ASTM D6653
Air transportation is one of the fastest yet most challenging shipping methods for packaged goods. In aircraft cargo holds, the ambient pressure drops significantly compared to ground-level conditions. This poses risks for packages, particularly those containing vacuum-packed, pressurized, or liquid-based contents, such as deformation, leakage, expansion, or even rupture. To evaluate a packaging system's ability to withstand these conditions, the ASTM D6653 standard was developed.
What Is ASTM D6653?
ASTM D6653 – Standard Test Method for Determining the Effects of High Altitude on Packaging Systems by Vacuum Method is a laboratory test procedure used to assess how packaging systems respond to low ambient pressure. The method simulates high-altitude conditions encountered during air transportation or overland transport through elevated terrain. The goal is to determine whether the packaging maintains structural integrity and protects its contents under reduced pressure.
Test Procedure
Test Sample Selection
Regular production products are selected and tested in their final packaging.Placement in Vacuum Chamber
The test specimen is placed inside a vacuum chamber large enough to accommodate expansion of both the package and its contents.Vacuum Application
The internal pressure is gradually reduced to simulate an altitude typically between 15,000 – 18,000 feet (4,500 – 5,500 meters).Observation and Recording
During a 1-hour vacuum period, the packaging is monitored for swelling, leakage, bursting, or other forms of damage. Temperature and humidity levels are also noted.
Typical Test Parameters
Number of Samples: 3
Conditioning Temperature: 5.6 ± 2°C for at least 24 hours
Duration Under Vacuum: 1 hour
Simulated Altitude: As specified in the test requirements
Temperature During Test: 5.6 ± 2°C
Relative Humidity: Ambient, unless otherwise specified
Tests may be performed at ambient or lower temperatures depending on the simulation scenario. Qualified technicians can provide guidance on the most appropriate test conditions.
Suitable Packaging Types
Vacuum-packed food products
Pressurized medical and beverage containers
Electronics packaging
Fragile component packaging
Cosmetic and perfumery packaging
Foam-supported or multilayer protective designs
Benefits of ASTM D6653 Testing
Verifies packaging resilience against air transportation pressure changes
Identifies potential design weaknesses before mass shipping
Reduces product return rates and enhances customer satisfaction
Supports internal quality assurance processes
Provides compliance documentation for audits and certifications
Evaluation Criteria
Upon test completion, the following criteria are reviewed:
Presence of swelling, leaks, or visible deformation
Integrity of product containment
Continued functionality of the package
Supporting photo and data records
Based on these observations, a final PASS or FAIL decision is reported.
Conclusion
ASTM D6653 is a critical test standard for verifying packaging safety under simulated high-altitude, low-pressure conditions. By replicating realistic transport environments, the method helps manufacturers and logistics providers ensure product safety and prevent costly shipping damage. This test is especially valuable for those involved in international distribution, air freight, and the shipment of sensitive or high-value goods.
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