Box Crush Test (BCT)

The box crush test (BCT) is a widely used method for measuring the compressive strength of fibreboard packaging, particularly corrugated shipping containers. It determines how much force a box can withstand before it collapses under pressure, simulating conditions such as stacking during storage or transport.

By applying a vertical compressive load to the box until failure, the test helps packaging engineers understand structural integrity, validate design, and reduce the risk of product damage. BCT is often used alongside other assessments such as edge crush and top-load testing to evaluate overall packaging performance.

The test is particularly relevant to fibreboard containers, where factors like flute profile, board grade and moisture content can all influence performance.

ASTM D642-00

This standard specifies methods for determining the compressive resistance of shipping containers, both filled and empty. The box is placed between two flat platens and compressed at a constant rate until it fails. Common in North American markets.

ISO 12048

This international standard outlines procedures for testing complete, filled transport packages under compressive load. It includes environmental pre-conditioning and detailed measurement protocols.

TAPPI T 804

Developed by the Technical Association of the Pulp and Paper Industry, this method focuses on corrugated and solid fibreboard containers. It includes procedures for evaluating compression strength under static loads and stacking conditions.

Testing in line with these standards ensures regulatory compliance, customer confidence and compatibility with logistics systems.

A successful box crush test requires consistent specimen preparation, suitable equipment and precise execution.

1. Condition the sample

Samples should be conditioned for at least 24 hours in a controlled environment, typically at 23 ± 2 °C and 50 ± 5 percent relative humidity.

2. Select the right equipment

Mecmesin offers a range of compression test systems suited to different packaging formats:

• MultiTest-dV - A compact, motorised tester ideal for smaller cartons and loads up to 2.5 kN
• OmniTest - Twin-column systems with high load accuracy, suitable for medium-sized boxes, typically up to 50 kN
• SqueezerPro - Designed for testing large-format containers with high compressive loads, up to 75 kN

For higher-capacity applications, Mecmesin also supports integration with large-scale compression test systems such as those provided by Lansmont.

3. Set up the specimen

Align the box centrally between two compression platens, ensuring that the load is applied evenly and without tilt. Poor alignment can lead to uneven results.

4. Apply the compressive load

The test system applies a vertical compressive force at a constant speed until the box structure fails. The VectorPro® software records the force and displacement throughout the test.

5. Review and analyse results

Peak force at failure, displacement and mode of collapse are recorded. VectorPro® enables real-time data capture, graphical analysis and export for quality assurance records.

Compression testing offers both commercial and technical benefits for manufacturers and logistics operations.

• Optimise packaging design - Identify opportunities to reduce material usage while maintaining required strength.
• Reduce in-transit damage - Ensure boxes withstand stacking loads without failure.
• Support compliance and quality - Demonstrate adherence to ISO, ASTM and TAPPI standards.
• Lower return rates - Stronger packaging reduces product damage and customer complaints.

For example, a food manufacturer reduced its packaging board grade by 12 percent after BCT data confirmed the new design met all handling requirements.

Box crush testing provides clear, measurable data to inform design and compliance decisions:

• Maximum compressive load (kN or N) - The peak force before collapse.
• Deflection at failure (mm) - The amount of compression experienced before failure.
• Failure mode - E.g. panel buckling, edge collapse or corner crush.

These results can be compared across batches or packaging types to ensure consistency and ongoing optimisation.

Real-world conditions can introduce challenges to test accuracy. These include:

• Specimen variability - Material or manufacturing inconsistencies affecting results.
• Fixture alignment - Misalignment can cause off-centre loading.
• Environmental effects - Moisture and temperature can influence fibreboard strength.
• Operator repeatability - Manual errors in setup or data recording.

Mecmesin systems address these with precision mechanics, controlled motion and automated test sequences. VectorPro® software enhances repeatability by standardising test parameters and simplifying operator workflows.

Mecmesin has over 45 years of experience in force measurement and is a trusted partner for packaging test systems across industries.

• Comprehensive equipment range - From benchtop testers to heavy-duty platforms.
• Accurate and consistent testing - Motorised control, precise loadcells and repeatable fixtures.
• VectorPro® software - Provides data capture, real-time plotting, result storage and export.
• Service and support - Includes calibration, application advice and post-sale technical assistance.

Whether you're testing small e-commerce cartons or industrial shipping crates, Mecmesin's equipment offers scalable solutions to suit your requirements.

BCT is used in sectors such as:

• FMCG - Ensuring product integrity through high-volume distribution
• Electronics - Protecting fragile goods against warehouse stacking loads
• Pharmaceuticals - Meeting regulatory demands for packaging validation
• Logistics - Minimising damage and returns during long-distance transport

An electronics supplier redesigned its packaging after BCT revealed corner weaknesses in stacked configurations. Following redesign and validation testing with the OmniTest system, product damage claims fell by 40 percent.

Contact our team of packaging test engineers to discuss your specific needs, from equipment selection and custom fixtures to advice on ISO, ASTM or TAPPI standard compliance. We’re here to help you improve packaging strength, test repeatability and logistics performance.