UNITED NATIONS / DOT PERFORMANCE CERTIFICATION 4G …s2/API 13-7125 (4G - 2x2.pdf · API Kirk Containers packaging referenced above has passed the standards of the DEPARTMENT OF

UNITED NATIONS / DOT

PERFORMANCE CERTIFICATION

4G DESIGN QUALIFICATION

2 x 2-1/2 Gallon F-Style Plastic Bottle (Mold #’s

221, 222, 223, & 224) Packaging Phoenix Closure with Two Liner Options:

#1) Induction Sealed Liner #2) PE Foam Liner

TEST REPORT #: 13-7125

un

4G / Y35.5 / S / ** USA / +AA4377

**Insert the year packaging is manufactured

TESTING PERFORMED FOR:

API KIRK CONTAINERS 2131 South Garfield Ave.

Commerce, CA 90040

ATTN: Martin Lara

TESTING PERFORMED BY:

TEN-E PACKAGING SERVICES, INC. 326 North Corona Avenue

Ontario, CA 91764 Phone: 909-937-1260

Fax: 909-937-1262

July 26, 2013

Test Report # 13-7125 July 26, 2013 Page 2 of 23

TABLE OF CONTENTS SECTION I: CERTIFICATION .................................................................................................................. 3 SECTIONS II & V: PACKAGING DESCRIPTIONS / COMPONENT DRAWINGS .................................. 4

COMPONENT INFORMATION ........................................................................................................ 5 SECTION III: TEST PROCEDURES AND RESULTS .............................................................................. 8

DROP TESTS Induction Sealed Liner .............. 8 DROP TESTS PE Foam Liner ......................... 9 STACKING & STACKING STABILITY TESTS Induction Sealed Liner ............ 10 STACKING & STACKING STABILITY TESTS PE Foam Liner ........................ 11 PRESSURE DIFFERENTIAL TEST Induction Sealed Liner ............ 12 PRESSURE DIFFERENTIAL TEST PE Foam Liner ........................ 13 VIBRATION TEST Induction Sealed Liner ............. 14 VIBRATION TEST PE Foam Liner ......................... 15 COBB WATER ABSORPTION TEST ............................................................................................ 16

REGULATORY AND INDUSTRY STANDARD REFERENCES ............................................................ 17 SECTION IV: MATHEMATICAL CALCULATIONS Foam Liner ..................... 18 SECTION IV: MATHEMATICAL CALCULATIONS Foil Liner ....................... 20 APPENDIX A: MANUFACTURER’S CLOSURE INSTRUCTIONS ...................................................... 22

NOTES AND COMMENTS Tested as a design qualification due to a change in the corrugated basis weight. The packaging will retain the +AA4377 Identification.


SECTION I: CERTIFICATION

Design Qualification of the API Kirk Containers 2 x 2-1/2 Gallon F-Style Plastic Bottle (Mold #’s 221, 222, 223, & 224) Packaging Phoenix Closure

with Two Liner Options: #1) Induction Sealed Liner

#2) PE Foam Liner TEN-E Packaging Services, Inc. is a current DOT UN Third-Party Certification Agency under §107.403 and certifies that the API Kirk Containers packaging referenced above has passed the standards of the DEPARTMENT OF TRANSPORTATION’S TITLE 49 CFR; Performance Oriented Packaging Standards, Section 178. This package is also certified under IMDG, ICAO/IATA Regulations and the UN Recommendations on the Transport of Dangerous Goods. It is the responsibility of the end user to determine authorization for use under these regulations. The use of other packaging methods or components other than those documented in this report may render this certification invalid.

SUMMARY OF PERFORMANCE TESTS UN / DOT

TEST CFR

REFERENCE TEST

LEVEL TEST

CONTENTS TEST

COMPLETED TEST

RESULTS Drop 178.603 1.6 m Methanol/Water July 24, 2013 PASS

Stacking 178.606 771.1 Kg – 24 Hours Water July 25, 2013 PASS Stacking 178.606 771.1 Kg – 24 Hours Water July 26, 2013 PASS Pressure 173.27 95 kPa - 30 Minutes Water July 24, 2013 PASS Vibration 178.608 4.0 Hz – 1 Hour Water July 26, 2013 PASS

Cobb 178.516 30 Minutes --- July 22, 2013 PASS TEST REPORT NUMBER: 13-7125 UN MARKING: (CFR 49 – 178.503)

un

4G / Y35.5 / S / ** USA / +AA4377

PACKAGING IDENTIFICATION CODE: 4G - Fiberboard Box (178.516) PERFORMANCE STANDARD: Y (Packaging meets Packing Group II and III tests) AUTHORIZED GROSS MASS: 35.5 Kg (78.2 Lbs) "S" DESIGNATION: Denotes Inner Packagings YEAR OF MANUFACTURE: ** Insert year the packaging is manufactured STATE AUTHORIZING THE MARK USA

PACKAGING CERTIFICATION AGENCY: (+AA) TEN-E Packaging Services, Inc. (Ontario CA #2006030021)

THIRD PARTY PACKAGING IDENTIFICATION: +AA4377 PERIODIC RETEST DATE: July 26, 2015 ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY THAT THE PACKAGING TESTED IS MERCHANTABLE OR FIT FOR A PARTICULAR PURPOSE, ARE DISCLAIMED. In no event shall TEN-E Packaging Services, Inc. liability exceed the total amount paid by API Kirk Containers for services rendered. In the event of future changes to the above referenced test standards, it is the responsibility of API Kirk Containers to determine whether additional testing or updating of past testing is necessary to verify that the packaging we have tested remains in compliance with those standards. MANUFACTURER:

API Kirk Containers 2131 South Garfield Ave. Commerce, CA 90040

S 2

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SECTIONS I

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ManufacturerDwg. #: 63-S

Description: Quantity: Material: Tare Weight:Overall Dime• Height • DiameterThread: • Type Finish Dimen• T • E • Thread PMarkings (QCLiner: Description: Tare Weight: Thickness: Diameter: Markings (QCLiner: Description: Tare Weight: Thickness: Diameter: Markings (QC

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3-7125 6, 2013 5 of 23

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3-7125 6, 2013 6 of 23


SHIPPER Manufacturer: International Paper: Bell, CA Description: Regular Slotted Container Die-Cut Hand Holes:

• Dimensions (Length x Width) 3-1/2” x 1-1/8”

• Location Short Side of Shipper Material/Flute (Inner to Outer): Double Wall Mottled White Corrugated Fiberboard; B/C-Flute

Basis Weight (Outer to Inner) Lbs./MSF:

• Specification 42/26/35/26/42 Tare Weight: 707 Grams

DIMENSIONS

Specification Dimensions (Inside) Measured Dimensions (Outside) • Length 13.5” 14”

• Width 9.125” 9-5/8”

• Height 14.4375” 15-1/2” Board Caliper (Nominal): 0.249”

Manufacturer’s Joint: Inside Glued, 1-3/8” Lap

Markings (QC Audit): u

n 4G/Y35.5/S/13 USA/+AA4377

200

BOX CERTIFICATE (A) Corrugated

Manufacturer: INTERNATIONAL PAPER

(B) Structure: Double Wall

(C) ECT: 51 Lbs. Per Sq Inch

(D) Size Limit: 105”

(E) Gross Wt Lt: 120 Lbs.

(F) Location: BELL, CA


SECTION III: TEST PROCEDURES AND RESULTS DROP TESTS Induction Sealed Liner

TEST INFORMATION TEST CRITERIA

TEST CONTENTS: Methanol/Water Solution (0.958 SG) • For packaging containing liquid, each packaging does not leak.

• There can be no damage to the outer packaging likely to adversely affect safety during transport. Inner receptacles, inner packagings or articles must remain completely within the outer packaging and there must be no leakage of the filling substance from the inner packaging.

• Any discharge from a closure is slight and ceases immediately after impact with no further leakage.

• No rupture is permitted in packagings for materials in Class 1 which would permit spillage of loose explosive substances or articles from the outer packaging.

(§178.603)

SAMPLE PREPARATION: Refer to Section II

CONDITIONING: -18°C (0°F) Freezer #201

CONTENTS TEMP.: -18.4°C (-1.12°F)

DROP HEIGHT: 1.6 Meters (63”) (Refer to Section IV)

TEST EQUIPMENT: L.A.B. Accu Drop 160

DROP ORIENTATIONS AND TEST RESULTS Sample #1: Flat on Bottom Sample #2: Flat on Top *Sample #3: Flat on Long Side

PASS: No leakage or damage. PASS: No leakage or damage. PASS: No leakage or damage. *Sample #4: Flat on Short Side *Sample #5: Bottom Corner **Sample #1: Top Corner

PASS: No leakage or damage. PASS: No leakage. Deformation to shipper on impact.

PASS: No leakage. Deformation to shipper on impact.

** Flat on Bottom Drop sample was also used for the Top Corner drop.


DROP TESTS PE Foam Liner


TEST CONTENTS: Methanol/Water Solution (0.958 SG) • For packaging containing liquid, each packaging does not leak.

• There can be no damage to the outer packaging likely to adversely affect safety during transport. Inner receptacles, inner packagings or articles must remain completely within the outer packaging and there must be no leakage of the filling substance from the inner packaging.

• Any discharge from a closure is slight and ceases immediately after impact with no further leakage.

• No rupture is permitted in packagings for materials in Class 1 which would permit spillage of loose explosive substances or articles from the outer packaging.

(§178.603)

SAMPLE PREPARATION: Refer to Section II

CONDITIONING: -18°C (0°F) Freezer #201

CONTENTS TEMP.: -18.4°C (-1.12°F)

DROP HEIGHT: 1.6 Meters (63”) (Refer to Section IV)

TEST EQUIPMENT: L.A.B. Accu Drop 160

DROP ORIENTATIONS AND TEST RESULTS Sample #12: Flat on Bottom Sample #13: Flat on Top *Sample #14: Flat on Long Side

PASS: No leakage or damage. PASS: No leakage or damage. PASS: No leakage or damage. *Sample #15: Flat on Short Side *Sample #16: Bottom Corner **Sample #12: Top Corner

PASS: No leakage or damage. PASS: No leakage. Deformation to shipper on impact.

PASS: No leakage. Deformation to shipper on impact.

** Flat on Bottom Drop sample was also used for the Top Corner drop.


STACKING & STACKING STABILITY TESTS Induction Sealed Liner


TEST CONTENTS: Water • There must be no leakage of the filling substance from the inner receptacle, or inner packaging.

• There can be no deterioration that could adversely affect transport safety or any distortion liable to reduce the package’s strength, cause instability in stacks of packages, or cause damage to inner packagings that is likely to reduce safety in transport.

(§178.606)

SAMPLE PREPARATION:

Refer to Section II

CONDITIONING: 73°F / 50% RH Quality Room #202

TEST LOAD APPLIED: 771.1 Kg (1,700.0 Lbs) (Refer to Section IV)

TEST DURATION: 24 Hours

TEST EQUIPMENT: L.A.B. Validator Plus Compression System

STACKING TEST SET-UP & RESULTS

Sample # Maximum Deflection After 24 Hours Results

6 0.089” PASS 7 0.089” PASS 8 0.089” PASS

Comments/Observations

Following the stack test there was no leakage or damage likely to result in failure of the packaging.

STACKING STABILITY TEST SET-UP & RESULTS

Results CRITERIA FOR PASSING THE TEST

PASS

• In guided load tests, stacking stability must be assessed after test completion.

• Two filled packagings of the same type must be placed on the test sample.

• The stacked packages must maintain their position for one hour.

(§178.606)

For stack stability, TEN-E places the filled samples one on top of the other. The bottom sample is rotated to the top until all three samples have been subjected to stacking stability for one hour each.

S

T

SP

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SULTS

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3-7125 6, 2013 1 of 23

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PRESSURE DIFFERENTIAL TEST Induction Sealed Liner


TEST CONTENTS: Water

• Packaging for which retention of liquid is a basic function must be capable of withstanding the pressure requirements without leakage.

(§173.27(c))

FILL CAPACITY: Maximum Capacity

CLOSURE APPLICATION:

Refer to Section II

CONDITIONING: Ambient

TEST PRESSURE: 95 kPa

TEST DURATION: 30 Minutes

AREA OF PRESSURIZATION:

Through the Bottom

TEST EQUIPMENT: Regulated Water Source Digital Pressure Gauge

HYDROSTATIC PRESSURE TEST SET-UP AND RESULTS

Sample # Results Comments/Observations

1 PASS

All three samples maintained the 95 kPa test pressure for 30 minutes without leakage.

2 PASS

3 PASS


PRESSURE DIFFERENTIAL TEST PE Foam Liner


TEST CONTENTS: Water

• Packaging for which retention of liquid is a basic function must be capable of withstanding the pressure requirements without leakage.

(§173.27(c))

FILL CAPACITY: Maximum Capacity

CLOSURE APPLICATION:

Refer to Section II

CONDITIONING: Ambient

TEST PRESSURE: 95 kPa

TEST DURATION: 30 Minutes

AREA OF PRESSURIZATION:

Through the Bottom

TEST EQUIPMENT: Regulated Water Source Digital Pressure Gauge

HYDROSTATIC PRESSURE TEST SET-UP AND RESULTS


1 PASS

All three samples maintained the 95 kPa test pressure for 30 minutes without leakage.

2 PASS

3 PASS


VIBRATION TEST Induction Sealed Liner


TEST CONTENTS: Water • Immediately following the period of vibration, each package must be removed from the platform, turned on its side and observed for any evidence of leakage.

• A packaging passes the vibration test if there is no rupture or leakage from any of the packages.

• No test sample should show any deterioration which could adversely affect transportation safety or any distortion liable to reduce packaging strength.

(§178.608)

SAMPLE PREPARATION:

Refer to Section II


TABLE DISPLACEMENT:

1”

TEST FREQUENCY: 4.0 Hz

TEST DURATION: 1 Hour

TEST EQUIPMENT: Vertical motion using L.A.B. Palletizer Vibration System

VIBRATION TEST SET-UP AND RESULTS


9 PASS

No leakage or damage. 10 PASS

11 PASS


VIBRATION TEST PE Foam Liner


TEST CONTENTS: Water • Immediately following the period of vibration, each package must be removed from the platform, turned on its side and observed for any evidence of leakage.

• A packaging passes the vibration test if there is no rupture or leakage from any of the packages.

• No test sample should show any deterioration which could adversely affect transportation safety or any distortion liable to reduce packaging strength.

(§178.608)

SAMPLE PREPARATION:

Refer to Section II


TABLE DISPLACEMENT:

1”

TEST FREQUENCY: 4.0 Hz

TEST DURATION: 1 Hour

TEST EQUIPMENT: Vertical motion using L.A.B. Palletizer Vibration System

VIBRATION TEST SET-UP AND RESULTS


17 PASS

No leakage or damage. 18 PASS

19 PASS


COBB WATER ABSORPTION TEST


NUMBER OF SAMPLES: 5

• An increase in mass greater than 155 g/m² over the 30 minute duration represents an unacceptable level of water resistance.

(§178.516)

SAMPLE SIZE: 5” x 5” (Minimum)


WATER APPLIED: 100 mL / Sample

TEST DURATION: 30 Minutes / Sample

TEST EQUIPMENT: UWE Analytical Balance Gurley Cobb Water Absorption Fixtures

COBB WATER ABSORPTION TEST RESULTS Sample # Water Absorbed

1 125 g/m² 2 109 g/m² 3 115 g/m² 4 128 g/m² 5 134 g/m²

AVERAGE: 122.2 g/m²

RESULT PASS


REGULATORY AND INDUSTRY STANDARD REFERENCES

REGULATORY REFERENCES

TEST 49 CFR UN IMDG ICAO IATA

October 2012 Edition

17th Edition

2012 Edition

2013-2014 Edition

54th Edition

Drop: 178.603 6.1.5.3 6.1.5.3 6; 4.3 6.3.3

Stacking: 178.606 6.1.5.6 6.1.5.6 6; 4.6 6.3.6

Pressure: 173.27(c) 4.1.1.4.1 4.1.1.4.1 4; 1.1.6 5.0.2.9

Vibration: 178.608 --- --- 4; 1.1.1 5.0.2.7

Cobb: 178.516(b)(1) 6.1.4.12.1 6.1.4.12.1 6; 3.1.11.1 6.2.12.2 United States Department of Transportation Code of Federal Regulations (CFR) Title 49, Transportation, Parts 100-185 The United Nations Recommendations on the Transport of Dangerous Goods – Model Regulations (UN – Orange Book) International Maritime Dangerous Goods Code (IMDG) Technical Instructions for the Safe Transport of Dangerous Good by Air (ICAO) International Air Transport Association (IATA) Dangerous Goods Regulations

INDUSTRY STANDARD REFERENCES

Drop: ASTM D5276: Standard Test Method for Drop Test of Loaded Containers by Free Fall

ISO 2248: Packaging – Complete, Filled Transport Packages – Vertical Impact Test by Dropping

Stacking: ASTM D4577: Standard Test Method for Compression Resistance of a Container Under Constant Load

ISO 2234: Packaging – Complete, Filled Transport Packages – Stacking Test using Static Load

Hydrostatic Pressure: ASTM D7660: Standard Guide for Conducting Internal Pressure Tests on United Nations

(UN) Packagings

Vibration: ASTM D999: Standard Test Method for Vibration Testing of Shipping Containers

ISO 2247: Packaging – Complete, Filled Transport Packages – Vibration Test at Fixed Low Frequency

Cobb: ISO 535: Paper and Board – Determination of Water Absorption – Cobb Method American Society for Testing and Materials (ASTM) International Organization for Standardization (ISO)

EQUIPMENT

All inspection, measuring and test equipment that can affect product quality is calibrated and adjusted at prescribed intervals, or prior to use, and is traceable to NIST, using ANSI Z540 as an overall guide for calibration certification.


SECTION IV: MATHEMATICAL CALCULATIONS Foam Liner

1,463.0 Grams

Methanol/Water 10,703.7 Grams SG: 0.958Water 11,173.0 Grams

2II

1.6001.00

Overall Height of one Package (OH): 15.50 InchesStack Test-# of Samples Tested Simultaneously: 3

OFC x 98%

10,703.7 x 98% = 10,489.7 Grams Methanol/Water11,173.0 x 98% = 10,949.6 Grams Water

PTW + (98% OFC x # IP)

1,463 + 10,489.7 x 2 Methanol/Water1,463 + 10,949.6 x 2 Water

Methanol/Water: 22.4 Kg 49.3 Lbs.Water: 23.3 Kg 51.3 Lbs.

PTW + (PSG x 98% OFC x # IP)1,463 + 1.6 x 10,950 x 2

36.5 Kg 80.4 Lbs.

Overall Packaging Tare Weight (PTW):Overflow Capacity (OFC):

INFORMATION USED FOR CALCULATIONS

Packing Group Multiplication Factor (MF):

Methanol/Water SG

Packing Group

Overflow Capacity (OFC) x 98%98% OF OVERFLOW

PACKAGE TEST WEIGHTS

Number of Inner Packagings (# IP):

Product Specific Gravity (PSG):

Overall Pkg Tare Weight (PTW) + (98% Overflow Capacity (OFC) x # of Inner Pkg (# IP)

Overall Pkg Tare Weight (PTW) + (Product SG (PSG) x 98% Overflow (OFC) x # of Inner Pkg (# IP))AUTHORIZED PACKAGE GROSS MASS CALCULATION (APGM)


PSG x MF Packing Group: II

1.6 x 1.00

1.60 Meter 63.0 Inches 63 Inches

(118 / OH) -1 = # 3m HS

118 / 15.50 -1 = 6.7

APGM x # 3m HS

36.5 x 6.7

244.6 Kg 539.2 Lbs.

Samples x (APGM x # 3m HS)3 x 36.5 x 6.7

733.7 Kg 1,617.5 Lbs.

Stacking Test Load Calculation Samples x Authorized Pkg Gross Mass (APGM) x # of Pkg in a 3m High Stack (# 3m HS)

Product Specific Gravity (PSG) x Packing Group Multiplication Factor (MF)

Number of Packages in a 3m High Stack (118 / Overall Pkg Height (OH) -1)118 / Overall Height of one Pkg (OH) - 1

Stacking Test Load Calculation (Individual Package)

Actual Drop Height

STACKING TEST MINIMUM LOAD CALCULATIONS

Authorized Pkg Gross Mass (APGM) x # of Pkg in a 3m High Stack (# 3m HS)

Required Drop Height

Calculation For Product Specific Gravities Exceeding 1.2DROP HEIGHT


SECTION IV: MATHEMATICAL CALCULATIONS Foil Liner

1,464.0 Grams

Methanol/Water 10,703.7 Grams SG: 0.958Water 11,173.0 Grams

2II

1.6001.00

Overall Height of one Package (OH): 15.50 InchesStack Test-# of Samples Tested Simultaneously: 3

OFC x 98%

10,703.7 x 98% = 10,489.7 Grams Methanol/Water11,173.0 x 98% = 10,949.6 Grams Water

PTW + (98% OFC x # IP)

1,464 + 10,489.7 x 2 Methanol/Water1,464 + 10,949.6 x 2 Water

Methanol/Water: 22.4 Kg 49.3 Lbs.Water: 23.3 Kg 51.3 Lbs.

PTW + (PSG x 98% OFC x # IP)1,464 + 1.6 x 10,950 x 2

36.5 Kg 80.4 Lbs.

Overall Packaging Tare Weight (PTW):Overflow Capacity (OFC):

INFORMATION USED FOR CALCULATIONS

Packing Group Multiplication Factor (MF):

Methanol/Water SG

Packing Group

Overflow Capacity (OFC) x 98%98% OF OVERFLOW

PACKAGE TEST WEIGHTS

Number of Inner Packagings (# IP):

Product Specific Gravity (PSG):

Overall Pkg Tare Weight (PTW) + (98% Overflow Capacity (OFC) x # of Inner Pkg (# IP)

Overall Pkg Tare Weight (PTW) + (Product SG (PSG) x 98% Overflow (OFC) x # of Inner Pkg (# IP))AUTHORIZED PACKAGE GROSS MASS CALCULATION (APGM)


PSG x MF Packing Group: II

1.6 x 1.00

1.60 Meter 63.0 Inches 63 Inches

(118 / OH) -1 = # 3m HS

118 / 15.50 -1 = 6.7

APGM x # 3m HS

36.5 x 6.7

244.6 Kg 539.2 Lbs.

Samples x (APGM x # 3m HS)3 x 36.5 x 6.7

733.7 Kg 1,617.5 Lbs.

Stacking Test Load Calculation Samples x Authorized Pkg Gross Mass (APGM) x # of Pkg in a 3m High Stack (# 3m HS)

Product Specific Gravity (PSG) x Packing Group Multiplication Factor (MF)

Number of Packages in a 3m High Stack (118 / Overall Pkg Height (OH) -1)118 / Overall Height of one Pkg (OH) - 1

Stacking Test Load Calculation (Individual Package)

Actual Drop Height

STACKING TEST MINIMUM LOAD CALCULATIONS

Authorized Pkg Gross Mass (APGM) x # of Pkg in a 3m High Stack (# 3m HS)

Required Drop Height

Calculation For Product Specific Gravities Exceeding 1.2DROP HEIGHT

A

APPENDIX AA: MANUFAACTURER’S

S CLOSUREE INSTRUCCTIONS

Test Report # 13July 26Page 22

3-7125 6, 2013 2 of 23

Test Report # 13July 26Page 23

3-7125 6, 2013 3 of 23

Documents

UNITED NATIONS / DOT PERFORMANCE CERTIFICATION 4G …s2/API 13-7125 (4G - 2x2.pdf · API Kirk Containers packaging referenced above has passed the standards of the DEPARTMENT OF