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F. aaa PROCEDURE PROCEDURE

NUMBER PK003

SERIES Packaging EFFECTIVE DATE 10/24/08

TITLE Packaging Structure Specification

REVISION D

REVISION DATE 04/01/16

A. PURPOSE

The purpose of this standard is to provide packaging structure requirements for use by The Coleman

Company, Inc. (“Coleman” or the “Company”) and it’s vendors. This also includes all brands in the

Coleman family (Stearns, Sevylor, Mad Dog, Etc).

Product packaging is critical to our ability to fulfill our customer’s delivery expectations. Accordingly,

Coleman and its vendors must adhere to this standard.

B. SCOPE

This standard outlines the general requirements for corrugated packaging. This standard applies for the

following:

1. Packaging structure designed, developed and provided by Coleman to vendors for 1) full color box or POS carton, 2) inner protective padding, 3) multi-pack cartons 4) master pack

cartons 5) repair part packaging 6) other packaging as specified by Coleman Co. Inc.

2. Packaging structure designed, developed and provided by vendors to Coleman for 1) full color box or POS carton, 2) inner protective padding, 3) multi-pack cartons 4) master pack

cartons 5) repair part packaging 6) other packaging as specified by Coleman Co. Inc.

C. DEFINITIONS

Burst Strength Test (Mullen) - A test that defines a board’s strength. The Mullen test measures

resistance to rupture in pounds per square inch (psi).

Carton Style – Style of carton – i.e. Top Load Carton or Front Load Carton

Corrugated Board- - A structured board formed by gluing one or more arched layers of corrugated

medium to one or more flat-facing linerboards. Also known as corrugate or simply, “board”.

Die lines - used to show the carton in a flat position (dimensioned drawing)

Dimensions - The three measurements of a box given in the sequence of length (left to right), width

(front to back) and depth (top to bottom). Inside dimensions are used to ensure proper fit around a

product. Outside dimensions are used in their carrier classifications and

determining pallet patterns.

ECR -Engineering Change Request

ECT (Edge Crush Test) - A test that defines a board’s strength. The Edge

Crush Test (ECT) measures the ability of combined board to sustain a top-to-

bottom load.

Flute Type - This refers to the wave shapes, or ridges, that are pressed into a

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sheet of material that has been softened by steam. This material is then sandwiched between flat sheets

of material to form corrugated board. Flute serves as protective cushioning and helps strengthen a

carton.

A-Flute: Flute thickness of 4.7 mm

B-Flute: Flute thickness of 2.5 mm

C-Flute: Flute thickness of 3.6 mm

E-Flute: Flute thickness of 1.5 mm

F-Flute: Flute thickness of 0.9 mm

Liner Board - The board that forms the inner and outer facings of corrugated boards.

Medium – The material that is fluted and separates the inner and outer facings of corrugated boards.

Masterpack Cartons- Masterpack cartons are required to protect the POS cartons or Multi-pack cartons

during transit and to insure that the shelf presence will not be compromised. Typically multiple POS

cartons or Multi-pack cartons will be packed into a masterpack carton. Masterpack cartons will be

made with natural Kraft and will be single color print. (Also known as Overpack Carton)

Multi-pack Cartons – Multi-pack cartons are required to protect the POS cartons during transit and to

insure that the shelf presence will not be compromised. Typically, multiple POS cartons will be packed

into a multi-pack carton. Several Multi-pack cartons are then packed into a Master carton. Multipack

cartons will be made with natural Kraft and will be single color print.

POS Cartons – Point of Sale Carton – Product packaging that is used to display product at customer

location (Also known as Full Color Box)

Repair Part Packaging – Packaging designed for single component parts used to repair an product.

(screws, knobs, nuts, bolts, etc).

D. GENERAL INFORMATION

D.1.0 PACKAGING QUALIFICATION AND CONTINUING CONFORMANCE

All materials furnished to Coleman or its representatives are subject to initial qualification approval. A Coleman team and the supplier on a case-by-case basis will establish

qualification plans and success criteria jointly.

Coleman or designates may inspect corrugated materials during contract period at its discretion.

Individual corrugated components and carton assemblies containing product will be tested for compliance.

Continuing approval is based on performance. Approval may be withdrawn if materials fail Coleman standards or qualification success criteria.

D.2.0 EXEMPTIONS AND CHANGES

Unless specifically exempted in writing by Coleman’s Packaging Engineer, Director of Packaging (or designates), all corrugated components must meet the Coleman Packaging

Structure Standard.

Changes to packaging design by vendor and/or others must be approved prior to implementation. An ECR (Engineering Change Request) must be submitted to the above

parties for approval.

Fig. 1 example of common flute types

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E. REQUIREMENTS FOR CORRUGATED PACKAGING Sections included:

E.1.0 - Material Requirements

E.2.0 - Package Performance Requirements

E.3.0 - Testing and Validation Requirements

E.4.0 - Fabrication Requirements

E.5.0 - Printing Requirements

E.6.0 - Warning Requirements for bags (See Procedure PK006 Section D)

E.7.0 - Drawing Requirements (Die lines)

E.8.0 – Repair Part Package Requirements

E.9.0 – Carton Size and Weight Requirements

E.1.0 – MATERIAL REQUIREMENTS

Board must meet prescribed material and strength requirements

Coleman will specify properties of its cartons in either Burst Strength (Mullen) or ECT

(Edge Crush Resistance). Coleman will specify Carton Style and Flute Type. The board

construction is not specified; therefore it is the vendor’s responsibility to determine the

construction needed to meet Burst Strength and ECT requirements.

E.1.1 - The Burst Strength (Mullen) minimum requirements for the following board grades

Coleman will specify are as follows: “E” Flute (150#, 175#, 200#), “B” Flute (15 #, 200#), “E/B”

Flute (180#, 200#), “C” Flute (150#, 200#), and “B/C” Flute (275#).

E.1.2 - The ECT requirements are generally specified in actual ECT value (e.g., the standard

category values of 26ECT, 29ECT, 32ECT, 40ECT and 44ECT).

E.1.3 Linerboard must contain predominantly unbleached virgin cellulose fibers, recycled fibers

or a combination of both, unless specified otherwise.

E.1.4 Medium, the corrugating material, must meet commercial industry standards and may be

made from recycled fiber, semi-chemical pulp and/or cellulose fiber combinations.

E.1.5 It is highly recommended that all masterpack carton be made of double wall corrugated

unless the carton is quite small (smaller than 6” x 6” x 6”). But the material needs to be fully

chosen based on all packaging considerations such as product weight, shape, size, and so on.

E.2.0 – PACKAGE PERFORMANCE REQUIREMENTS

E.2.1 - The acceptability of the POS carton is very subjective. Coleman is the Industry Leader in

“Outdoor Products”. A consistent look, both carton integrity and graphic presentation, of our

product on the shelves in extremely important. Because of this importance the POS carton must

have clean breaks at the scores lines and the product must not bulge the carton. The closures must

not be loose and should have gaps no greater than .06 inches (.15 cm).

E.2.2 - Compression Strength

If a compression test is required of the item, the test method and acceptance criteria will need to be

established jointly by Coleman and the supplier.

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E.2.3 DEFECTS

The following defects are not acceptable on any corrugated board or package: This list is not all-inclusive. Defects are listed as examples.

Warping

Liner Separation – Delamination

Leaning/Crushed Flutes

Wrinkles and Cuts

Blisters

Wash boarding

False Scores

Dirt

Splices

Exposed Fluting

Excessive Gaps

Loose flap

Weak media or liner board

Large gap is unacceptable.

Tab does not close properly.

Tab does not close properly.

Fig 2 Sample Defects

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E.3.0 - TESTING AND VALIDATION REQUIREMENTS

Successful completion of packaging validation testing must be done to receive packaging

approval. A Coleman team and the supplier on a case-by-case basis will establish

qualification plans and success criteria jointly.

1. Testing can be done by the factory or by using a test lab approved by Coleman. Coleman expects all product and parts to be received by our customers in pristine condition. It is the

responsibility of our suppliers to ensure that all packages can be shipped via small parcel and

be received by our customer with no damage.

2. ISTA Test Procedures – Below are highlights of the test procedure. The ISTA 1A Test Procedure is composed of a vibration test and a drop test

3. Fixed Displacement Vibration Test: The test consists of vibrating the product for a total of 14,200 Vibratory Impacts.

Test Duration (in minutes) = 14,200 Vibratory Impacts

Cycles/Minute (CPM)

4. Drop Test: This test consists of ten drops at a determined height based on product weight.

Fig 3 Drop Test

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E.4.0 – FABRICATION REQUIREMENTS

E.4.1 - Scoring -

Flap scores should be standard point-to-point offset on single-wall board unless otherwise specified. Double wall board may have male-female three-point scoring. Suppliers unable

to comply must notify Coleman and request a specific exception.

All score lines must be well defined with clear impressions on both the inner and outer liners, providing ease of folding by hand or on automatic equipment over entire score without

breaks, cracks or fractures.

Both horizontal and vertical scores must fold straight. False scoring is not allowed.

Liner fracturing at scores is to be avoided.

E.4.2 - Cutting -

Edge cuts, slits, and slots must be clean and free of scrap.

Bent corners and torn edges must be avoided.

E.4.3 - Glue Joint – Manufacturer’s Joint

Single wall – Boxes must have a manufacturer’s joint formed by lapping the sides of the box forming the joint not less than 1.25 inches (3.18 cm) and securing the joint by gluing the

joint throughout the entire area of contact with a water resistant adhesive.

Double wall -Boxes must have a manufacturer’s joint formed by lapping the sides of the box forming the joint not less than 1.25 inches (3.18 cm) and securing the joint by

gluing/stitching the joint throughout the entire area of contact with a water resistant adhesive.

Triple wall - Boxes must have a manufacturer’s joint formed by lapping the sides of the box forming the joint not less than 2.00 inches (5.08 cm) and securing the joint by

gluing/stitching the joint throughout the entire area of contact with a water resistant adhesive.

E.4.4 - Dimensioning-

Length - The box length is always the greater of the flap opening dimensions.

Width - The box width is the width of the minor flap.

Depth - The box depth is the inside dimension between the top and bottom inner flaps.

Flute Direction - The flute direction should run from the top of the carton to the bottom in order to allow for the greatest stacking strength. Any deviation to flute direction must be

approved by Coleman Packaging Engineer.

TOP LOAD BOX END LOAD BOX

E.4.5 - Container Closure – Coleman will specify closure type.

Unless otherwise specified in writing by Coleman, boxes must be securely closed. Method of closure must be of adequate strength and quantity to contain the product during shipment

and while on display. Self–locking closure systems, where tape/glue are not used, must be

able to pass the performance requirements of International Safe Transit Association (ISTA)

Procedure 1A or 1B.

NOTE: Staples are not to be used as a closure method without the written approval of

Coleman’s Packaging Engineer.

Fig 4 Container Types

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E.5.0 - PRINTING REQUIREMENTS - For specific information pertaining to artwork printing

requirements contact Coleman Brand Design.

General Requirements:

1. Six color capability – Four color CMYK process plus two PMS spot colors.

C – Cyan

M – Magenta

Y – Yellow

K – Black

2. Ink Information

Ink is to contain cobalt and manganese as drying agent, either individually or a combination of the two.

3. Coating – Aqueous

Rub Test Procedure- This test is used to determine if the printing is resilient to abrasion.

Test Specimen – The test requires two pieces of stock, the test specimen and a test receptor. Cut a test specimen, approximately seven by two inches (17.78 cm x 5.08 cm). When the

printed area permits, the seven-inch (17.78 cm) direction should be cut across the grain of the

sample, but must not cross pressed or cut scores. Clip a test strip to the four-pound (1.8 Kg)

test block, with the abrasive surface away from the rubber pads. Mount the test specimen

securely (printed material, mount with printed side up) on the rubber pad of the base plate.

Remove any dust or foreign material from the sample. Place the weights over the sample;

making sure that the two by four inch (5.08 cm x 10.16 cm) rubber pad of the test block is

over the area to be tested. Set the speed as required and begin the test. Evaluate samples at

200 cycles, 300 cycles, 450 cycles, 600 cycles and 1000 cycles.

Test results – When the rub has been completed, examine both test strips for signs of abrasion.

400 cycles or less – Failure

4. Paper - Label

70#, coated 1 side litho paper, #2 sheet is required. If carton is larger than 40", an 80# paperweight is required.

***FOR CARTON MARKING AND BARCODE

LABELING INSTRUCTIONS PLEASE REFER TO

COLEMAN’S B2B WEBSITE (b2b.coleman.com)***

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E.6.0 –BAGS (Warnings fully listed in PK006 Procedure – Section D)

E.7.0 DRAWING REQUIREMENTS (DIE LINES) – All Die Line Drawings Must be Dimensioned in

Inches.

E.7.1 - Drawings -

Die lines are required and used to show the carton in a flat position and will be used to apply Graphics. Coleman will need an “outside” view. The Title Block will need to contain the

following information:

A) Model Number I) Carton Scoring (L/R) B) Product Name J) Carton Scoring (T/B) C) Date K) Corrugation Direction D) Carton Size (I.D.) L) Label Number E) Carton Size (O.D.) M) Label Size F) Carton Style N) G) Board Grade (ECT/Mullen, Flute, Finish) O) Ink Colors (for Overpacks/Masterpacks) H) Manufacturer’s Joint P) Special Instructions

Drawing Sample

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E.7.2 – Overpack/Masterpack Dieline Standard

Wall thickness of glue joint needs to be taken into account when creating the dieline.

E.8.0 – REPAIR PART PACKAGING REQUIREMENTS

All repair parts will be packaged individually in cartons except for knobs, screws, bolts, nuts and other

hardware, which may be in a plain envelope, padded envelope or poly bag. All cartons are required to

meet standards outlined in this document (Packaging Structure Standard – Packaging Requirements)

E.8.1 List of approved internal protective materials

1. Bubble Wrap 2. Corrugated Padding 3. EPS (Styrofoam) 4. Poly bag – sealed 5. Plain Envelope 6. Padded Envelope

E.8.2 List of approved closures for Poly bag and Bubble Wrap bag

1. Heat Seal 2. Self Adhesive or tape

E.8.3 List of approved closures for Plain and Padded Envelopes

1. Self Adhesive or tape 2. Staple – When using staples, envelope must be sized so that

contents, including literature, are not damaged when envelope is

stapled.

E.8.4 Marking Requirements

1. Items that are individually packed into bags/envelopes must have the following markings as specified ON EACH ITEM: --The

assigned part number, --Description, --Quantity per bag, --Country

of Origin

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2. It is required that these markings be printed on a label and placed on the poly bag or envelope.

E.8.5 Label marking and dimension requirements.

E.9.0 – CARTON SIZE AND WEIGHT REQUIREMENTS

All Cartons must meet size and weight requirements. The guidelines listed below apply to POS, Multi-

pack and Master Pack Cartons.

1.0 Carton weight should not exceed 40 lbs (18 kg), unless single item weight exceeds 40 lbs (18 kg).

2.0 Unless a single unit exceeds the stated maximum dimensions, carton maximum dimensions should

not exceed:

24" (inches) (61 cm) in height

20" (inches) (51 cm) in width

30" (inches) (76 cm) length

Carton minimum dimensions should not be smaller than:

3" (inches) (8 cm) in height

4" (inches) (8 cm) in width

6" (inches) (15 cm) in length

Exceptions to these size and weight requirements should be approved by Coleman Packaging or

designated resource.

F. Packaging and Printed Materials

1.0 Packaging Description & Markings

Follow the Packaging Structure Standard – Packaging Requirements. Carton will be marked per Coleman Carton Marking and Barcode Labeling Instructions.

2.0_WARNING REQUIREMENTS FOR PLASTIC BAG/FILM

Follow the Coleman Packaging Regulations and Compliance Procedure – PK006 (located in Section D).

http://coleweb/pdf/packaging.PDFhttp://coleweb/pdf/marking.PDF

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3.0 Other Various notes:

3.1 Packing Type - Refer to Supply Chain Data Section of the Individual Sleeping Bag Data Sheet for information about master carton, multi-pack qty, multi-pack dimension, multi-pack I2 of 5, UPC code and POS Package Dimensions.

3.2 POS Carton - The printing on the POS carton shall include the Coleman® logo, part name, product part number, Law Label information, Bar Code in UPCA format, and the country of origin. Printing shall meet the requirements of Coleman approved artwork supplied by Coleman Marketing Department/Packaging.

G. Packaging Performance Tests

Carrybag Handle Jerk Test

With the product(s) stowed in the carrybag as intended, resting on the ground, suddenly lift

the unit ("jerk" the unit) upwards by the handles of the carrybag. If carrybag has

shoulder straps, repeat "jerk" with the shoulder straps. Handles & shoulder straps

will not pull loose from the carrybag and seams will not split on carrybag.

H. Packaging Structure Test

Packaged Product 150 lb (68 kg) or Less must be tested according to International Safe Transit Association (ISTA) Section 1A. Any deviation from test method/s must be approved by the Coleman Company’s packaging engineer or qualified designate.

Drop Test – In compliance with the apparatus section of ASTM D 5276-98

Vertical Shock Test – In compliance with the apparatus section of ASTM D 5487-98

Alternative Incline Test – In compliance with the apparatus section of ASTM D 880-92(-97)

Alternative Horizontal Test – In compliance with the apparatus section of ASTM D 4003-98 Packaged Product 150 lb (68 kg) or More must be tested according International Safe Transit

Association (ISTA) Section 1B. Any deviation from test method/s must approved by the Coleman Company’s packaging engineer or qualified designate.

Drop Test – In compliance with the apparatus section of ASTM D 5276-98

Vertical Shock Test – In compliance with the apparatus section of ASTM D 5487-98

Alternative Incline Test – In compliance with the apparatus section of ASTM D 880-92(-97)

Alternative Horizontal Test – In compliance with the apparatus section of ASTM D 4003-98

Rotational Test – In compliance with the apparatus section of ASTM D 6179-97 Compression Test – In compliance with method and apparatus defined in ASTM D 642-00

Minimum compression values are calculated using the following formulas for each Flute type. IMPORTANT: Use inserted chart (.xls file) for calculation. Calculation and compression results will be in Pounds Per Square Inch (PSI)

“E/B” FLUTE = (5.87)*(42)*(SQRT(((2*L)+(2*W))*(0.1875)))

“E” FLUTE = (5.87)*(32)*(SQRT(((2*L)+(2*W))*(0.0625)))

“B” FLUTE = (5.87)*(32)*(SQRT(((2*L)+(2*W))*(0.125)))

“C” FLUTE = (5.87)*(32)*(SQRT(((2*L)+(2*W))*(0.1875)))

L = Length (Outside Dimension) W = Width (Outside Dimension) NOTE: MINIMUM CORRUGATE THICKNESS FOR THE FOLLOWING FLUTE TYPES.

“E/B” Flute: Corrugate Thickness of (0.1875 in.) “E” Flute: Corrugate Thickness of (0.0625 in.)

“B” Flute: Corrugate Thickness of (0.125 in.) “C” Flute: Corrugate Thickness of (0.1875 in.)

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Length (L) Width (W) Height (H) Compression

lbs/sq. in.

6.00 6.00 6.00 523

Calculated Compression Requirement

Compression Requirements for "E/B" Flute (Ref. 42# ECT) - All

dimensions are outside dimensions and carton is empty.

INCHES

Required Manual Input ( L and W )

Not Required ( Height )- But good information

INSTRUCTIONS FOR MINIMUM COMPRESSION CALCULATION:

1) To calculate minimum compression requirements double click inside above chart to open .xls file.

2) Select appropriate flute tab at bottom of spreadsheet. 3) Input in inches the cartons outside length and width dimensions in

appropriate light blue cells and spreadsheet will calculate required

minimum compression and display in green cell.

9.0 Approvals:

INITIATOR SIGNATURE TITLE DATE

Rick L. Looslie Dir., Design Services 2005

SPECIFICATION SERIES OWNER

SIGNATURE TITLE DATE

Adam Schettle Dir., Packaging 9/24/08

10.0 Revision History:

DATE REV ECN # INITIATOR CHANGE

10/24/08 A Adam Schettle Revise to new format, change bag printing info, change repair parts info, other minor

changes

2/11/09 B Adam Schettle Revise the Bag warning to multi lingual.

4/27/11 C Rani Tjugito Routed Section E.6.0 – BAGS to PK006 Procedure, strikethrough E.6.0 on pg. 3

4/27/11 C Rani Tjugito Incorporate Section F.2.0_Warning

Requirements for Plastic or Film to PK006 (located in Section D)

4/1/16 D Michelle Mark Revised Repair Part Packaging Req E.8.4

and E.8.5. Added in W.7.2