What Is ASTM D6653/D6653M-13 Testing? A Complete Guide to High-Altitude (Low Pressure) Package Testing

What is ASTM D6653/D6653M-13 Testing?

ASTM D6653/D6653M-13 is a standard test method that evaluates the effects of high-altitude (low-pressure) conditions on packaged products and packaging systems. This test simulates the reduced air pressure that packages experience during air transportation or when passing through high-altitude regions.

By exposing the packaging system to a controlled vacuum environment, this method helps determine how the package and its contents respond to differential pressure—such as swelling, bursting, leakage, or seal failure.

ASTM D6653 provides critical insight into the integrity and performance of packaging under simulated high-altitude conditions, ensuring that products remain safe, sealed, and undamaged during transit.

Why is ASTM D6653 Testing Important?

Transportation by air or across mountainous regions subjects packages to reduced atmospheric pressures. These pressure drops can cause sealed packages to expand, rupture, or leak, especially when air or gases are trapped inside.

ASTM D6653 testing helps manufacturers:

• Evaluate the resistance of packaging to pressure differentials encountered during air shipment.
• Identify potential failure points, such as seal weaknesses or material deformation.
• Ensure product safety and compliance with shipping and storage regulations.
• Support the design and validation of packaging for air, land, and international shipping.
• Prevent costly damage, leakage, or contamination during transport.

This method is essential for packaging engineers, quality assurance teams, and logistics specialists to verify that packaging designs can withstand the real-world challenges of altitude variation.

Which Packaging Systems Can Be Tested Under ASTM D6653?

ASTM D6653/D6653M-13 applies to a wide range of packaging types and configurations, including:

• Flexible packages (e.g., pouches, vacuum-sealed bags, sachets)
• Rigid containers (e.g., bottles, cans, jars, plastic containers)
• Corrugated boxes and cartons containing sealed inner packages
• Food and beverage packaging with sealed atmospheres or modified gas content
• Consumer goods with air-filled or foam cushioning materials

The method can be used for primary, secondary, or tertiary packaging, depending on the shipping configuration being simulated.

What Information Do ASTM D6653 Test Results Provide?

The test provides valuable data regarding packaging performance under reduced pressure, typically summarized as:

These results help determine whether packaging maintains functional integrity and containment when exposed to simulated high-altitude conditions.

What Industries Use ASTM D6653 Testing?

ASTM D6653 testing is utilized across multiple sectors where packaging integrity is critical, including:

• Aerospace and aviation logistics
• Pharmaceutical and healthcare industries
• Food and beverage packaging (e.g., chips, snacks, coffee)
• Consumer electronics and sensitive equipment packaging
• Chemical and hazardous materials transport
• E-commerce and international shipping sectors

Testing supports product qualification, regulatory compliance, and risk mitigation across industries that rely on high-performance packaging systems.

What Equipment Is Used for ASTM D6653 Testing?

The test requires a vacuum chamber system capable of controlling internal pressure to simulate various altitudes. The standard setup includes:

• A vacuum chamber large enough to accommodate the test package
• Pressure control system with a vacuum pump and a pressure gauge
• Data acquisition system to record pressure changes and test duration
• Observation window or camera to monitor package behavior
• Leak detection apparatus (optional, for advanced diagnostics)

The equipment must be capable of maintaining pressure differentials representative of altitudes up to approximately 14,000 feet (4,300 meters) or as specified by shipping conditions.

How Is the ASTM D6653 Test Performed?

Step-by-Step Procedure:

• Sample Preparation:
  The test package is prepared as it would be for shipment, including seals, closures, and labels.
• Chamber Setup:
  The package is placed inside the vacuum chamber, and the initial pressure is recorded (standard atmospheric pressure).
• Vacuum Application:
  Chamber pressure is gradually reduced to simulate the target altitude—typically between 0 and 60 kPa absolute pressure. The rate of pressure reduction is controlled to avoid shock effects.
• Observation Period:
  The package is observed during and after depressurization for signs of deformation, leakage, or rupture.
• Return to Ambient Conditions:
  After exposure, the chamber is returned to normal pressure, and the package is inspected again for permanent damage or seal failure.
• Data Collection:
  Pressure levels, duration, visual observations, and failure modes are documented for analysis and evaluation.

What Are the Standard Test Conditions?

Maintaining consistent and controlled test conditions ensures reliable and repeatable results.

Key Properties Measured

ASTM D6653 primarily measures the resistance of packaging systems to pressure differentials created by high-altitude or low-pressure conditions. The key properties evaluated include:

• Structural durability
• Seal strength and airtightness
• Material flexibility and expansion response
• Leakage resistance
• Ability to maintain product protection under simulated transport stress

Related Testing Methods

ASTM D6653 is often used alongside other packaging performance tests, such as:

• ASTM D3078: Bubble Emission Test for Detecting Leaks in Packaging
• ASTM D4991: Leakage Testing of Empty Rigid Containers
• ASTM D4169: Performance Testing of Shipping Containers and Systems
• ASTM F2096: Gross Leak Detection for Flexible Packaging (Bubble Test)
• ASTM D7386: Drop Test of Loaded Containers by Free Fall

Together, these methods provide a comprehensive understanding of how packaging performs during transportation and handling.

Conclusion

ASTM D6653/D6653M-13 is a vital test method for assessing how packaging systems respond to high-altitude, low-pressure conditions that occur during air or mountain transport.

By simulating altitude effects through vacuum exposure, this standard helps identify potential failure modes such as swelling, bursting, or seal leaks, ensuring product safety and integrity.

Manufacturers and packaging engineers rely on this method to validate packaging designs, enhance quality assurance, and meet global transportation standards.
In short, ASTM D6653 plays a crucial role in developing reliable, high-performance packaging solutions that protect products from origin to destination—even when the journey takes place at high altitudes.

Why Choose Infinita Lab for ASTM D6653?

At the core of this breadth is our network of 2,000+ accredited labs in the USA, offering access to more than 10,000 test types. From advanced metrology (SEM, TEM, RBS, XPS) to mechanical, dielectric, environmental, and standardized ASTM/ISO testing, we give clients unmatched flexibility, specialization, and scale. You’re not limited by geography, facility, or methodology—Infinita connects you to the proper testing, every time.

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