When it comes to packaging, strength matters a lot. You can see how delicate items are safely transported long distances daily. Have you ever wondered what ensures the strength of those packaging materials? The secret lies in the edge crush testing. This test is the ultimate criterion for judging the true strength of corrugated boxes.
Knowing this test is crucial, whether you are a supplier or a manufacturer. It helps you choose the right packaging material and prevents the items from being damaged. So, what exactly is the edge crush test, and how do you perform it? Don’t know? Worry not! In this article, I will explain the complete procedure, its benefits, and its application. So, let’s get started!
What is the Edge Crush Test?
The edge crush test (ECT) is the simplest way to measure the edge-wise strength of corrugated boxes. This test is performed stepwise, and the final ECT value indicates the strength of the material. For example, if the ECT value is higher, the material is stronger, and vice versa.
In simple words, this test indicates how much pressure a corrugated box can handle before crushing. As you know, these boxes undergo continuous stress during transportation. They are stacked on each other and face the vibration of moving trucks. Sometimes, these boxes even drop, which can affect the inner item.
If the corrugated box is strong and ECT tested, it will protect the item. However, if this box is not strong enough, it will crush and damage the items. Thus, manufacturers use this test to ensure their products are transported and stored safely. Remember that corrugated boxes come in different types, and the ECT value varies with them.
Step-by-Step Procedure of the Edge Crush Test
Have you got a basic understanding of the edge crush test from the above section? If yes, let’s proceed and explore how this test is performed step by step!
Step 1: Preparing the Sample
It is the first and most crucial step for an edge crush test. In preparation for the sample, you must choose a small piece from a large corrugated board. After selection, this piece must be cut in a rectangular form with standard dimensions of 100 mm × 25 mm. WHY? Corrugated boards come in this shape, which simulates the real-world scenario.
Moreover, this sample should be cut accurately. Uneven and rough edges can affect the ECT value. However, some ECT machines have an automatic cutting procedure that does not require manual cutting. Cutting different samples from different areas of the board is far better. Testing multiple samples helps determine the overall strength and uniformity.
Step 2: Positioning the Sample
Once you have prepared the sample, the next step is positioning it. Actually, ECT machines contain two metal plates that exert pressure. Here, the key is that the sample must be placed vertically between these two plates. As I said above, this test measures the strength of the edges of a corrugated box. So, you have to stand the sample on its edges.
This position is necessary to apply pressure directly on the flutes. Flutes are wavy layers in the middle of the corrugated board that describe its strength. So, these flutes must be perpendicular to the machine plate. Moreover, during the sample placement, you should ensure it is in the middle of the plates. Misalignment may cause an uneven pressure distribution, affecting the final results.
Step 3: Applying the Load
After correctly positioning the sample, the next step is applying the load. This step detects how much pressure a corrugated box can handle. So, carefully activate the ECT machine. This machine starts applying the pressure gradually, but vertically to the flutes. First, it applies low pressure, and the flutes remain undefeated. Over time, the pressure slowly increases, and you will notice that the flutes start bending.
Gradually, this pressure increases. At the end, a point comes at which the edges of the corrugated box collapse and crush. This is the maximum limit of force a box can withstand. Remember, TAPPI T 811 or ASTM D 6413 sets the rate at which pressure is applied. You must follow those instructions, as uneven pressure can cause premature breaking of the box.
Step 4: Recording the Results
After crushing the sample, the last step is analyzing the results. This step indicates how much force a corrugated box can handle. As I said above, when applying loads, a point comes at which the sample breaks. At this point, maximum force is measured in Pounds per inch (lb/in) or Kilonewtons per meter (kN/m). ECT machines automatically record this maximum force.
The higher the value of this force, the stronger the box, and vice versa. Manufacturers compare this value with industry standards such as ASTM D 6413 and TAPPI T 811. If the ECT value meets these standards, it is declared strong and safe for transporting goods. If the box fails at a lower force than required, it is remanufactured and adjusted to meet the criteria.
Benefits of the Edge Crush Test
The edge crush test is one of the critical quality tests. Safe packaging and transportation are impossible for any industry without this test. It ensures that packaging meets the standards. Want to know its diverse benefits? Let’s dive in!
1- Ensures Packaging Strength and Durability
Imagine you want to store or transport a fragile item. But you do not know about the strength of the corrugated box. If it is not strong enough, your delicate item will break. Right? That’s where the ECT test comes into the scene. This test tells us about the ultimate strength of the packaging material. If this material has a higher ECT value, it means it is strong and safe to use, and vice versa. In this way, manufacturers and suppliers benefit from this test in determining the strength of their corrugated boxes.
2- Helps in Selecting the Right Box for Shipping
Selecting the correct box for the right item is key. So, ECT helps choose just the right amount of protection without extra cost. Let me explain it with an example. Often, you come across three types of material. First, non-fragile but lightweight items such as clothes and plastics need a box with a lower ECT value.
Second are fragile and lightweight items. They need extra attention during transportation. So, these times require a box with a higher ECT value. Last, it comes to heavyweight products. These products need extra-strong corrugated boxes to handle stacking pressure. This way, the manufacturer chooses the right material for the goods using ECT.
3- Reduces Material and Shipping Costs
As I said above, ECT-rated boxes help safely transport products. However, if the corrugated box is too weak, it will burst, damaging costly products. The material of both the box and the product is wasted, which also causes financial damage. Moreover, using too strong boxes for products wastes material and increases shipping costs. However, ECT helps the factories choose the right amount of material to keep costs low.
4- Improves Sustainability by Reducing Waste
Presenting eco-friendly packaging is a significant concern for companies. ECT helps them improve environmental sustainability. HOW? First, using a strong box reduces the material waste of products. This waste otherwise ends up in landfills that cause pollution. ECT also helps use the right amount of material for making boxes and reduces cardboard waste. Moreover, a strong box lasts long and can be recycled. This reduces the need for remanufacturing, which saves natural resources.
5- Enhances Brand Reputation and Reduces Returns
When you order any item, you want it delivered safely. A torn box and damaged product reduce the trust in manufacturers, right? And most probably, you return that package and ask for a refund. All these complaints damage a brand’s reputation. However, when a manufacturer uses an ECT-rated box, it will not crush or break. This enhances customer satisfaction and trust in the brand.
Applications of the Edge Crush Test
A weak corrugated box damages goods and causes losses. Therefore, several industries rely on edge crush tests to avoid such damage to goods. In the section below, we will explore all those sectors that rely heavily on ECT. Let’s begin!
1- Packaging and Shipping Industry
One of the primary uses of ECT is in the shipping industry. It helps the industry choose the correct box according to the fragility of the items. The first form of the shipping industry is e-commerce. Online platforms such as Amazon, Walmart, etc., use ECT-rated boxes to deliver products to customers. Moreover, warehouses also use this testing system to ensure the safe stacking of products.
2- Food and Beverage Packaging
Food industries demand hygienic and strong packaging for fruits and vegetables. As you know, food items are delicate. So, they need extra strong boxes for storage and delivery. Thus, ECT ensures that those products remain fresh and undamaged. For example, cartons for dairy products and beverages are tested through ECT. Food delivery services and restaurants also use ECT-rated boxes for safe transport.
3- Pharmaceutical and Medical Packaging
The pharmaceutical industry requires contamination-free and strong packaging. A weakened or untested box can cause damage to costly medicine. So, this industry also uses ECT to test the box for medicine shipment. This test ensures the box is strong enough to protect lab samples and diagnostic kits from external stress. Moreover, a tested box also prevents contamination from entering. Thus, it ensures the hygienic delivery of medicines.
4- Military and Defense Packaging
As you know, military equipment is expensive, heavy, and sensitive. So it needs extra protection during transportation. Items like weapons and electronic gear should be transported in strong boxes. In weak boxes, they can collapse and cause serious safety hazards. So, this industry also uses ECT to ensure the strength of the corrugated box. It helps them safely transfer their sensitive items to remote areas.
5- Electronics Packaging
Electronics such as smartphones, laptops, and televisions are highly fragile. Even small vibrations can cause cracking and severe damage. If the packaging is weak, these items cannot withstand stacking pressure. As a result, they can break, leading to costly damage. To prevent this, manufacturers use ECT to measure the strength of the boxes. It helps them choose the best-quality packaging to transport these items safely.
Frequently Asked Questions
What is the best way to improve a box’s ECT value?
Improving the ECT value means enhancing the strength of the boxes. You can increase this value in several ways. For example, use high-quality materials, increase flute strength, and add reinforcement layers to the box.
Can recycled materials pass the ECT?
Yes, recycled material can pass ECT. But remember, these materials will show a low ECT value. However, you can improve their strength by blending them with virgin fiber. Moreover, adding flute layers can also enhance the stability.
Can ECT be used for all types of packaging?
No, ECT cannot be used for all types of packaging. It is confined to corrugated cardboard. Metal and plastic boxes cannot be tested using ECT machines.
Conclusion
The edge crush test is a critical way of measuring the strength of corrugated boxes. It ensures the safe transport of several items to distant areas. In this article, I have covered the conducting process and its benefits. For example, this test is performed by a machine known as the edge-crush tester.
This tester has two metal plates that exert pressure on the box sample. At one point, this sample breaks, and the maximum force is measured. This is called the ECT value. If it matches the quality standards, it is declared safe and strong, and vice versa. ECT has become a necessity for several industries. For example, the shipping, military, and electronic industries heavily rely on ECT.