Specification Packaging general requirements

Transcription

1 Issued by Signature Authorised by Signature Replaces: Allan Dickner, Acting Packaging Development Manager, IKEA of Sweden Vladimir Brajkovic, Manager Product Requirement & Compliance, IKEA of Sweden AA Contents This specification describes IKEA regulations and instructions for the design of packaging solutions, the selection and quality of packaging materials, the marking of packaging, neat & clean packaging, low handling material and test methods. This specification also defines standard unit load dimensions and fixation requirements. About this specification This specification establishes a set of minimum requirements for the design of packaging throughout IKEA. The requirements stated in this specification complement and have priority over all other Packaging Requirements regarding establishing minimum requirements. Stated requirements are valid throughout the IKEA supply chain. All symbols and self declaration templates applicable in this specification are also available in the Supplier Portal. This specification is divided into a requirement part, where all requirements are stated, and an appendix part containing test methods and supporting documents. Implementation of changes Changes in this specification, version no, shall be implemented in production at the latest from packaging date stamp 1801 (year 2018 week 01). Products having a packaging date stamp earlier than 1801 shall be shipped to IKEA before shipping products compliant with this version of the specification. The following requirements shall be implemented by the stated date stamps: Table 1 Date stamps in Requirement Date stamp Grace period for the FSC requirement (year 2018 week 35) The following requirements are included for informational purposes only and will be reconfirmed in coming version of the specification. The specification shall be seen as implemented and confirmed as such even though these requirements have not been secured. Table 2 Date stamps in Requirement Date stamp All paper material used as packaging material shall come from 1935 (year 2019 week 35 More Sustainable Sources (MSS) No plastic material coming from 100% virgin fossil based raw 2035 (year 2020 week 35) material is allowed for packaging purposes. Inter IKEA Systems B.V Page 1 (86)

2 Table of contents 1 Supplier Information Responsibility General Tolerances Dangerous Goods Approved Packaging Materials Packaging Materials Quality Requirements Corrugated Cardboard Quality Load Bearer Quality Plastic Material Quality Shrink Film Quality Stretch Film Quality Plastic Bag Quality Adhesive Tape Quality Strap Quality Inside Filler Marking of Packaging Materials General Placement of Marking Marking Standard for Identification of Packaging Materials Suffocation warning symbol The Green Dot Marking Standard for Japan Marking of Corrugated Cardboard Quality Marking of Load Bearer Quality Marking of Corrugated Cardboard Packaging Construction ISPM 15 International Standards for Phytosanitary Measures Other Symbols Other Markings Consumer Packaging Multi-Pack Packaging Unit Load Transport Packaging Top and Bottom Protection Corner Protection Unit Load Fixation Low Handling Material Paper Pallet Loading Ledge Plastic foot Feet Pattern Load Bearer Sheet Unit Load Unit Load Types Modules and Storage Units Filling solution Top Filling solution Length and Side Filling Solution Unit Load Stacking Capacity Unit Load Stability Requirements Neat & Clean Packaging Requirements Neat & Clean Requirements for Consumer Packages Neat & Clean Requirements for Transport Packaging Definitions References Appendix A: Test methods... Appendix B: Self declaration for packaging materials... Appendix C: Paper Pallet Standards... Appendix D: Unit Load Requirement when using Air Transportation... Appendix E: General Tolerances Packaging Construction... Appendix F: How to fulfil IKEA requirement on More Sustainable Sources... Summary of Changes in version Inter IKEA Systems B.V Page 2 (86)

3 Background IKEA packaging ambition is to contribute to IKEA Democratic design by: protecting what it sells and selling what it protects through the different stages of the handling process, from the supplier all the way to the customers home. inspiring the customers and simplifying the buying process by being an information carrier for the product. developing packaging solutions that will contain the minimum adequate amount of packaging material, so that the packaging is correctly adapted to its purpose. developing packaging solution in order to minimize volume to enable efficient distribution and enable easy handling. producing handling materials with good design and good function at a low price. giving priority to packaging materials derived from renewable or recycled raw material. using materials that are easy to separate in order to enable the end-user to sort the materials at the packaging end of life. following present and new rules along with laws concerning producer responsibility for packaging and packaging waste locally and globally. 1 Supplier Information Responsibility In order to comply with environmental reporting legislations, the usage of packaging material per individual packaging part shall be defined in the Dimension Weight and Packaging (DWP) application by the supplier. It is the supplier s responsibility to provide accurate information (part type, material type, dimensions, weight, marking, etc.) in Actual DWP for the supplied packaging. This shall be done always when a new or updated packaging solution is introduced and when the weight/dimensions/materials etc. of the packaging are changed. As a minimum it shall be reviewed on a yearly basis. Information shall be registered in Actual DWP before dispatch from the supplier. The tolerance on weight is +/- 5% unless specified in the IKEA product documentation. If weight deviation is more than 5% a re-measurement and update of Actual DWP is required. Accuracy of DWP information is essential in order for IKEA to fulfil producer responsibility obligations. Inaccurate information can result in heavy business consequences for IKEA and its supplier. 2 General Tolerances In all packaging documentation, dimensions follow the ISO tolerance standard (see Appendix E: General Tolerances Packaging Construction) unless otherwise stated by IKEA product documentation. 3 Dangerous Goods Some products are dangerous goods and have to be handled, packaged, labelled and transported accordingly. Dangerous goods regulations are applicable and shall be followed. Dangerous goods are materials or items with hazardous properties which, if not properly controlled, present potential hazard to human health and safety, infrastructure and/or their means of transportation. The regulations for transport of dangerous goods are built on the UN model regulation. One example of a product that is dangerous goods are Lithium-ion battery (>20 Wh/cell or >100 Wh/battery). The UN number for Lithium-ion battery is 3480 or 3481 when packed with equipment. Note: Suppliers shall not define which goods are deemed dangerous. Definition and classification of dangerous goods is specified by the IKEA product documentation. Inter IKEA Systems B.V Page 3 (86)

4 5 Packaging Materials Quality Requirements 5.1 Corrugated Cardboard Quality Table 4 shows the minimum requirements for IKEA corrugated cardboard quality codes that shall be met to make sure that the quality of corrugated cardboard is acceptable. If no IKEA quality code is specified in the Packaging Requirement, then the lowest quality code of each flute type is the lowest quality allowed as packaging material. It is allowed to use higher quality codes than specified by IKEA but it is not allowed to change the flute type (for load bearer/top protection/sheet stabilizing a unit load, it is allowed to change flute type). Compliance shall be documented in accordance with Appendix B: Self declaration for packaging materials, and shall be registered in Connect. All tests of corrugated cardboard shall take place after the corrugating process, but before the converting process. Table 4 Corrugated Cardboard (CB) qualities 1 IKEA Code Bending stiffness 2 (Nm) Edgewise crush test (ECT) (kn/m) Bursting strength test (BST) 3 (kpa) Flat crush test (FCT) (kpa) Cobb 60 test, water absorptiveness 4 (g/m 2 ) Flute Type Thickness (mm) Mottling Coefficient of variations (COV on white corrugated board) ISO 5628 ISO 3037 ISO 2759 ISO 3035 ISO 535 ISO 3034 According to STFI method 5 IKEA CB E Max 2.5% IKEA CB E Max 2.5% IKEA CB B Max 2.5% IKEA CB B Max 2.5% IKEA CB B Max 2.5% IKEA CB B Max 2.5% 1 The value is based on the average calculated from 10 measurements. 2 Bending stiffness = MD x CD (MD = Machine direction, CD = Cross direction). Average calculated from 20 measurements (10 on MD/CD). 3 Bursting strength shall be tested on both in and outside. Average calculated from 20 measurements (10 on inside/outside). 4 Cobb 60 shall be tested on both in and outside, average is reported for each side individually. 5 White corrugated board or liner samples to STFI mottling test shall be sent to ITTC Shanghai. 2 pieces, size 200x200 mm per piece, is required. Inter IKEA Systems B.V Page 9 (86)

5 Table 4 Corrugated Cardboard (CB) qualities 1 IKEA Code Bending stiffness 2 (Nm) Edgewise crush test (ECT) (kn/m) Bursting strength test (BST) 3 (kpa) Flat crush test (FCT) (kpa) Cobb 60 test, water absorptiveness 4 (g/m 2 ) Flute Type Thickness (mm) Mottling Coefficient of variations (COV on white corrugated board) ISO 5628 ISO 3037 ISO 2759 ISO 3035 ISO 535 ISO 3034 According to STFI method 5 IKEA CB C/A / Max 2.5% IKEA CB C/A / Max 2.5% IKEA CB C/A / Max 2.5% IKEA CB C/A / Max 2.5% IKEA CB Double wall -- Max 2.5% IKEA CB Double wall -- Max 2.5% IKEA CB Double wall -- Max 2.5% IKEA CB Max 2.5% IKEA CB Max 2.5% IKEA CB Max 2.5% 6 C/A means either C or A flute. Inter IKEA Systems B.V Page 10 (86)

6 5.2 Load Bearer Quality The purpose of a load bearer (LB) is to support the load of products as well as to fixate paper pallet feet or loading ledges, see Figure 1. This requirement is valid for all kind of load bearers made of fibre based material. Figure 1 Load Bearer (LB) sheet. Table 5 Load bearer (LB) qualities. IKEA Code Compression strength (kn) Deflection, ΔH (mm) Cobb 60 (g/m 2 ) Test Load (kg) ISO 535 IKEA LB IKEA LB IKEA LB IKEA LB IKEA LB IKEA LB Column Test Load (kg), see Table 5, describes the weights used during deflection test to verify the LB quality. For test methods of compression strength and deflection, see Appendix A: Test methods 7, IOS- TM-0037: Load Bearer Compression Test and IOS-TM-0038: Load Bearer Sheet Deflection Test. 5.3 Plastic Material Quality The term Polyolefin (POF) is a family name for a group of thermoplastic materials and shall not be used to specify plastic material. A more specific definition shall be used (e.g. PP, PE) Shrink Film Quality Table 6 shows the allowed quality for shrink film used as a consumer package. Special requirements are specified in the Packaging Requirement. If no IKEA quality is specified in the Packaging Requirement, the minimum quality to use is IKEA SH 10. Shrink film used for goods fixation and test methods, see section Table 6 Shrink Film (SH) for consumer packages qualities. IKEA Code Material Puncture thumb edge (mm) Puncture sharp edge (mm) Tear strength MD/TD (N) Haze (%) IKEA SH 10 Polyethylene IKEA SH 20 Polyethylene IKEA SH 30 Polyethylene For test method, see IOS-TM-0033: Shrink Film Puncture Test. 7 From now on the reference will be only to test method number, Appendix A: Test methods will not be included. Inter IKEA Systems B.V Page 11 (86)

7 Table 7 shows recommended shrink film qualities for specific use. Shrink film shall be applied according to film suppliers instructions/data sheets. All welding shall be performed with good workmanship. Table 7 Recommended shrink film for specific use. Use IKEA SH 10 for soft bending products. Use IKEA SH 20 for flat, rectangular shapes. Use IKEA SH 30 for irregular shapes, where there is empty space etc. Note: Toys with shrink film packaging shall follow shrink film requirements set in IOS-PRG-0010 Toys Safety Requirements Stretch Film Quality Table 8 shows allowed stretch film quality. Special requirements are specified in the Packaging Requirement. Table 8 Stretch film quality. Wrapping technique Material Colour Haze (%) Horizontal wrapping Polyethylene No N/A Vertical wrapping Polyethylene Semi-transparent Stretch film shall be applied according to film manufacturer instructions/data sheets. The usage of stretch film shall fulfil unit load goods fixation and test methods, see section Figure 2 Horizontal wrapping Figure 3 Vertical wrapping Plastic Bag Quality Special requirements are specified in the Packaging Requirement. If no IKEA quality is specified in the Packaging Requirement, the minimum quality shall be followed. Table 9 shows the material requirements for plastic bags. Table 9 Plastic bag material qualities. Type Material Thickness (µm) Haze (%) Colour Polyethylene, low density (PE-LD) Plastic bags Polyethylene, high density (PE-HD) Polypropylene (PP) 40 8 No Note: Haze and colour requirements are not applicable for fitting bags. Inter IKEA Systems B.V Page 12 (86)

8 If nothing else stated in the Packaging Requirement, assembly instructions shall be located in package number 1 and shall (if possible) be visible when the customer opens the package. 8 Multi-Pack Packaging A multi-pack packaging contains several consumer packages. The purpose of a multi-pack packaging is to avoid single item handling in the supply chain and adapt the quantity to the forecasted sales. As the multi-pack packaging is intended for manual handling, maximum weight limitation is 15 kg. Multi-pack packaging with weight more than 15 kg has to be constructed as a module (i.e. low unit load) with handling material, see section Unit Load Transport Packaging All unit loads where the consumer packaging or Ready-To-Sell packaging solution (RTS) is unprotected shall have top and bottom protection as well as corner protection, see Figure 5. Additional sheets may be required for stabilizing the unit load. Unit loads consisting of multipack packaging do not need top/bottom protection and corner protection. Special requirements to follow are stated in the Packaging Requirement. Figure 5 Unit load protection. 9.1 Top and Bottom Protection The requirements for top and bottom protection are: The top protection shall cover the total surface of the products. The top protection sheet shall follow the same tolerances as the load bearer sheet, see Figure 17. The bottom protection shall cover the total surface of the products. If paper pallet is used no extra bottom protection is required. Bottom protection shall follow the same tolerances as the load bearer sheet, see Figure 17. To secure load safety, the top and bottom protection shall have a minimum friction of µ=0.5 (which corresponds to 27 degree tilting), wherever measured on the surface. See IOS-TM-0044: Unit Load Stability Test This is the same requirement as in section The top protection shall be able to withstand the stacking capacity value indicated in Actual DWP, see unit load stacking capacity requirement in section If Stacking Indication = No, then only dust/dirt protection is needed. The lowest flute height of double wall or glued together corrugated cardboard sheets shall be facing upwards. Inter IKEA Systems B.V Page 22 (86)

9 9.2 Corner Protection The requirements for corner protection are: The corner protection shall at a minimum be a 50/50 mm profile, strong enough to withstand minor collisions, and keep a straight line under all conditions where feasible. Corner protection shall be made from paper- based material. Quality requirement: max 6 mm penetration. For test method, see IOS-TM-0043: Corner Protection Puncture Test. All vertical corner protections shall cover the total height of the goods. If bottom trays are used, the corner protectors shall cover the unprotected part of the unit load above the bottom tray. For application tolerances see Figure 6 and Figure 7. Figure 6 Corner protection application tolerances. Figure 7 Tolerances for UL with Bottom tray Note: Unit loads for products with edge radius more than 25 mm and which do not show any damage or deformation after being exposed to minor collisions, do not require corner protection as long as they comply with section 12 Neat & Clean Packaging Requirements. 9.3 Unit Load Fixation The allowed different methods to fixate the load onto the handling material are: Strapping (for strap qualities, see section 5.3.5). Stretch filming (for stretch film qualities, see section 5.3.2). Shrink filming (for shrink film qualities, see section 5.3.1) What method to use depends on the shape, the weight of the goods that shall be fixated, the performance and quality of the fixation method etc. If straps are used, appropriate edge protection is required in order to avoid permanent marks on the packaging, see section 12. Note: When fixating the load onto the handling material do not cover the fork entry of the handling material. It is not allowed to join several unit loads together with any fixation method. A unit load shall always be handled as a separate unit load and never joining together two-by-two. This is valid for both horizontal and vertical joining for unit loads. When modules are made as storage unit, the modules shall be strapped together. For modules and storage units, see section This requirement is also applicable for filling solutions, except for load safety reasons. Inter IKEA Systems B.V Page 23 (86)

10 Figure 18 Example where lowest flute height of the sheet is glued to the feet. 11 Unit Load This section describes the dimension and weight limits allowed (unit load constraints) for all types of unit loads used within IKEA Unit Load Types Table 25 shows the different unit load types and sizes used at IKEA. Unit loads shall always be within the maximum gross dimensions and weight. Note: Exceeding maximum gross dimensions or weight of the unit loads is against the IKEA safety rule. Table 25 Unit load types Unit load AL, FULL PALLET, low handling material Gross length 1200 mm (max 1600 mm) Gross width 760 mm (max 1000 mm) Gross height Max 1000 mm, including low handling material Gross weight Max 677 kg, including low handling material Gross length Gross width Gross height Gross weight Unit load BL, HALF PALLET, low handling material 760 mm (max 1000 mm) 600 mm (max 800 mm) Max 1000 mm, including low handling material Max 338 kg, including low handling material Gross length Gross width Gross height Gross weight Gross length Gross width (Ø) Unit load DL, LONG PALLET, low handling material 2000 mm (max 2500 mm) 760 mm (max 1000 mm) Max 1000 mm, including low handling material Max 713 kg, including low handling material Unit load Type E, BUNDLED UNIT LOAD Max 2400 mm Max 800 mm Gross height -- Gross weight Max 350 kg Unit load Type F, NOT UNITISED This unit load type is only applicable when required in the IKEA product documentation. The use of this unit load type is strictly limited. Inter IKEA Systems B.V Page 29 (86)

11 Table 25 Unit load types Unit load Type G, OTHER TYPE OF UNIT LOAD This unit load type is only available when required in the IKEA product documentation. The following test methods shall not be used for unit load type G: IOS-TM-0042: Unit Load Stacking Capacity Test IOS-TM-0044: Unit Load Stability Test - 27 IOS-TM-0045: Unit Load Stability Test - 10 IOS-TM-0046: Unit Load store Handling Test IOS-TM-0047: Unit Load Transportation Test This does not apply to strand board pallets, for which above mentioned test methods shall still be followed. Examples: flower trolleys, special roll containers, strand board pallets and other special types of constructions approved by IoS. Unit load Type A, FULL PALLET, Europe (EUR-pallet) Gross length 1200 mm (max 1600 mm) Gross width Gross height Gross weight Gross length Gross width Gross height Gross weight Gross length Gross width Gross height Gross weight 800 mm (max 1000 mm) Max 1150 mm, including EUR pallet Max 700 kg, including EUR pallet Unit load Type B, HALF PALLET, Europe 800 mm (max 1000 mm) 600 mm (max 800 mm) Max 1150 mm, including HALF pallet Max 350 kg, including HALF pallet Unit load Type D, LONG PALLET, Europa (IKEA pallet) 2000 mm (max 2400 mm) 800 mm (max 1000 mm) Max 1150 mm, including IKEA pallet Max 750 kg, including IKEA pallet Tilting of unit loads during transportation or storage is not allowed. The unit load construction is not considering other orientation than upright position. Note: The unit load type BL/B is constructed as being a ready-to-sell (RTS) solution and always equal to a MDQ/MDU. Note: Requirements for unit loads that are transported by air freight, see Appendix D: Unit Load Requirement when using Air Transportation. Inter IKEA Systems B.V Page 30 (86)

12 11.5 Unit Load Stability Requirements Table 27 shows the stability requirements for a unit load with and without goods fixation. All tests require both length and width testing. Table 27 Stability test for unit loads. Good fixation Test Requirement Test method Transportation The unit load shall be able to be IOS-TM-0047: Unit Load test transported without any damage. Transportation Test With goods fixation Without goods fixation 27 test 10 test Store handling test The load (or any part of the load) shall not start to slide when tilting 27. The load (or any part of the load) shall not start to slide when tilting 10. The load (or any part of the load) shall not start to slide or fall off when handling the unit load. IOS-TM-0044: Unit Load Stability Test - 27 IOS-TM-0045: Unit Load Stability Test - 10 IOS-TM-0046: Unit Load store Handling Test Inter IKEA Systems B.V Page 34 (86)

13 13 Definitions Term Consumer packaging Date stamp Dimension Weights and Packaging (DWP) Energy recovery Equipment utilization Filling solutions FP/MP labels Forest Stewardship Council (FSC) Handling material Home Furnishing Accessories (HFA) Haze Identification label IKEA Nominated Packaging Suppliers (NPS) Label Low Handling Material (LHM) Load bearer Loading Unit Type (LUT) M-board Module MDU MDQ MDQ label More Sustainable Sources (MSS) Description Consumer packaging, i.e. primary packaging, refers to all packaging which is in direct contact with the product and ends up in the customers home. It also serves the purpose as bearer of product information. The date stamp shows the packing year and week of a product. The Dimension, Weights and Packaging information is a fundamental part of the IKEA information infrastructure and is used within many different functions within IKEA. DWP application is the IT-tool where DWP-information is documented. Requirements are defined by IoS in required DWP and actual values are defined by the supplier in Actual DWP. Energy recovery means the use of combustible packaging waste as a means to generate energy through direct incineration with or without other waste. The efficiency in a container, truck or wagon in terms of Net Cubic Meters/Shipment, Weight Utilization and Filling Rate. Nm 3 /Shipment. A method of splitting unit loads during transportation to fill empty spaces in the loading units (containers, trucks etc.). When unloading such a loading unit, these parts can be added together so that the resulting unit load has the same amount of pieces as an original unit load. Multipack labels (FP is the Swedish abbreviation for multipack), these labels has been replaced by the MDQ label. The Forest Stewardship Council (FSC) is a non-profit organization that sets certain high standards to make sure that forestry is practiced in an environmentally responsible and socially beneficial manner. If a product, like a piece of tropical hardwood patio furniture, is labelled as "FSC Certified," it means that the wood used in the piece and the manufacturer that made it met the requirements of the Forest Stewardship Council. Handling material refers to devices designed to support handling and transport throughout supply chain. All items which are presented and sold in distinct shops in market hall and show room at the IKEA store. Degree of transparency, lower value is more transparent. An identification label is a label that has a bar code. IKEA Nominated Packaging Supplier is a packaging supplier having a general agreement with IKEA components. Label means the product identification as described in IOS-PRG A label shall be seen as packaging material needed for the presentation of goods Low Handling Materials, 50 mm fork entry. See also Handling material The sheet mainly of paper based material that is meant to support the load. Different types of transport equipment, e.g. trailer, truck, or container. M-board is a lightweight fibre based material to be used mainly for load bearer. A low unit load built in a way that a number of modules can be stacked on top of each other in order to be stored together as a storage unit. Minimum Delivery Unit Minimum Delivery Quantity for a store. Minimum Delivery Quantity label. Replaces FP and MP labels. More Sustainable Sources is pre- and post-customer reclaimed wood material (recycled material) or wood from forests verified as responsibly managed according to a forest certification system recognized by IKEA. Wood certified according to FSC meets the IKEA requirements for More Sustainable Sources. Inter IKEA Systems B.V Page 41 (86)

14 Multi-pack (MP) packaging Oversize Parcel packaging Packaging Drawing (PD) Plastic bag Printing original Packaging solution Ready-To-Sell (RTS) packaging solution Recycling/ recyclability Reuse Service Packaging Single item/single package Stacking indication IKEA Standard handling equipment Standard wooden pallet Storage unit Store facing Strand board pallet Transport packaging Unit load Unit Load Label (ULL) Unit Load Stacking Capacity Unit load Type A/AL Unit load Type B/BL Unit load Type D/DL Multi-pack packaging, i.e. secondary packaging, refers to packaging designed to contain several consumer packages. The measurements of a unit load where the products have dimensions larger than standard gross measurements. Packaging used to facilitate distribution of one or several consumer packages to one receiver (i.e. CDC operations, e-commerce) in the parcel operation. Also part of the definition of Transport packaging. A technical drawing of the packaging construction. Plastic bag is a structure of plastic film closed on at least 3 sides. At IKEA, the print original for consumer packages intended for home furnishing accessories is called a packaging original. Packaging solution is a minimum delivery unit including handling material, multi-pack packaging, consumer packages, all other packaging parts and material and connected documentation. The product can be sold without any single-item handling just by removing the transport packaging. Recycling means the reprocessing of packaging waste materials for the original purpose or for other purposes including organic recycling but excluding energy recovery. Reuse means any operation by which packaging, which has been designed to accomplish within its lifecycle a minimum number of trips, is refilled or used for the same purpose with or without reconditioning/repair Service packaging refers to all packaging materials provided at point of sale in order to carry products or multiple products as a help to customer. E.g. wrapping paper, carrier bags etc. There is only one Consumer Package (e.g. corrugated cardboard box or shrink film package) consisting of one main element (e.g. door, kitchen front, candle, picture frame, mattress, carpet, lamp, textile items). A parameter describing if it is permitted to stack any weight on top. It is defined in required DWP as Yes or No. Refers to normal forklifts, pallet jacks, and mono forks used in IKEA. Three standard types of wooden pallets exist: EUR pallet (1200 x 800 x 150 mm) IKEA pallet (2000 x 800 x 150 mm) HALF pallet (600 x 800 x 150 mm) A storage unit contains multiple modules stacked together to fill a storage location in a warehouse. Side facing the customer in the store. A one way wooden based pallet with wooden feet. Transport packaging refers to all packaging material used to protect and facilitate handling during transportation of consumer packages or multi-pack packages. Unit load is a manageable unit consisting of one or several consumer packages or several Multi-pack packages, fixated to a handling material, designed to fit supply chain and storage facilities. A label to track goods during supply chain, described in IOS-PRG The Unit Load Stacking Capacity defines the maximum weight (in kg) that can be stacked on top of the unit load. A type that is developed for logistic purpose, where combinations of consumer packs, multipacks and RTS can be used. A type that is developed to fit the sales locations and store equipment, where RTS is used. A type that is developed for logistic purpose, for consumer packages with a length exceeding 1600 mm. Inter IKEA Systems B.V Page 42 (86)

15 Appendix A: Test methods Documentation... 2 Packaging Test Methods... 3 IOS-TM-0027: Corrugated Cardboard Receiving Inspection and Test Methods... 3 IOS-TM-0027 Part A: Weight Comparison Test... 4 IOS-TM-0027 Part B: Compression Comparison Test... 5 IOS-TM-0027 Part C: Surface Test... 6 IOS-TM-0027 Part D: Water Absorption Test... 7 IOS-TM-0033: Shrink Film Puncture Test... 8 IOS-TM-0034: Packaging Tape Adhesive Capacity Test IOS-TM-0036: Consumer Package Handling Test IOS-TM-0043: Corner Protection Puncture Test Handling Material Test Methods IOS-TM-0037: Load Bearer Compression Test IOS-TM-0038: Load Bearer Sheet Deflection Test IOS-TM-0039: Pallet Foot Compression Test IOS-TM-0040: Pallet Foot Insert Side Compression Test IOS-TM-0041: Pallet Foot Shear Strength Test Unit Load Testing Methods Unit Load Test Sequence IOS-TM-0042: Unit Load Stacking Capacity Test IOS-TM-0047: Unit Load Transportation Test IOS-TM-0044: Unit Load Stability Test IOS-TM-0045: Unit Load Stability Test IOS-TM-0046: Unit Load Store Handling Test Inter IKEA Systems B.V Appendix A Page 1 (1)

16 Handling Material Test Methods IOS-TM-0037: Load Bearer Compression Test Frequency Test shall always be carried out whenever there is a change of condition (e.g. change of packaging material supplier, failed test on material), new/changed/updated packaging solution (e.g. material, dimension, construction), or change in process parameters (e.g. new equipment). As a minimum, all tests shall always be renewed within 12 months. Environment Test in IKEA approved laboratory. Equipment Five load bearer samples (300x300 mm). Compression testing machine (sample area min. 300x300 mm). Load applicator (100x100 mm), e.g. block made of wood. Preparation All test samples shall be pre-conditioned for 24 hours before testing in the following conditions: Relative humidity: 50% ± 5% Temperature: 23 C ± 2 C These conditions shall also prevail during the test. Procedure 1. Place test sample on a flat, hard, rigid, horizontal surface. 2. Place a rigid load applicator on the middle of the test sample, see Figure Apply a uniformly distributed load on the load applicator with a constant speed of 10 mm/min, and measure the maximum force that is reached before the deformation reaches 5 mm. For material below 10 mm measure the maximum force that is reached before the deformation reaches 4 mm. The compression force shall include the weight of applicator. 4. Document the reached compression force for each sample. Figure 40 Compression test setup. Assessment According to load bearer compression strength requirement, see Table 5. Inter IKEA Systems B.V Appendix A Page 14 (14)

17 IOS-TM-0038: Load Bearer Sheet Deflection Test Frequency Test shall always be carried out whenever there is a change of condition (e.g. change of packaging material supplier, failed test on material), new/changed/updated packaging solution (e.g. material, dimension, construction), or change in process parameters (e.g. new equipment). As a minimum, all tests shall always be renewed within 12 months. Environment Test in IKEA approved laboratory. Equipment 10 samples (100x450 mm). Fixture support (height 50 mm), e.g. paper pallet foot or other light weight block. Static load. Load applicator (90x180 mm), e.g. paper pallet foot or other light weight block. See Figure 42 for test set up. Note: The total weight of the static load excluding load applicator shall be according to Table 5. Figure 41 Deflection test setup; front view. Preparation All test samples shall be pre-conditioned for 24 hours before testing in the following conditions: Relative humidity: 50% ± 5% Temperature: 23 C ± 2 C These conditions shall also prevail during the test. Procedure 1. Use the fixture support as support for the sample to be tested. The distance between the supporting blocks shall be 300 mm, see Figure Measure the distance between the load bearer and the table. 3. Place the static load in the middle of the test sample. Use a load applicator in order to distribute the load. 4. Wait 10 minutes. 5. Measure the deflection (Δ H), see Figure Perform the deflection test for five samples in the machine direction (MD) and five samples in the cross machine direction (CD). 7. Note the deflections of each sample. 8. Calculate the average value in each direction. Inter IKEA Systems B.V Appendix A Page 15 (15)

18 Figure 42 Deflection of load bearer. Assessment The average value shall be according to load bearer deflection requirement, see Table 5. Inter IKEA Systems B.V Appendix A Page 16 (16)

19 IOS-TM-0039: Pallet Foot Compression Test Frequency Test shall always be carried out whenever there is a change of condition (e.g. change of packaging material supplier, failed test on material), new/changed/updated packaging solution (e.g. material, dimension, construction), or change in process parameters (e.g. new equipment). As a minimum, all tests shall always be renewed within 12 months. Environment Test in IKEA approved laboratory. Equipment Compression testing machine. 10 pallet feet samples. Preparation All test samples shall be pre-conditioned for 24 hours before testing in the following conditions: Relative humidity: 50% ± 5% Temperature: 23 C ± 2 C These conditions shall also prevail during the test. Procedure 1. Place test sample on a flat, hard, rigid and horizontal surface according to Figure Run the compression testing machine with a constant speed of 10 mm/min, and measure the maximum force that is reached before the deformation reaches 5 mm. 3. Repeat the test for all ten samples. 4. Note the reached compression force for each sample. 5. Calculate the average for all ten samples. Figure 43 Paper pallet foot compression test procedure. Assessment The average value shall be according to paper pallet foot compression requirement, see Table 21. Inter IKEA Systems B.V Appendix A Page 17 (17)

20 IOS-TM-0040: Pallet Foot Insert Side Compression Test Frequency Test shall always be carried out whenever there is a change of condition (e.g. change of packaging material supplier, failed test on material), new/changed/updated packaging solution (e.g. material, dimension, construction), or change in process parameters (e.g. new equipment). As a minimum, all tests shall always be renewed within 12 months. Environment Test in IKEA approved laboratory. Equipment 10 pallet foot insert samples (without cover). Compression testing machine Preparation All test samples shall be pre-conditioned for 24 hours before testing in the following conditions: Relative humidity: 50% ± 5% Temperature: 23 C ± 2 C These conditions shall also prevail during the test. Procedure 1. Place the test on a flat, hard, rigid and horizontal surface according to Figure Run the compression testing machine with a constant speed of 10 mm/min, and measure the maximum force that is reached before the deformation reaches 5 mm. 3. Repeat the test for all ten samples. 4. Note the reached compression force for each sample. 5. Calculate the average for all ten samples. Figure 44 Paper pallet foot insert compression test procedure. Assessment The average value shall be according to paper pallet foot insert side compression requirement, see Table 21. Inter IKEA Systems B.V Appendix A Page 18 (18)