
susceptibility ty to abras
abrasion,
ion,
forms used within shipping containers to protect contents from corrosion, temperature, static electricity, or magnetic fields; the
damage in distribution by cushioning, bracing, spacing from ability to hold a load in compression, the contents’ ability to
container walls, preventing abrasion, filling voids, and so forth. withstand the effects of shock and vibration during handling
3.2.2   transport packaging —packaging for containment and and transportation, and intended shelf life. See Test Methods
protection of goods during handling, storage, and transporta- D 3332
3332 and D 3580 3580 for met method
hodss of det determ
ermini
iningng sho
shock
ck and
tion in the physical distribution process. The scope of transport vibration fragility of products.
packaging includes all of industrial packaging as well as the 5.3   Determine Marketing and Distribution Requirements :
shipping containers, interior protective packaging and unitizing 5.3.1 Package design must include include consideration of market- market-
required for consumer packages. ing and distribution requisites in addition to product character-
istics.
istics. These requirements
requirements,, in many case cases, s, take the form of 
4. Signi
Significanc
ficancee and Use
marketing
marke ting grap
graphics,
hics, produ
productct ident
identificat
ification,
ion, and compl compliance
iance
4.1 This guide assists
assists users in design and development
development of  labeling.
packaging intended for the protection of goods while they are
5.3.1.1
5.3 .1.1 Complia
Compliance nce lablabeli
eling
ng can als alsoo tak
takee man
manyy for
formsms..
in transit from point of origin to final destination. By following
Some items to consider are identification of country of origin,
all steps
steps of thi
thiss gui
guide,
de, users will be ass
assure
uredd tha
thatt the most
hazardous materials transportation regulations, Truth in Pack-
import
imp ortant
ant fac
factor
torss are inc
includ
luded
ed in pac
packag
kagee des
design
ign.. In som
somee
aging requirements, and bar coding. Besides the actual printed
cases, the sequence of steps may be changed, and often the
grap
graphihics
cs,, on
onee ma may y wawantnt to co cons
nsid
ider
er prprop
oper
er su subs
bstr
trat
atee fo
forr
steps may occur simultaneously with concurrent work activi-
printing and any required coatings.
ties.
5.3.1.2 Distribution requirements
requirements can likewise take on many
4.2 The design process
process focuses on prote
protection
ction from hazards
hazards
forms of consideration including: the number of units that will
of handling and shipping while recognizing the economics of 
ship
shi p in a con contaitainer
ner;; the com
compos
positition
ion and att attrib
ribute
utess of the
all other facets of distribution, including packaging materials
primary package; the identity of customers and their handling
and labor, handling, storage, and transportation.
and storage requirements; the package disposal criteria; total
5. Proc
Procedur
eduree volumee expec
volum expected ted per shifshift/da
t/day/yea
y/year;r; expec
expected ted life cycle; the
planned modes of transport; domestic and international rules or
5.1   Introduction :
regulations for packaging via those transport modes; types of 
5.1.1 Although no single procedure
procedure can be expected to to meet
distributi
distr ibution
on chann
channels;els; maxi
maximizi
mizingng loads in carr carrier
ier vehic
vehicles;
les;
all requirements for all design options, there are general areas
freight classification; handling and storage requirements; pro-
of information that are necessary for the design process to be
duction equipment; environmental issues; etc.
most useful. The more information in each of these areas that
can be obt obtain
ained
ed acc
accura
uratel
tely
y, the gre greate
aterr the pro
probab
babili
ility
ty of  5.3.1.3 This listing
listing is not all inclusive
inclusive and other consider
consider--
optimizing the final design for cost performance utility, time- ations than these also may be important to the total package
liness,
line ss, and envir
environmen
onmentaltal consi
considerat
derations.
ions. Other inte
interest
rested
ed design.
parties, such as customers or end users, should be contacted for 5.4   Identify
Identify EnviEnviron
ronmenta
mentall Hazar
Hazards ds Your Packa Packages
ges May
any specific package design criteria.  Encounter —Knowledge
—Knowledge of the distribution environment is key
5.1.2 The following
following sequence,
sequence, listlisted
ed in 5.2-5
5.2-5.12,
.12, may not to designing an optimum transport package. Major hazards to
always
alw ays be appapplic
licabl
ablee to eve
every
ry des
design
ign process
process and may be be expected in the environment are: rough handling; vibration
changed
chang ed to fit part
particul
icular
ar circ
circumst
umstances
ances,, produ
products,
cts, mark
markets,
ets, and shock in-transit; compression in storage or in-transit; high
distribution methods, etc. Environmental hazards presented by humidity and water; atmospheric pressure; salt/corrosion; static
the dis
distri
tribut
bution
ion env
enviro
ironme
nmentnt (se
(seee 5.4
5.4)) may be knoknown
wn lon
longg electricity; temperature extremes; pilferage; insect infestation;
before a new product (see 5.2) is fully designed or ready for and concentrated impact forces. Identifying these hazards and
distribution (see 5.3). Such knowledge can in fact contribute to quantifyi
quant ifying
ng them may incl include
ude obser
observati
vation,
on, condu
conductin
ctingg mea-
the design of the product to ultimately reduce the amount of  surements, or reading research reports (see the references listed
in Practice D 4169).
5.5  Consider All Available Alternatives :
8
Available from IATA, Customer Service Rep., 2000 Peel St., Montreal, Quebec 5.5.1 There are many alte alternati
rnatives
ves avai
available
lable for shipp
shippinging
H3A 2R4.
9
container
conta iners,
s, inte
interior
rior prot
protecti
ective
ve pack
packaging
aging,, and unit load loads.s. All
Available
Av ailable from Super
Superintend
intendent
ent of Docum
Documents,
ents, U.S. Govern
Government
ment Printing
Office, Washington, DC 20402-9371. should be considered and reviewed before selecting the final
10
Available from ISTA, 1400
1400 Abbott Road, #310, East Lansing, MI 48823-1900. types for further development. Trade-off comparison analysis

2
 D 6198
technique
techni quess oft
often
en hel
helpp in the selselect
ection
ion pro
procescess.
s. Rat
Rather
her tha
thann such as impact, vibration, and compression not only identify
consid
con sideri
ering
ng onl
onlyy ma mater
terial
ialss tha
thatt one has exp experi
erienc
encee wit
with,
h, shor
sh ortc
tcom
ominings
gs in de desisign
gn,, bu
butt alalso
so he help
lp to fin fine-
e-tu
tune
ne to an
comparing paper versus plastic versus wood versus metal is a optimum solution for anticipated hazards. Test Methods D 642,
good exercise at times to assure the optimum solution for a D 880
880,, D 999999,, D 400 4003, 3, D 47 472828,, D 5275276,
6, D 54 5487
87,, D 60 605555,,
particular project. D 6179, and D 6344 are frequently utilized for this purpose.
5.5.2 Three major factors influencinginfluencing selection
selection of altealterna-
rna- (See Section 2 for these test methods.)
tives are: package performance, total system cost, and envi- 5.6.3
5.6 .3 An add additi
itiona
onall benbenefit
efit of eng engine
ineeri
ering
ng tes
tests
ts dur
duringing
ronmental impact of materials. packag
pac kagee devdevelo
elopme
pment nt can be rea realiz
lized
ed by the inc inclus
lusion
ion of 
5.5.2.1 The final package design will will also have a significant instrume
inst rumentat
ntation
ion duri
during ng the test proc procedur
edureses (se
(seee Prac
Practic
ticee
impact on overall distribution costs. It will influence materials D 6537)
6537).. Throu
Through gh instinstrumen
rumentedted meas
measurem
urements
ents of the pack-
costs, labor costs, capital requirements, overhead allocations, age’s performance during such testing, the designer can deter-
handling costs, freight and transportation costs, damage costs, mine more precisely the margin by which the package being
and those costs and issues involved with the eventual disposal tested
tes ted eit
either
her meemeets ts or fai fails
ls the des design
ign cri
criter
teria.
ia. For tho thosese
of the package components. instances in which the package is insufficient, the designer can
5.5.2.2
5.5.2. 2 The overall environmen
environmental tal impact of a desi design
gn may use the measured values to establish the best and most efficient
be quite difficult to quantify. Factors such as broad access to ways in which to improve the design. When the package passes
recycling systems or markets will have significant impact on the design criteria, the designer can also gain valuable infor-
thiss iss
thi issue.
ue. One com common
monlyly use
usedd app
approa
roachch to deadealin
ling
g wit
withh mation
mat ion thrthroug
ough h ins
instru
trumen
mentat
tation
ion to det determ
ermineine whe
whethe therr the
environmental impact for broadly distributed goods has been to design is too conservative and might result in overpackaging.
use a desi
design
gn appro
approach ach prioritizin
prioritizing g the common concerns of  5.7   Selec
Selectt the Pr Prope
operr Type of Clo Closur
suree for the Shi Shippi
pping ng
Reduce, Reuse, Recycle, Energy Recovery, and Safe Disposal. Container —The—The ef effec
fectiv
tivene
enessss of the tra transp
nsport
ort pac
packagkagee in
For packages developed for products having focused markets retain
ret aining
ing and pro protec
tectin
tingg its conconten
tentsts dur
during
ing han
handli
dlingng and
in specific locations, it may be more beneficial to emphasize a transportation is influenced by the package closure method. In
single element of the preceding concerns (that is, returnable addition to handling hazards, method of packing, and type of 
packaging for products sold only locally, and so forth). The produc
pro ductt to be pac packedked,, the sel select
ection
ion of the clo closur
suree sho
shoulduld
design
des ign app
approa
roach
ch coucould
ld als
alsoo be alt altere
ered
d to eit either
her inc
increa
rease
se include consideration of any rules or regulations pertaining to
environmen
envir onmentaltal ef
effficie
iciency
ncy or comp
comply ly with approappropriat
priatee regul
regula-a- the product, package, or transport mode. For fiberboard boxes,
tions, legislation, or organization policies. Test Method D 1974 provides guidance for methods of closure.
5.5.2.3 One means of evaluating the overall overall effectiveness
effectiveness of  5.8   Determine Adequacy of Overall Protection by Perfor-
a package design is to benchmark or compare it to designs from mance Tests:
competitors for like products or to designs from companies or 5.8.1
5.8 .1 Aft
Afterer the shipping
shipping unit des designign is com
complepleted
ted,, its ad-
organizations recognized for packaging excellence. Often such equacy for protecting goods in-transit should be checked prior
compariso
comp arisons
ns can help confirm orig original
inal desi
design
gn assu
assumpti
mptions
ons to acactu
tual
al shship
ipme
ment nt.. Th
Thee ac acce
cept
pted
ed pr prac
acti
tice
ce is to pe perf
rfor
ormm
(required performance levels, acceptable costs, and so forth) laboratory pre-shipment testing procedures designated as per-
and can provide an additional level of confidence for a new form
fo rmanance
ce tetest
sts.
s. Th
This is cocons
nsis
ists
ts of su subj
bjec
ecti
ting
ng ththee ununitit to a
design.
desig n. If a benc
benchmark
hmarking
ing effort
effort indi
indicate
catess the design is not sequence of anticipated hazards/tests in the laboratory for the
within the original design assumptions, a design review might purpose of a pass/fail decision. Will the shipping unit protect
be in order. its contents all the way through distribution? In developing a
5.6   Design the Transport Package : testt pla
tes plann tha
thatt wou
would ld bes
bestt sub
subjec
jectt the shipping
shipping units to the
5.6.1 Afte
Afterr basi
basicc mate
material
rialss and information
information are esta establis
blished
hed hazards that may be encountered within the distribution cycle,
in the preprevio
vious
us ste
steps,
ps, the des
design
ignerer can the then n sys
system
temati
atical
cally
ly refer to the following: Practice D 4169, ISO 4180, Rule 180
develop a transport package, and unit load where appropriate. (NMFC), ISTA, or CFR 49, or Specification D 4919.
Each
Eac h com
compon
ponent
ent of the tra transp
nsport
ort pacpackag
kagee is ana analyz
lyzed
ed for 5.8.2
5.8 .2 The per perfor
forman
mance ce tes
tests
ts in Pra Practi
ctice
ce D 416 4169 9 uti
utiliz
lizee
strength and other required properties and compared to tech- ASTM test methods having considerable experience and his-
nical data available from suppliers. Some packaging materials tory
tor y beh
behind
ind thetheir
ir dev
develoelopme
pment nt and use use,, and a suc succes
cessfu
sfull
have good design data available, but most do not. Designers completion of a properly designed and formulated performance
frequently rely on experience to reach a successful solution, test sequence greatly increases the probability of damage-free
but others may find that lack of information makes it difficult shipments for the distribution cycle intended. For users who
to arrive at an optimum solution. Such lack of information may can cleclearl
arlyy defi
definene the their
ir dis
distri
tribut
bution
ion cyc
cycles
les,, but find the themm
require
requi re that the desidesigner
gner approach
approach the supplier or suppl suppliers
iers different than the standard cycles listed, Practice D 4169 also
involved to request that they take whatever steps are necessary provides a means of developing a unique sequence of tests,
to pro
provid
videe the inf
inform
ormati
ation
on neeneeded
ded.. If thi thiss app
approa
roach
ch is not result
res ulting
ing in per perfor
formanmance ce tes
tests
ts whi
whichch can mor moree pre precis
cisely
ely
feasible,
feas ible, thir
third-pa
d-partyrty labo
laborator
ratories,
ies, consu
consultant
ltants,
s, or acad
academic
emic simulate the actual conditions of the user’s environment.
institutions may be an alternative resource. 5.8.3 The inclu inclusion
sion of inst
instrume
rumentat
ntation
ion durin
during g perf
performa
ormancence
5.6.2 Evaluation and improvement
improvement of package package design can be be testing for verification of design may provide added beneficial
shortened by conducting engineering tests in package devel- informati
infor mationon (see Prac Practice
tice D 6537)
6537).. Throu
Through gh such meas measure-
ure-
opment. Most helpful in the design process is the establishment ments
men ts of the pac packag
kage’s
e’s perperfor
forman
mance ce in sucsuchh tes
testin
ting,
g, the
of test requirements prior to finalizing for sample making. Tests designer can determine more precisely the margin by which the

3
 D 6198
package being tested either meets or fail
package failss the performance
performance an improved packing method or equipment requires a new or
criteria. For those instances in which the package is insuffi- modi
mo difie
fiedd pa
pack
ckag
agee de
desi
sign
gn,, be su
sure
re to tetest
st th
thee re
rede
desi
sign
gned
ed
cient, the designer can use the measured performance values to package.
establish the best and most efficient ways in which to improve 5.11   Document ALL Work —One—One step often overlooked in
thee de
th desi
sign
gn.. Ev
Even
en if ththee pa
pack
ckag
agee pa
pass
sses
es ththee pe
perf
rfor
orma
mancncee the design process is documentation. This includes document-
verification procedures, the designer can gain valuable infor- ing original requirements, test results, specifications, drawings,
mation
mat ion thr
throug
oughh ins
instru
trumen
mentattation
ion to detdeterm
ermineine whe
whethe
therr the and methods of packing. Names of persons involved should
design is too conservative and might result in overpackaging. always be included on all documents. Drawings should be in
5.9   Redesign the Package or Product if Required : company
compa ny stan
standard
dard form
formats
ats with appr
appropria
opriate
te desi
designati
gnations
ons for
5.9.1 If the package or product
product fails to pass
pass the performance reference
reference in the corpo
corporate
rate specification
specification system. RelyiRelying
ng on
tests, one or both need to be redesigned and the performance supplier sketches or drawings as the reference document is not
test repeated. advisable. They should be transferred to company format so
5.9.2 Testi
esting
ng may reve
revealal poten
potential
tial produ
product ct impr
improveme
ovementsnts purcha
pur chasin
sing,
g, man
manufa
ufactu
cturin
ringg and engengine
ineeri
ering
ng can ref refere
erence
nce
thatt may hel
tha helpp inc
increa
rease
se the strstreng
engthth of the proproduc
ductt thr
throug
oughh them.
product redesign. This is especially important when the cost of 
5.12   Monitor Shipping Experience —When a new or modi-
the product redesign is less than the extra packaging that would
fied packaging design has been implemented, it is beneficial to
be req
requir
uired
ed if pro
produc
ductt imimpro
provem
vement
entss wer
weree not mad made.e. Use
monitor its performance during actual production, warehous-
Product Fragility Test Methods D 3332 and D 3580 to identify
ing, shipping, sale, and use. One method is to use customer
product improvement opportunities and measure the increase
complaints
compl aints as a meas
measurem
urement,
ent, alth
although
ough this may underunderstat
statee
in strength when product improvements have been made.
actuall probl
actua problems.
ems. It is ofte
oftenn bett
better
er to proa
proactive
ctively
ly audi
auditt field
5.10   Develop the Methods of Packing —An important part
performance by inspections, customer feedback forms, or by
of package design is deter determini
mining
ng the optimum method method and
direct customer interviews. Feedback on this shipping experi-
equipment
equip ment for packi
packing
ng of goods in ship shipping
ping containers.
containers. Al-
encee can be use
enc usedd as the package
package design
design is conconsid
sidere
eredd for
though this may be the responsibility of someone else, that is,
modification.
industrial engineering, the package designer must be aware of 
cost factors and the appropriateness of mechanizing or auto-
6. Keyw
Keywords
ords
mating all or part of the operations. Sometimes a trade-off of 
package design for improved packing methods is required to 6.1 comp
compressi
ression;
on; dist
distribut
ribution
ion envi
environme
ronment;
nt; handl
handling;
ing; im-
achieve overall system economy. Ease and economy of pack- pact; interior protective packaging; performance test; shipping
ing, closure, and opening are key factors to consider. Whenever container; shock; transport package; unit load; vibration

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