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

  1. Test Sample Selection
    Regular production products are selected and tested in their final packaging.

  2. 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.

  3. Vacuum Application
    The internal pressure is gradually reduced to simulate an altitude typically between 15,000 – 18,000 feet (4,500 – 5,500 meters).

  4. 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.