Compression Testing Machine Operating Method & Packaging Strength Testing Applications

What is a Compression Testing Machine?

A packaging compression testing machine (often called a box compression tester) applies force between two platens to simulate stacking pressure on a package.​
The result shows compressive resistance—how strongly a shipping container resists external compressive loads before excessive deformation or collapse.​

Because packaging performance can change with factors like humidity and whether the package is tested empty or with contents, many test plans define conditioning and the test configuration up front.​

The Standard Operating Method

A standard operating method ensures comparable results across batches, suppliers, and sites by controlling the atmosphere, setup, alignment, loading, and reporting.

Many packaging programs align compression work with recognized standards used in industry, such as ASTM D642 and broader distribution tests that include compression as one hazard (for example, ISTA 3A)​.

1. Sampling Conditioning

Stabilizes packaging materials before testing so results reflect real-world storage and shipping environments instead of short-term moisture swings.

For corrugated packaging, this is particularly important as performance can change with environmental exposure, and in many cases, these effects are taken into account in ASTM-style compression work evaluation.

2. Machine Calibration & Setup

Calibration and setup ensure that the load is applied consistently by the tester so that the measured peak force and deformation are reliable for design and quality decisions. The setup also includes the choice of test approach (platen type and application of load), since the goal is to represent the real compressive stress distribution that the package will experience.

3. Sample Placement

Correct placement centers the package so the applied load is uniform and does not introduce unintended bending or edge-loading.​

Since ASTM D642 can be used to apply compressive loads to faces, edges, or corners, depending on the objective, placement must match the chosen orientation and reporting requirement.​

4. Executing the Test

During execution, the machine applies compressive force in a controlled way until a defined endpoint—commonly failure, collapse, or a specified deformation level.​
This produces a compression response that packaging teams can use to verify whether the container meets the intended resistance for stacking and handling.​

5. Data Collection

Values show the maximum force and deformation at that point, along with notes on how the failures occur.​ Documenting the package configuration matters because small changes in materials or construction can significantly change performance and may require retesting in some programs.

6. Reset and Analysis

The machine resets after every run, and the specimen is reviewed so results can be interpreted against acceptable values (for example, allowable deformation, no loss of function, or pass/fail rules).

Core Packaging Strength Testing Applications

Compression testing machine supports packaging design, supplier qualification, and ongoing quality control by confirming that packs resist stacking loads in storage and distribution.​

It is also used as part of broader parcel-delivery simulation protocols where compression is evaluated alongside drop and vibration to reflect common shipping hazards.

Corrugated Box Compression Testing (BCT)

Corrugated box compression testing defines how fiberboard shipping containers resist compressive forces and the ability of the material to withstand stacking compression.​

ASTM D642 is widely referenced for determining compressive resistance of shipping containers, components, and unit loads, including corrugated boxes and crates.​

Plastic Container Top-Load Testing

Top-load testing checks how much vertical force rigid plastic packaging can tolerate before paneling, buckling, or closure distortion affects usability.​

Since shipping environments are likely to apply compression during storage and handling. Such kind of testing helps confirm that containers hold shape and protect the product through distribution.​

Pallet and Shipping Crate Evaluation

Compression testing can be applied to unit loads and shipping crates to understand how stacked weight transfers through the load during warehousing and transport.​

ASTM D642 explicitly covers shipping containers and can be used for multiple containers or unit loads, supporting comparisons between different load designs.​

Flexible Packaging Tests

While flexible packs do not behave like rigid boxes, controlled compression can still help study crushing sensitivity, deformation, and load-sharing behavior when packed in secondary cartons.​

In parcel systems, flexible packs are often evaluated in a “system” view—product plus package, because performance depends on how the full pack-out absorbs distribution stresses.

Why Packaging Strength Matters for Business

Investing in compression testing equipment requires upfront capital, but it solves massive financial problems for modern supply chains.

Reducing Product Damage Rates

The contents inside are often damaged when a box is crushed in transit. The company loses the cost of the product, shipping, and possibly future business with the customer. Proper testing makes sure the packaging can withstand the worst case.

Material Optimization & Cost Savings

Some over-package their goods. It uses cardboard much thicker than necessary for safety reasons. Thicker cardboard costs more. Compression testing lets engineers work with thinner or lighter materials. 

Once test results show a lighter, cheaper box still meets strength requirements, the company can switch materials and save millions of dollars a year on packaging costs.

Sustainability Initiatives

Fewer packages mean fewer landfills. Brands can calculate strength requirements precisely without compromising product safety. Weighing a plastic bottle through rigorous top-load testing lowers overall plastic consumption over a year of production.

Enhance Your Packaging Quality Control

A practical quality workflow uses compression testing to verify incoming packaging, approve design changes, and confirm that production lots remain within performance targets.​

When used alongside a structured test plan and documentation (photos, configuration notes, acceptance criteria), compression testing becomes easier to audit and more useful for continuous improvement.

Contact Presto Group Today!

Our range of Compression Testing Machines ensures durability and precision without compromising on functionality. We guide businesses in strengthening their products as per industry standards through strategic implementations. . 

Call us: +91 9210903903
Email: info@prestogroup.com
Visit: www.prestogroup.com
Address: Plot No. I, 42, NH-19, Block C, DLF Industrial Area, Sector 32, Faridabad, Haryana 121003