What to check after a carton drop test

Agree what constitutes a pass before testing

Put the post-drop checks in the inspection brief before testing starts. Identify the product and packing revision, reference sample, test procedure, products to examine, functional checks and acceptable damage. Distinguish permitted carton scuffing from unacceptable product damage or loss of protection. Use our inspection guide for the wider brief and packaging test guide when choosing the test.

Record the condition and functional results of the actual products before the drop test. Keep their identities linked to the tested carton. If acceptance criteria are missing or ambiguous, report the findings and request a buyer decision before calling the result a pass.

Open the pack without losing evidence

Photograph the carton markings, impacted areas, crushed corners, split seams and closures before opening. Record whether the carton still contains and protects its contents. Open it carefully, keeping cutting tools away from the product, and photograph each packing layer before moving anything.

Open the retail packs inside the shipping carton. Record where each product, insert and accessory is found before lifting it out. Keep damaged packaging and loose fragments with the identified sample so the buyer can distinguish damage discovered after testing from damage caused during unpacking.

Check concealed damage and displaced inserts

Remove sleeves, bags and protective pieces to inspect hidden surfaces, bases, joints, hinges and attachment points. Look for cracks, chips, dents, distortion, loosened fixings, leakage and parts that have shifted. Compare with the recorded condition before testing. An intact outer carton is not enough to support a pass.

Compare the packing arrangement with the approved packing photographs. Check for inserts that have slipped, split, compressed or left their locating points. Look for product contact with carton walls, neighbouring products or loose accessories. Record movement even when no product damage is visible, then assess it against the agreed protection criteria.

Inspect accessories and repeat functional checks

Unpack accessories separately and check their condition as well as their presence. Examine cables, connectors, adaptors, handles, fittings and loose hardware where supplied. Check that accessory bags remain closed and that accessories have neither escaped nor struck the main product. Confirm that instructions remain readable and assembly parts still fit.

Repeat the agreed pre-drop functional checks on the same products using the same setup, loads and operating conditions. Check relevant assembly, movement, closures, controls and operating performance, rather than recording only that the product switches on. Record changed behaviour, unusual noise and intermittent faults. Stop powered checks if damage suggests a safety risk and refer the sample for competent assessment.

Record the decision and control any retest

For each criterion, record the observation, photograph or test result and pass, fail or not checked status. Separate carton damage, loss of packing protection, product damage and accessory faults. State any limits on access or testing. Our inspection report guide helps buyers review the evidence.

Keep failed samples and their original results. Ask the factory to identify the cause and propose a correction. Record the revised packing or product specification and agree the retest scope before repeating the test. Do not replace a failed result with a photograph of a repacked carton. Use our corrective action guide to organise follow-up.

A packaging result supports the agreed inspection decision; it does not establish the whole product's safety compliance. Manufacturers and importers must demonstrate compliance with relevant regulations and safety requirements before placing products on the market. Keep that compliance evidence separate from the carton drop-test report.