UN Plastic Box Testing: What’s Involved and What You Can Expect from our Test Lab

UN certified plastic box packaging plays a vital role in the secure and compliant transportation of hazardous goods across the globe. UN packaging systems are specifically engineered to endure the stresses of handling and transport, helping to prevent spills, leaks and environmental harm.

At Air Sea Containers, we are experts in the testing and certification of UN-approved plastic boxes. As a UKAS accredited laboratory and an authorised testing facility for the VCA (Vehicle Certification Agency), we provide a complete solution, from product testing to certification management and 5 year revalidation.

What’s Required to Test Plastic Boxes to UN Performance Standards

UN testing for plastic boxes consists of performance assessments and technical inspections that confirm the packaging’s ability to maintain integrity under transport conditions. These tests are tailored according to the box type, hazard classification, density and packing group of the contents involved.

1. Drop Testing

This evaluates how well the packaging protects its contents if dropped during handling or transit.

• Sample Quantity: 5 test units required
• Drop Heights:
  • High danger (PG I): 1.8 metres
  • Medium danger (PG II): 1.2 metres
  • Low danger (PG III): 0.8 metres
  • Infectious materials: 9 metres
• Drop Positions:
  • Base, top, long side, short side, and one corner
• Pre-Test Conditioning: If the packaging contains plastic inners, they must be cooled to -18°C or lower before testing.
• Pass/Fail Criteria: No rupture or leakages. Inner containers must remain fully contained and undamaged.

2. Stack Testing

This test simulates pressure from other packages stacked during storage or shipment.

• Sample Quantity: 3 per design variant
• Test Load: Equivalent to the total weight of similar units in a 3 metre high stack
• Duration: 24 hours
• Pre-Test Conditioning: Same requirements as the drop test
• Pass/Fail Criteria: The packaging must remain intact with no leaks or structural damage that compromises safety or stability.

3. Specification and Construction Checks

To verify compliance and ensure repeatability, each packaging system undergoes material and design verification. These assessments confirm that every future production run matches the approved sample exactly.

Common checks include:

• Wall thickness and material grade
• Dimensions and tolerances
• Closure systems (caps, seals, tape, fasteners)
• Moulding consistency and performance attributes

Information Required from You

To begin testing, we need:

• 9 identical plastic containers from the same manufacturing batch.
• The specified closure system (e.g. adhesive).
• Detailed description of contents, including density, PG and classification.
• Any inner components, such as bottles, cushioning or absorbent materials.

What Services We Provide

Air Sea Containers offers comprehensive testing services for UN plastic boxes, including:

• UN Performance Testing: We test your packaging against UN Regulations performance testing criteria to ensure it meets required standards.
• Pre-Certification Evaluation: If you’re still refining your design, we can test early-stage models to identify design limitations before full certification.
• Five-Year Revalidation: UN-certified packaging must be retested periodically. We handle specification checks and manage re-certification through the VCA.
• Custom Plastic Packaging Solutions: From design to certification and manufacturing, we can manage the entire lifecycle of your custom plastic packaging, including long-term compliance and inventory support.
• Expert Guidance: Our team offers technical advice to help you avoid common failures, reduce testing delays and streamline your approval process.

Upon successful testing, we submit a full report to the VCA. Following their review, certification is issued and the packaging is granted an official UN specification mark.

Why UN Certification Is Essential

Achieving UN approval for your plastic box:

• Demonstrates full compliance with international DG transport regulations
• Confirms durability and containment strength
• Helps prevent leaks, spills and accidents
• Enhances your reputation for safety and regulatory responsibility

Ready to Begin?

UN plastic box packaging performance testing is a critical step in ensuring your dangerous goods are transported safely and in line with UN DG transport regulations. At Air Sea Containers, we simplify the process and provide you with expert support every step of the way.

Contact our team today for help with UN testing, certification or revalidation of your plastic packaging systems.