Mastering ISTA Drop Testing for Packaging
Complete Guide to ISTA Drop Test Systems for Packaging Reliability
Why Drop Testing Matters in Product Durability
In today’s global shipping and logistics landscape, products endure rough handling, long-haul transportation, and varied storage conditions. Whether it’s consumer electronics, heavy-duty machinery, or medical devices—packaging and product integrity must withstand real-world forces.
That’s where drop test systems come into play.
Drop testing simulates accidental falls, impacts during transit, and everyday drops that could damage a product or its packaging. It’s not just about preventing cracks—it’s about ensuring reliability, reducing warranty claims, and maintaining customer satisfaction.
At TMC Solutions, we specialize in delivering precision drop test systems that comply with ISTA standards, offering customizable solutions for diverse industries and product specifications.
What is ISTA Drop Testing?
ISTA (International Safe Transit Association) sets standardized test procedures to simulate the physical hazards products face in distribution. Drop testing, a vital element of these standards, helps determine whether packaging can adequately protect the product during transit.
Below is the detailed information of ISTA Series Drop Testing Standards
ISTA 1 Series: Non-simulation integrity drop testing standard for basic screening during early design
ISTA 2 Series: Enhanced non-simulation integrity drop testing standard
ISTA 3 Series: General simulation performance testing
ISTA 6 Series: Member-specific protocols (e.g., Amazon, FedEx, Sam’s Club) simulating real-world supply chain conditions
TMC Solutions’ ISTA-Compliant Drop Test Systems
Based on the above standards, TMC has small drop test machine with drop range 300-1500mm and 300-2000mm, zero distance drop test machine and double lift zero distance drop test machine.
Small Drop Test System
Zero Distance Drop Test System
Double Lift Zero Distance Drop Test System
Application Examples
PROJECT ONE
Drop height range (mm): 300-1500
Max. Specimen weight (kg): 85
Max. Specimen dimensions (mm): 800x800x800
Drop mode: Freefall
Customer wants to do surface, edge and corner drop
Based on the requirement, we provided DS150 and below photos show how to do surface, edge and corner dop.
TMC Drop Test System DS150 - Edge Drop
TMC Drop Test System DS150 - Corner Drop
TMC Drop Test System DS150-Surface Drop
PROJECT TWO
Specimen weight: 500kg
Specimen dimensions: 24" L x 24" W x 72" H (610x610x1829mm), 36" L x 28" W x 48" H (915x711x1219mm), 50" L x 28" W x 86" H (1270x711x2184mm)
Drop height: 0-1550mm
Special requirements 1: customer requires two double lift zero distance drop testers to work simultaneously
Special requirements 2: the single drop tester can work independently if there is small package
Based on the requirement, we provided customized system NDS500C. NDS500C is a customized system composed of two single double lift zero distance drop tester. The two drop testers can work simultaneously and each of them can work separately.
Below are the design schemes of this customized system.
Specimen dimensions: 24" L x 24" W x 72" H (610x610x1829mm)
Specimen dimensions: 36" L x 28" W x 48" H (915x711x1219mm)
Specimen dimensions: 50" L x 28" W x 86" H (1270x711x2184mm)
TMC Drop Test - corner drop test
TMC Drop Test - corner drop test
TMC Drop Test - edge drop test
TMC Drop Test - edge drop test
TMC Drop Test - surface drop test
TMC Drop Test - surface drop test
Why Choose TMC Solutions for ISTA Testing?
✅ Custom Engineering – From small units to massive packaging systems
✅ Accuracy & Repeatability – High-precision equipment with intuitive control
✅ Versatile Drop Modes – Surface, edge, and corner testing covered
✅ Test Various Package Sizes – Easily accommodate small to extra-large products
✅ Meets ISTA Standards – Ensures your product packaging meets global compliance
ISTA drop testing is a cornerstone of reliable packaging design. TMC Solutions offers cutting-edge drop test systems tailored to meet your exact testing needs and ensure your packaging is ISTA-certified and logistics-ready. From initial R&D to full-scale quality control, our machines are built to deliver confidence at every drop.
🔗 Explore our Drop Test Systems
📩 Contact us to find the right equipment for your packaging requirements.