What Is Altitude Package Testing? Protecting Products Shipped by Air
Products shipped by air cargo travel through low-pressure environments that most distribution testing programs never simulate. As aircraft climb to cruising altitude, the pressure in cargo holds drops significantly — and while cargo holds are pressurized on most commercial aircraft, they are not pressurized to sea-level conditions. For sensitive or sealed packages, this differential pressure can compromise package integrity, cause flexible packages to balloon and seal, damage pressure-sensitive contents, and allow contamination to enter through temporarily stressed seals.
Altitude package testing simulates these low-pressure conditions in the laboratory, enabling manufacturers and distributors to verify that their packaging systems maintain integrity throughout air shipment without the cost and uncertainty of actual flight testing.
What Is Altitude Package Testing?
Altitude package testing, also called altitude simulation testing or low-pressure packaging testing, subjects packages to reduced atmospheric pressure conditions equivalent to those experienced in aircraft cargo holds during flight. The test is designed to:
- Assess whether sealed packages maintain their integrity at altitude
- Identify seals, closures, or package structures that fail under low-pressure conditions
- Verify that products sensitive to pressure changes are protected from altitude-induced stress
- Confirm compliance with ISTA and ASTM standards that govern air shipment testing
The test is non-destructive for packages that pass — the package is returned to ambient conditions after exposure, and the contents and seals are inspected.
How Altitude Testing Works
Altitude package testing is conducted in a controlled vacuum chamber that simulates the reduced atmospheric pressure at altitude. The key standard governing this test is ASTM D6653 / D6653M — the standard test method for determining the effects of high altitude on packaging systems by the low-pressure method.
The general procedure:
- Packages are conditioned per ASTM D4332 at defined temperature and humidity
- Packages are placed in the vacuum chamber
- Chamber pressure is reduced at a controlled rate to the target test pressure, which corresponds to the simulated altitude
- Packages are held at the target pressure for the specified dwell time
- Pressure is returned to ambient at a controlled rate
- Packages are inspected for seal failure, leakage, deformation, and any damage to contents
Typical altitude simulation levels used in packaging testing correspond to pressures equivalent to:
- 11,000 feet (3,300 m) — equivalent to typical pressurized aircraft cargo hold pressure
- 14,000 feet (4,200 m) and higher for specialized cargo aircraft or unpressurized cargo compartments
Why Altitude Testing Is Critical for Specific Products
Certain product categories are particularly vulnerable to altitude-induced packaging stress:
Liquids and Pressure-Sensitive Products — liquid-containing packages experience pressure differentials that can drive leakage through small seal imperfections that would not fail at sea level.
Airtight and Vacuum-Sealed Packages — packages with controlled atmospheres or vacuum seals must maintain their internal environment throughout air transport.
Fragile or Pressure-Sensitive Contents — some components are sensitive to low ambient pressure itself (e.g., certain electronic components, pressurized containers).
Sealed Flexible Packages — pouches and bags can expand significantly at altitude, stressing seals that were adequate at sea-level pressure.
Medical and Laboratory Samples — containers used for sensitive biological or chemical samples must be validated for air transport integrity.
Applicable Standards
- ASTM D6653 / ASTM D6653M — primary standard for altitude simulation testing of packaging
- ISTA 2A, 2B, 3A, 3B — ISTA distribution simulation protocols that include altitude testing elements for products shipped by air
- ASTM D4169 — standard practice for performance testing of shipping containers and systems (includes altitude simulation)
Infinita Lab holds ISTA and ISO 17025 accreditation, confirming that altitude package testing results are technically valid and accepted by major retailers, logistics providers, and regulatory agencies.
Why Choose Infinita Lab for Altitude Package Testing?
With Infinita Lab (www.infinitalab.com), you are guaranteed a Nationwide Network of Accredited Laboratories spread across the USA, the best Consultants from around the world, Convenient Sample Pick-Up and Delivery, and Fast Turnaround Time.
Our team understands the stakes and subtleties of every test. Whether you’re validating a new Product, de-risking a prototype, or navigating complex compliance requirements, our specialists guide the process with rigor and clarity.
Looking for a trusted partner to achieve your research goals? Schedule a meeting with us, send us a request, or call us at (888) 878-3090 to learn more about our services and how we can support you. Request a Quote
Frequently Asked Questions (FAQs)
What is altitude package testing? Altitude package testing subjects packages to reduced atmospheric pressure conditions (simulating air cargo environments) to verify that seals, closures, and package structures maintain integrity during air shipment.
What pressure level is used in altitude testing? Testing pressure corresponds to the altitude of the aircraft cargo hold during cruise — typically equivalent to 11,000 feet for pressurized cargo holds, with higher altitudes specified for unpressurized compartments.
What products are most vulnerable to altitude-induced packaging failure? Liquid-containing packages, vacuum-sealed products, airtight flexible pouches, medical samples, and pressure-sensitive contents are most at risk.
Is altitude package testing destructive? Not inherently — packages that survive testing can be inspected and, if undamaged, returned to inventory. Packages that fail testing have sustained damage and must be assessed individually.
Why should companies invest in altitude package testing? Air shipping introduces pressure differentials that are not experienced in ground transport. Without altitude testing, seal failures and product damage during air shipment may not be discovered until after customer delivery — with associated replacement costs, delays, and reputation damage.
