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Amazon’s PFP and Overbox Testing Standard Update | May 2026

The Prep-Free Packaging (PFP) test procedure has been revised.

The updated PFP certification now uses the ISTA 6-Amazon.com OVERBOX test. Specifically, this procedure simulates how Amazon Standard Identification Numbers (ASINs) ship either individually or alongside other products inside Amazon outbound packaging.

As a result, the revision changes how laboratories set up PFP testing and prepare overbox configurations. It also affects how vendors should plan future enrollments. Because Amazon is updating packaging materials, overbox sizes, hazardous item pairings, and sample quantity requirements, vendors should review upcoming PFP testing as early as possible. Doing so will help avoid delays before the revised 2026 procedure becomes mandatory on August 1.

Why is this important?

Amazon updated the procedure to keep its test methods aligned with changes across its fulfillment network. Specifically, the company removed air pillow dunnage from outbound packaging and adjusted multi-item shipment configurations to reflect evolving customer ordering behavior.

The main test setup changes include:

  • Paper Dunnage: The most significant change replaces air pillow dunnage with paper dunnage. As a result, the procedure now reflects the packaging materials Amazon currently uses throughout its outbound network.
  • Updated Overbox Sizing: In addition, the revised procedure updates overbox dimensions, hazard item sizes and weights, and test specimen pairings to better represent current shipping conditions.
  • Paper Tape Recommendation: The updated PFP procedure also recommends using paper tape. Consequently, test preparation more closely matches Amazon’s current outbound packaging practices.
  • Sample Quantity Changes: Finally, Amazon revised the required test sample quantities. Therefore, vendors should confirm the number of samples required under the 2026 ISTA 6-Amazon.com OVERBOX procedure before scheduling testing.

How Does This Affect Amazon Vendors?

For vendors, Amazon is allowing a four-month transition period where either the 2018 or 2026 version of the test will be accepted. This is meant to reduce disruption for vendors with testing already in progress and to give labs time to implement the changes.

As labs and vendors adjust to the revised PFP procedure, our Package Testing Lab Manager highlights what companies should keep in mind during the transition:

“The new test procedure will significantly increase the time, difficulty, and overall cost of testing. This is driven by higher sample requirements and reduced cushioning within the carton.

Under the previous specification, testing required five samples for liquid or fragile products and two samples for non-fragile products. The latest iteration increases these requirements to eight samples for liquid or fragile products and four samples for solid, non-fragile products weighing under 15 lbs.

Collectively, these changes are expected to increase material usage, testing effort, and cost while also making successful test outcomes more difficult to achieve.”

When Do The New Amazon PFP Requirements Go Into Effect?

Effective August 1, 2026, all PFP enrollments must use the new 2026 ISTA 6-Amazon.com OVERBOX test procedure. ASINs that are already PFP certified will remain certified as long as they stay in good standing.

Amazon notes they may be decertified for issues such as high damage rates, concessions, safety escalations, or non-compliant packaging.

Professional Packaging Testing To The Newest Amazon Standards

As an Amazon-accredited testing lab, Applus+ Keystone stays continuously up to date on the latest standard revisions. Our team provides clear communication throughout the testing process and works closely with engineers to help ensure each program is aligned with the newest requirements.

Request a quote today and find out for yourself why manufacturers trust Keystone with their packaging testing needs.

If you’re unsure of what type of amazon testing you might need, please don’t hesitate to contact us or visit our Amazon Packaging Testing Quiz.

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