Distribution testing at Smithers
Watch this video from Smithers distribution testing experts to get an overview of how they help clients validate packaging performance, simulating every part of the supply chain.
Summary
ISTA 6-Amazon.com Over-Boxing is a general simulation test designed for e-commerce fulfillment shipments where individual retail packaged-products are placed into a corrugated master shipping container, or “over box”, for parcel distribution.
The procedure evaluates the ability of both the product and packaging system - including primary packaging, secondary packaging and transport packaging - to withstand the motions, forces and environmental conditions commonly encountered throughout e-commerce parcel delivery networks.
The procedure was updated in 2026 to reflect evolving supply chain practices, consumer ordering patterns and current packaging formats used within e-commerce fulfillment operations. Updates also include revised guidance around over-box selection, kraft paper dunnage requirements and multi-product shipment configurations.
Test Details
Packages may be subjected to the following tests:
- Atmospheric preconditioning at ambient temperature and humidity conditions
- Optional atmospheric conditioning using controlled temperature and humidity profiles
- Shock testing using free-fall drop methods
- Vibration testing using random vibration profiles with top load
- Additional shock testing using drop methods, including drops on hazards
- Integrity testing using leak detection methods for liquid-containing products onl
- ISTA 6-Amazon.com Over-Boxing applies to individual packaged-products weighing 70 lbs (31.75 kg) or less when prepared for e-commerce fulfillment using an over-box shipping configuration.
- The procedure covers both single-item and multi-item shipment configurations where retail packaged-products are placed into a corrugated over-box with kraft paper dunnage prior to parcel distribution.
- Multi-product shipment testing may also incorporate defined hazard products intended to simulate additional packaged items within the shipment.
Please Note: The information outlined above is to be used as reference for ISTA 6-Amazon.com-Over Boxing. Please refer to ISTA's website for current information on the proposed procedure.
Support for ISTA Distribution Testing
If you are considering testing to ISTA 6 - Amazon.com Over-Boxing, or would like support selecting the most appropriate distribution testing approach, Smithers can help. Our experts support organisations with transit simulation, packaging validation, and distribution testing programmes aligned with real-world supply chain conditions. Speak with a distribution testing specialist.
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