WPKG-PRINT-001 Rev06 — Packaging & Printed Material Specification

1.0Scope

This specification defines the inspection, print quality, and material requirements for all printed packaging and packaging components supplied to Wahl Clipper Corporation. It applies to all suppliers producing or printing any Wahl packaging component and is incorporated by reference into the Wahl Supplier Quality Agreement.

Section	Category
2.0	Inspection Methods & Conditions
3.0	Sampling Procedures
4.0	Defect Classification
5.0	POS Box, Sleeve & Insert (Paper / SBS / CRB)
6.0	POS Box, Sleeve & Insert (Plastic / PET)
7.0	Master Carton & Insert
8.0	Labels
9.0	Documentation / IFU
10.0	Pulp Trays & Lids
11.0	Plastic Thermoformed Tray / Lid
12.0	Palletizing
13.0	Molded Fiber — Dry Press & Wet Press
14.0	Fabric Pouches with Zippers
15.0	EVA Cases
16.0	Delivery & Transit Packaging Protection
Appendix	Illustrations & Reference

Sustainability Preference — Paper-Based Materials
Wahl Clipper encourages the use of sustainably sourced fiber for all paper-based packaging components. Suppliers are encouraged to source from certified forests or recycled content and maintain chain-of-custody certification. This is not a contractual requirement. Recognized programs include:

FSC — Forest Stewardship Council (fsc.org)
PEFC — Programme for the Endorsement of Forest Certification (pefc.org)
SFI — Sustainable Forestry Initiative (forests.org)
ATFS — American Tree Farm System or equivalent regional programs

Suppliers with certified materials are encouraged to note the applicable certification and chain-of-custody code on submitted material data sheets and PO confirmations.

2.0Inspection Methods & Conditions

2.1 Inspection Distance

18 inches (457 mm) from eye to unit.

2.2 Inspection Duration

Part Description	Duration
Label	3–5 seconds per part
Tray / Lid	5–7 seconds per part
Molded Fiber Component	5–7 seconds per part
Fabric Pouch	8–10 seconds per part
EVA Case	8–10 seconds per part
Documentation / IFU	3–5 seconds per sheet
POS Box / Sleeve / Insert	8–10 seconds per part
Master Carton / Insert	8–10 seconds per part

2.3 Inspection Conditions

Rotate 30° from the horizontal plane. Rotate 30° right and left during inspection.

2.4 Light Source

Normal light condition: 80–120 ft-candles, white fluorescent lamp.

3.0Sampling Procedures

Attribute	Requirement
Standard	ISO 2859-1 (ANSI/ASQ Z1.4)
Inspection Level	Level II — Normal Inspection
Sampling Type	Single Sample Inspection
AQL — Critical	0.65
AQL — Major	0.65
AQL — Minor	0.65

A single AQL of 0.65 applies uniformly across all defect classes per this specification. This is a stricter standard than typical industry practice and reflects Wahl's quality expectations for all supplier tiers.

4.0Defect Classification

Class	Definition
Critical	A defect that impedes the usage of the product. Cause for rejection.
Major	A defect that causes substantial degradation to the usability of the product for its intended application.
Minor	A defect that is not a substantial degradation for the product application, or a deviation from existing standards irrelevant to the effective use of the product.

5.0POS Box, Sleeve & Insert (Paper / SBS / CRB)

5.1 Panel Classification

Panel	Definition
Panel A	Major/primary panels — panels containing legal copy or critical design elements
Panel B	Secondary panels — sides, interior
Panel C	Hidden panels — dust flaps

5.2 Dimensional Tolerances

All dimensions refer to internal finished dimensions of the erected carton unless otherwise stated on the item drawing.

Dimension	Tolerance
Length / Width / Depth	±1.0 mm
Caliper (board thickness)	±0.05 mm (per TAPPI T 411)
Bleed registration to artwork spec	±3.0 mm
Bleed from score line (top/bottom)	±5.0 mm
Bleed from score line (sides)	±8.0 mm
Sleeve misalignment	±1.0 mm max
Embossing / UV / foil registration	±1.6 mm (1/16")

Tolerances listed are maximums. Item-level drawings supersede where tighter tolerances are specified.

Critical5.3 Critical Defects▼

Dimensions deviate sufficiently to impede usage of the product
Smearing, bleeding, or hazing sufficient to impede usage of the product
Cracking that impedes structural functionality of the package
Sleeve misalignment sufficient to impede usage of the product
Printed text illegible
Bleed registration deviates sufficiently to impede usage
Insufficient glue that impedes usage of the product

Major5.4 Major Defects▼

Dimensions deviate from dimensional specification tolerances
Discoloration — color density outside approved tolerances
Specks, hickies, bubbles, blemishes: >2 mm diameter on Panel A; more than 3 defects no closer than 30 mm apart on Panel A
Scratches: >5 mm × 0.5 mm on Panel A; more than 3 defects no closer than 30 mm apart
Creases >5 mm on Panel A
Cracking of paper on flat panel surface (not at score line) on Panel A and B
Cracking at score/fold line: >0.5 mm thickness — max score/fold length; 0.6–1 mm — max ½ score/fold length; >1 mm — not allowed
Corner split >5 mm
Excessive glue or foreign materials on Panel A and B
Paper peeling or separation at scores
Dents and deformation >5 mm on Panel A and B
Water mark >5 mm on Panel A
Pressure mark >10 mm on Panel A and B
Sleeve misalignment >1 mm
Bleed registration: >±3 mm from artwork; >±5 mm top/bottom or >±8 mm side from score lines
Missing ink on printed side of Panel A and B
Barcode will not scan or returns incorrect data
Embossing, UV coating, or foil stamping registration >1.6 mm (1/16")
Foil stamping — missing, broken, or ragged edges >1.5 mm
Tears, holes, and contamination (oil/grease/moisture)
Scuffing resulting in paper show-through or white mark >5 mm × 0.5 mm on Panel A and B

Minor5.5 Minor Defects▼

Specks, bubbles, hickies, blemishes: >2 mm on Panel B (max 3, ≥30 mm apart); <2 mm on Panel A
Scratches: >5 mm × 0.5 mm on Panel B (max 3); <5 mm × 0.5 mm on Panel A
Creases >5 mm on Panel B
Deep label artwork creases >½ length on Panel A and B
Blistering of the label
Water mark >5 mm on Panel B
Pressure marks >5 mm but ≤10 mm on Panel A and B
Missing ink on printed side of Panel C, or ink on unprinted side
Notching >1.5 mm on Panel A and B (see Illustration 6)

6.0POS Box, Sleeve & Insert (Plastic / PET)

Panel classification same as Section 5.1 — Panel A (primary), Panel B (secondary), Panel C (hidden).

6.2 Dimensional Tolerances

Dimension	Tolerance
Length / Width / Depth	±1.0 mm
Sleeve misalignment	±1.0 mm max
Bleed registration to artwork spec	±3.0 mm
Bleed from score line (top/bottom)	±5.0 mm
Bleed from score line (sides)	±8.0 mm
Embossing / UV / foil registration	±1.6 mm (1/16")

Tolerances listed are maximums. Item-level drawings supersede where tighter tolerances are specified.

Critical6.3 Critical Defects▼

Dimensions deviate sufficiently to impede usage
Smearing, bleeding, or hazing sufficient to impede usage
Cracking that impedes structural functionality
Sleeve misalignment sufficient to impede usage
Printed text illegible
Bleed registration deviates sufficiently to impede usage
Insufficient glue that impedes usage
Tears, holes, and contamination (oil/grease/moisture)

Major6.4 Major Defects▼

Dimensions deviate from specification tolerances
Discoloration — color density outside approved tolerances
Specks, hickies >2 mm on Panel A; more than 3 no closer than 30 mm apart
Scratches >5 mm × 0.5 mm on Panel A (max 3 no closer than 30 mm apart)
Creases >5 mm on Panel A
Cracking: none on Panel A; up to 5 mm on Panel B; up to 10 mm on folds/Panel C
Corner split >5 mm
Excessive glue or foreign materials on Panel A and B
Dents and deformation >5 mm on Panel B
Water mark >5 mm on Panel A; Pressure mark >10 mm on Panel A and B
Sleeve misalignment >1 mm
Bleed registration: >±3 mm from artwork; >±5 mm top/bottom or >±8 mm sides
Missing ink on Panel A and B; barcode will not scan
Embossing/UV/foil registration >1.6 mm; foil edges ragged >1.5 mm
Scuffing on Panel A and B >5 mm × 0.5 mm

Minor6.5 Minor Defects▼

Specks, bubbles >2 mm on Panel B (max 3, ≥30 mm apart); <2 mm on Panel A
Scratches >5 mm × 0.5 mm on Panel B; <5 mm × 0.5 mm on Panel A
Creases >5 mm on Panel B

7.0Master Carton & Insert

7.1 Dimensional Tolerances

Dimension	Tolerance
Internal L / W / H	±2.0 mm
Wall caliper (corrugated)	Per supplier board grade; ECT ≥ 32 lb/in (5,600 N/m)
Gap width at score line	≤ 9.5 mm (5/16") max
Fishtail gap width from score	±3.2 mm (1/8") max
Horizontal slot movement	±3.2 mm (1/8") max
Slot depth movement	±4.8 mm (3/16") max
Insert flatness deviation	≤ 5 mm across full face

Internal dimensions govern for product fit. Supplier to provide board test records confirming ECT rating with each production lot.

Critical7.2 Critical Defects▼

Dimensions deviate sufficiently to impede usage of the product
Cracks that impede structural functionality
Insufficient or excessive glue impacting box use
Shipping carton does not meet or exceed ECT rating of 32 lb/in (5,600 N/m)
Overpack BMC does not match raw material provided (where BMC is specified in the art plan)

Major7.3 Major Defects▼

Dimensions deviate from specification tolerances
Cracking showing inside liner
Exposed glue when box is folded
Print text illegible; dents >5 mm; corner splits >5 mm; foreign materials >5 mm
Gap width >9.5 mm (5/16") from score line
Fishtailing: gap width difference >±3.2 mm (1/8"); gap >8.7 mm
Horizontal slot movement >±3.2 mm (1/8"); slot depth movement >±4.8 mm (3/16")
Paper peeling and separation at scores
Supplier to maintain board test records for 1 year from supply date

Minor7.4 Minor Defects▼

Dents and deformation <5 mm
Tears, holes, and contamination (oil/grease/moisture)
Overpack art does not conform with print art plan

8.0Labels

8.1 Dimensional Tolerances

Tolerances apply to finished, die-cut labels. Reference: TLMI recommended manufacturing standards.

Dimension	Tolerance
Finished label length / width	±0.8 mm
Die-cut to print registration	±0.5 mm
Color-to-color registration	±0.25 mm
Adhesive / zone coat position	±1.0 mm
Label gap on liner (auto-apply)	3 mm min
Roll core inside diameter	76.2 mm (3") nominal
Max roll outside diameter	Per purchase order

For labels applied by automated equipment, tolerance conformance must be validated against the application machine's specification sheet prior to production approval.

Critical8.2 Critical Defects▼

Dimensions deviate sufficiently to impede usage
Smearing, bleeding, or hazing sufficient to impede usability
Printed text and information illegible
Excessive glue that impedes usability
Tears, holes, and contamination
Use of adhesives that do not meet specification for tack or release

Major8.3 Major Defects▼

Dimensions deviate from specification tolerances
Misalignment of text deviating from specification tolerances
Discoloration — color density deviations from CMYK/Pantone specification
Damage and label tearing
Incorrect label orientation in the roll

Minor8.4 Minor Defects▼

Glue or foreign material visible on the surface
Specks, bubbles, hickies, and blemishes visible on the surface

9.0Documentation / IFU

9.1 Dimensional Tolerances

Dimension	Tolerance
Finished trim size (L × W)	±1.5 mm
Page-to-page registration (folded)	±1.0 mm
Fold position from edge	±1.5 mm
Caliper / paper stock	Per specified GSM ±5% (TAPPI T 411)
Color density variation	≤ 10% from approved Pantone reference

Critical9.2 Critical Defects▼

Dimensions deviate sufficiently to impede usage
Printing errors that impede usage
Misalignment of pages sufficient to impede usage
Incorrect formatting or sequence deviates from specification
Printed text illegible
Excessive or insufficient glue impacting usage of the manual
Paper stock deviates from specification
Tears, holes, and contamination

Major9.3 Major Defects▼

Dimensions deviate from specification tolerances
Color density variation >10% of Pantone color
Crease on visible area; paper separation at scores; paper peeling or tearing
Corner split >3 mm
Glue or foreign material on visible surface
Barcode will not scan or returns incorrect data
Scratch or scuff >5 mm × 0.5 mm; more than 3 defects <30 mm apart
Hickie, speck, or blemish >1 mm; more than 3 defects <30 mm apart

Minor9.4 Minor Defects▼

Blistering of cover and other visible areas
Scratch or scuff <5 mm × 0.5 mm
Hickies, specks, and blemishes <1 mm

10.0Pulp Trays & Lids

10.1 Dimensional Tolerances

Dimension	Tolerance
Overall L / W / H	±1.5 mm
Pocket / cavity depth	±1.5 mm
Wall thickness	±0.5 mm of nominal
Flatness / warp across full face	≤ 3.0 mm deviation from flat reference
Lid fit clearance	0 – 1.5 mm gap when nested

Critical10.2 Critical Defects▼

Dimensions deviate sufficiently to impede usage
Splits and cracks that impede structural functionality
Printed text and logo illegible

Major10.3 Major Defects▼

Dimensions deviate from specification tolerances
Discoloration — color density outside approved tolerances
Specks/stains: >1 mm on Wahl text (max 3, ≥20 mm apart); >2 mm on logo area (max 3, ≥20 mm apart); >5 mm outside logo area (max 3, ≥10 mm apart)
Scratches >5 mm; creases >30 mm on non-text area; cracking outside pocket rib area
Foreign material on front side; paper peeling and separation; tears, holes, contamination

Minor10.4 Minor Defects▼

Intense blemishes
Deep crease on front side of tray

11.0Plastic Thermoformed Tray / Lid

11.1 Dimensional Tolerances

Dimension	Tolerance
Overall L / W / H	±0.5 mm
Pocket / cavity depth	±0.5 mm
Wall thickness	±0.2 mm of nominal
Flatness / warp across full face	≤ 1.0 mm deviation from flat reference
Lid fit clearance	0 – 0.8 mm gap when nested
Haze / clarity	Per approved limit sample or spectrophotometer reference

Critical11.2 Critical Defects▼

Dimensions deviate sufficiently to impede usage
Splits and cracks that impede structural functionality
Printed text and logo illegible
Material resin marks not matching material used in production (excludes #7 Other resin)

Major11.3 Major Defects▼

Dimensions deviate from specification tolerances
Discoloration; haze and clarity outside approved tolerance
Foreign material or damage in Zone A (see Illustration 5)
Scratches >5 mm; creases >30 mm on non-text area; cracks, tears, holes, contamination
More than 3 craters or gels >1 mm² in Zone A; more than 3 carbon specks >0.3 mm² <25 mm apart in Zone A
Nick or notch >1 mm; recycle symbol formed into plastic

Minor11.4 Minor Defects▼

Intense blemishes
Defects in Zone B and Zone C

12.0Palletizing

12.1 Dimensional Tolerances

Dimension	Tolerance
Pallet footprint (L × W)	Per pallet specification (WPQD_PALLET_REV01)
Load overhang from pallet edge	≤ 25 mm any side
Max stacked load height	Per purchase order / load plan
Top board gap width	≤ 9.5 mm between boards
Exposed splinter length	≤ 76 mm (critical threshold)

Critical12.2 Critical Defects▼

Pallet dimensions beyond allowable tolerance
Pallets with broken, split wood and/or exposed nails
Missing or broken boards
Exposed splinters >76 mm
Partial footings (¼ of stringer board missing at nail)
Taper breaks with depth >25 mm along 250 mm length
Cracks on top or bottom boards >3 mm wide × 380 mm long
Double stringers, patched boards, or metal repair plates
Grade C Tier Pallet (see WPQD_PALLET_REV01 §1.4.3)

Major12.3 Major Defects▼

Pallet not meeting minimum Grade B tier standard
Load not secured or improperly stretch-wrapped
Stacking pattern does not match approved load plan

Minor12.4 Minor Defects▼

Excessive discoloration and staining; noticeable odor
Tapered breaks <25 mm along 250 mm length
Non-continuous weathering cracks on top surface
Sink holes or knit lines >6 mm in plastic pallets

13.0Molded Fiber — Dry Press & Wet Press

13.1 Process Overview

Attribute	Dry Press (Traditional)	Wet Press (Thermoformed)
Primary Use	Inner cushioning, master carton inserts	Retail-facing trays, premium inserts
Surface Finish	Rough/fibrous non-mold side; smooth mold side	Smooth, high-definition both sides
Wall Thickness	3.0 – 6.0 mm typical	0.8 – 2.0 mm typical
Dimensional Tolerance	±1.0 mm	±0.5 mm

Critical13.2 Critical Defects (Both Processes)▼

Dimensions deviate sufficiently to prevent proper fit or assembly
Splits, cracks, or fractures that impede structural functionality or product retention
Sharp edges or protruding fibers capable of causing injury
Mold contamination — visible mildew, mold growth, or biological matter
Foreign matter embedded in the fiber structure
Moisture causes structural softening or collapse under normal handling
Printed text, logo, or regulatory markings illegible or missing where specified
Dimensional deviation causing product movement >3 mm inside final package assembly

Major13.3 Major Defects — Dry Press▼

Dimensional

Wall thickness outside ±1.5 mm of nominal
Overall part dimensions outside ±1.0 mm
Warping >3 mm from flat reference across any 100 mm span
Pocket or cavity depth outside ±1.5 mm

Structural

Delamination or fiber separation on mold-side >5 mm
Cracks or splits >10 mm on any load-bearing surface
Visible voids >10 mm² reducing wall section by >25%
Stacking or compression failure under standard pallet load

Surface & Appearance

Stains, discoloration >10 mm on mold-side surface
Fiber pull or de-bonding on mold-side >15 mm²
Screen marks >20 mm on mold-side surface
Flash or fiber overflow at edges >3 mm beyond trim line

Moisture

Moisture content >12% by weight at receipt (TAPPI T 412)
Visible water damage, staining, or softening

Major13.4 Major Defects — Wet Press▼

Dimensional

Wall thickness outside ±0.5 mm; overall dimensions outside ±0.5 mm
Warping >1.5 mm from flat reference across any 100 mm span
Pocket or cavity depth outside ±0.5 mm

Structural

Delamination or fiber separation on either surface >3 mm
Cracks or splits >5 mm on any surface
Visible voids >5 mm² reducing wall section by >20%
Any pin holes or perforations visible on mold-side surface

Surface & Appearance

Stains or contamination >5 mm on either surface
Surface blemishes >2 mm diameter on visible side: more than 3 no closer than 30 mm apart
Color density variation outside approved specification on printed areas
Hazing or surface dulling on gloss/semi-gloss areas
Embossed text: registration >1.0 mm from specified position
Flash at edges >1.5 mm beyond trim line

Moisture

Moisture content >10% by weight at receipt (TAPPI T 412)
Visible water damage, warping, or surface softening

Minor13.5 Minor Defects (Both Processes)▼

Stains or blemishes within acceptable size limits on non-visible surfaces
Slight color variation within approved range on non-printed areas
Minor surface roughness on non-mold side of dry press components
Flash or fiber overflow: ≤1.5 mm (wet press) or ≤3 mm (dry press)
Minor fiber fuzz that does not affect product fit or structural integrity

13.6 Material & Certification Requirements

Requirement	Specification
Fiber source	Virgin or recycled fiber; PCW content as specified on PO
Prohibited substances	REACH SVHC compliant; no PFAS/PFOA
Moisture at receipt	≤ 12% (dry press) / ≤ 10% (wet press) — TAPPI T 412
Density range	0.8 – 1.2 g/cm³
Waterproofing agents	AKD or equivalent; food-safe grade; declared on MSDS
Records retention	2 years from ship date

13.7 Transit & Functional Testing

Test Type	Reference Standard
Drop test	ASTM D5276 or ISTA 1A/3A
Vibration test	ASTM D999 or ISTA 1A/3A
Environmental conditioning	ASTM D4332 (23°C / 50% RH, 24 hr minimum)
Compression / stacking	ASTM D642

Supplier is responsible for providing test reports with first article submission. Wahl reserves the right to require re-validation upon any change in material, tooling, or process.

14.0Fabric Pouches with Zippers

14.1 Dimensional Tolerances

All dimensions refer to the finished, closed pouch unless otherwise stated on the item specification.

Dimension	Tolerance
Overall length / width / height	±3.0 mm
Seam allowance width	±1.5 mm of specified
Zipper tape position from edge	±2.0 mm
Zipper pull stop position from end	±3.0 mm
Stitch density	8–12 SPI; ±1 SPI of specified

14.2 Logo, Mark & Decoration Tolerances

Decoration Type	Placement Tolerance	Notes
Embroidered logo	±3.0 mm from center point	All axes
Woven label (sewn in)	±3.0 mm from specified position	All four sides flat and tacked
Heat transfer / screen print	±3.0 mm from center point	All axes
Debossed / embossed mark	±2.0 mm from specified position
Patch (sewn on)	±3.0 mm; all edges stitched	No lifting edges

Embroidery Attribute	Requirement
Thread color match	Within ±1 Pantone step of approved specification
Fill density	No visible gaps in fill area >1.0 mm
Underlay	Required beneath all embroidery; no fabric distortion around logo
Stitch direction	Per approved artwork file
Jump stitches on visible surface	Not allowed — must be trimmed flush
Loose thread tails on embroidery	≤ 3.0 mm; trimmed flush preferred

14.3 Sewing & Seam Quality

14.3.1 Loose Thread Allowances

Location	Loose Thread Limit
External — primary (front face)	None allowed >3.0 mm; must be trimmed ≤3.0 mm
External — secondary (back, sides)	≤ 5.0 mm; trimmed preferred
Internal lining — visible areas	≤ 5.0 mm
Internal lining — non-visible / hidden	≤ 10.0 mm acceptable
At zipper attachment seam	None allowed — all tails trimmed flush
At logo / label attachment seam	None allowed — all tails trimmed flush

Thread tails must be cut cleanly, not burned. Burned or melted thread ends on visible surfaces are a Major defect.

14.3.2 Sewing Gap Standards

A sewing gap is any break, skip, or separation in a seam where thread is absent or seam integrity is compromised.

Seam Zone	Allowable Gap
Structural seam (load-bearing, perimeter)	Zero gaps allowed
Zipper attachment seam	Zero gaps allowed
Logo / label attachment — all four sides	Zero gaps allowed
Decorative top-stitch (non-structural)	≤ 1 skip per 100 mm; max 1 occurrence per seam
Interior lining seam (non-structural)	≤ 2.0 mm gap; max 1 occurrence per seam

Any sewing gap at a stress point (corner, zipper end, strap anchor) is a Critical defect regardless of gap size.

Critical14.4 Critical Defects▼

Sharp or broken zipper teeth, slider fragments, or metal hardware capable of causing consumer injury
Needle, pin, wire, or foreign object found inside or embedded in the pouch
Toxic or chemically hazardous odor from material or dye
Open or broken structural seam allowing contents to escape
Zipper completely non-functional — will not open or close
Fabric hole or tear compromising the pouch's ability to retain contents
Sewing gap at any stress point (corner, zipper end, strap anchor)
Labeling or compliance markings missing where required by applicable regulation
Fabric or dye fails restricted substance requirements (REACH SVHC, CPSIA, Prop 65)

Major14.5 Major Defects▼

Zipper & Hardware

Zipper jams, skips teeth, or requires excessive force; halves don't meet flush (gap >2.0 mm)
Zipper tape not fully sewn — open attachment >5.0 mm from end; end stop missing or loose
Metal hardware loose, uneven, or non-functional; zipper pull type/color not per specification

Sewing & Construction

Skipped stitches — more than 1 per 50 mm; seam alignment deviation >3.0 mm
Seam allowance <5.0 mm at any structural seam
Open or unfinished seam edge on any external or visible interior surface
Corner reinforcement missing at stress points; burned or melted thread end on visible surface
Sewing gap exceeding zone allowances in §14.3.2

Logos, Marks & Decoration

Logo/mark placement outside ±3.0 mm of specified position
Embroidery fill with visible gap >1.0 mm; jump stitches visible on external surface
Loose thread tail >3.0 mm on primary or >5.0 mm on secondary surface
Woven label with unstitched edges or lifting corners
Heat transfer/print with lifting, cracking, or feathered edge >1.0 mm; logo color outside ±1 Pantone step
Fabric distortion or puckering around embroidery >3.0 mm from logo boundary

Material & Surface

Fabric color/finish doesn't match approved sample; dye bleeding or migration on visible surface
Lining detached or bubbling >20 mm²; fabric pilling >10 mm on primary face
Water resistance failure on coated fabrics — ingress within 1 minute

Minor14.6 Minor Defects▼

Loose thread ends ≤5.0 mm on secondary/interior surfaces (within zone limits of §14.3.1)
Slight uneven stitch spacing within ±1 SPI of specification
Minor color shading between components — within grey scale rating 4 (ISO 105-A02)
Surface lint, dust, or minor soiling removable without damage
Small fabric irregularities (neps, slubs) <3.0 mm on secondary surfaces

14.7 Material & Certification Requirements

Requirement	Specification
Fabric type	Per item specification (polyester, nylon, canvas, etc.)
Zipper type	Per item specification; YKK or approved equivalent
Thread	Polyester core-spun; color matched to specification
Restricted substances	REACH SVHC compliant; CPSIA compliant (if applicable)
Colorfastness	Minimum grey scale rating 4 (ISO 105-A02)
Seam strength	≥ 45 N at all structural seams (ASTM D1683 or ISO 13935-1)
Zipper durability	≥ 500 open/close cycles without failure
Records retention	2 years from ship date

15.0EVA Cases

15.1 Dimensional Tolerances

All dimensions refer to the finished, closed case unless otherwise stated on the item specification.

Dimension	Tolerance
Overall L / W / H (external)	±1.5 mm
Interior cavity L / W / H	±1.0 mm
EVA shell wall thickness	±0.5 mm of nominal
Foam insert thickness	±1.0 mm of nominal
Zipper tape position from edge	±2.0 mm
Case closed gap (halves meeting)	≤ 1.5 mm any point along perimeter

15.2 Logo, Mark & Decoration Tolerances

Decoration Type	Placement Tolerance	Notes
Debossed / embossed mark on EVA	±2.0 mm from specified position	Depth consistent across full mark
Screen print / pad print on EVA	±2.0 mm from specified center	All axes
Embroidered logo (fabric-covered)	±3.0 mm from specified center	All axes
Woven label (sewn in)	±3.0 mm from specified position	All four sides flat and tacked
Heat transfer on fabric shell	±3.0 mm from specified center	All axes
Patch (sewn on)	±3.0 mm; all edges stitched	No lifting edges

Deboss / Emboss Attribute	Requirement
Depth consistency	Uniform across full mark — variation ≤ 0.3 mm
Edge definition	Clean — no tearing, crumbling, or feathering of EVA at mark edge
Placement	±2.0 mm from specified center in all axes

15.3 Sewing & Seam Quality (Fabric-Covered EVA)

See Section 14.3 for embroidery standards. Loose thread and sewing gap standards below apply independently to EVA cases.

Location	Loose Thread Limit
External fabric — primary face	None >3.0 mm; must be trimmed
External fabric — secondary (sides, back)	≤ 5.0 mm; trimmed preferred
At zipper attachment seam	None allowed — all tails trimmed flush
At logo / label attachment seam	None allowed — all tails trimmed flush
Interior lining or non-visible seams	≤ 10.0 mm acceptable

Seam Zone	Allowable Gap
Structural seam (perimeter, load-bearing)	Zero gaps allowed
Zipper attachment seam	Zero gaps allowed
Logo / label attachment — all four sides	Zero gaps allowed
Decorative top-stitch (non-structural)	≤ 1 skip per 100 mm; max 1 occurrence per seam
Interior lining seam (non-structural)	≤ 2.0 mm gap; max 1 occurrence per seam

Any sewing gap at a stress point (corner, zipper end, hinge area) is a Critical defect regardless of gap size.

Critical15.4 Critical Defects▼

Sharp edges, cracks, or fractures on EVA shell capable of causing consumer injury
Needle or foreign object found inside the case
Zipper completely non-functional — will not open or close
Interior cavity prevents product from fitting or being removed
Shell deformation or compression set prevents case from closing
Toxic or chemically hazardous odor from EVA, foam, or adhesive
Sewing gap at any stress point (corner, zipper end, hinge)
Structural seam or hinge failure causing case to separate into halves
Material fails applicable restricted substance requirements (REACH SVHC, CPSIA, Prop 65)

Major15.5 Major Defects▼

Dimensional & Fit

External dimensions outside ±1.5 mm; interior cavity outside ±1.0 mm
Shell wall thickness outside ±0.5 mm; case halves don't align flush (gap >1.5 mm)
Foam outside ±1.0 mm or doesn't return to shape within 60 seconds after compression

Zipper & Hardware

Zipper jams, skips teeth, or requires excessive force; halves don't seat correctly
Zipper tape not fully bonded or sewn — separation >5.0 mm from end
Zipper end stop missing or loose; pull tab missing, mismatched, or non-functional

Shell & Surface

EVA shell warping — deviation >3.0 mm from flat reference across any 50 mm span
Cracks, chips, or splits on EVA shell exterior
Laminated fabric bubbling, delaminating, or peeling >10 mm²
Discoloration, staining, or dye migration on any external surface
Glue squeeze-out visible on exterior >5.0 mm; uneven lamination >20 mm on primary face

Logos, Marks & Decoration

Logo/mark placement outside tolerance defined in §15.2
Deboss/emboss depth inconsistency >0.3 mm; tearing or feathering of EVA at mark edge
Print with lifting, cracking, or feathered edge >1.0 mm
Jump stitches visible on external fabric; thread tail >3.0 mm on primary or >5.0 mm on secondary
Burned or melted thread end on visible surface; woven label with unstitched edges

Foam Interior

Foam dimensions outside ±1.0 mm; foam fails to retain product under 0.5 G lateral force
Foam tears or holes >5.0 mm; foam not bonded to shell — lifts >10.0 mm from any edge

Minor15.6 Minor Defects▼

Minor surface scuffs <5.0 mm on non-primary (bottom/back) EVA surfaces
Slight color variation within approved range
Loose thread ends within zone limits defined in §15.3
Minor foam surface irregularities (indentations <3.0 mm) on non-visible interior surfaces
Small glue residue <3.0 mm on non-visible interior surfaces

15.7 Material & Certification Requirements

Requirement	Specification
EVA shell	Ethylene Vinyl Acetate; hardness per item spec (Shore C or A)
Foam insert	PE or EVA foam; density and hardness per item spec
Fabric covering	Per item specification; color matched to approved sample
Zipper type	Per item specification; YKK or approved equivalent
Restricted substances	REACH SVHC compliant; CPSIA compliant (if applicable)
RoHS compliance	Required for all cases packaged with electronic accessories
Drop performance	1.0 m drop onto concrete — 6 faces, 4 edges, 2 corners; product undamaged
Compression performance	50 cycles at 500 N; product inside undamaged
Temperature range	Functional −20°C to +60°C; no deformation or seal failure
Records retention	2 years from ship date

16.0Delivery & Transit Packaging Protection

16.1 Supplier Accountability Statement

The supplier is responsible for ensuring that all Wahl Clipper packaging components and materials arrive at the designated delivery location in the condition specified in this document. This responsibility extends beyond the quality of the article itself to include the adequacy of the delivery system — meaning the outer packaging, inner protection, moisture barriers, and any supplementary protective measures used to protect the article during transit, handling, and storage prior to receipt.

Any article damage, degradation, or contamination attributable to an inadequate or non-conforming delivery packaging system is the responsibility of the supplier and is subject to claim, return, or cost recovery per the Wahl Supplier Quality Agreement.

Damage Attribution: If water ingress, moisture damage, crushing, contamination, or other transit-related damage is found at receiving inspection, and the delivery packaging is found to be absent, insufficient, or non-conforming to this specification, the damage is presumed attributable to the supplier's delivery system unless evidence of external carrier damage is documented at the time of delivery.

16.2 General Delivery Packaging Requirements

Suppliers must design their delivery packaging system to protect articles against all foreseeable hazards including mechanical shock and vibration, compressive loading, moisture (humidity, condensation, direct water contact), temperature cycling, and contamination. The delivery packaging system must be validated prior to first production shipment. Any change to packaging material, configuration, or supplier requires re-validation.

16.3 Moisture & Hydration Protection

16.3.1 Moisture Protection by Article Type

Article Category	Minimum Required Protection
Paper / SBS / CRB folding cartons	Poly bag liner inside master carton or moisture-resistant master carton liner
Master cartons (corrugated)	Moisture-resistant box liner for ocean / high-humidity shipments
Labels (roll stock)	Individual roll poly bags sealed; master carton lined
Documentation / IFU	Poly bag per bundle; master carton lined for ocean shipments
Molded fiber — dry press	Poly bag per tray stack or master carton liner; desiccant required
Molded fiber — wet press	Individual poly bag per unit or tray-level poly sleeve; desiccant required
Pulp trays & lids	Poly bag per stack; desiccant required
Fabric pouches	Individual poly bag per unit or sealed poly bag per pack quantity
EVA cases	Individual poly bag per unit
Plastic thermoformed trays	Individual poly bag per unit or tray-stack poly bag

16.3.2 Desiccant Requirements

Desiccant is required for fabric pouches (sewn construction) and EVA cases where absorbed moisture during transit or storage creates a critical risk of mold, mildew, or biological growth on fabric, foam, or textile materials. Desiccant is not a general requirement for paper-based or corrugated packaging unless specifically called out on the applicable purchase order or drawing.

Requirement	Specification
Desiccant type	Silica gel (ISO 9001 grade) or clay desiccant; molecular sieve acceptable
Unit size	Per supplier calculation based on carton volume and transit duration; minimum 1 unit per master carton
Packaging form	Tyvek sachet or non-woven sachet — no loose granule packets
Placement	Inside sealed poly liner, adjacent to articles — not in direct contact with printed surfaces
Indicator	Humidity indicator card (HIC) required inside each master carton for ocean shipments — single-use, 3-spot minimum
Prohibited	Do not use calcium chloride desiccants — liquid release risk

16.3.3 Box / Carton Liners

Liner Type	Minimum Specification
Poly bag liner (master carton)	LDPE or LLDPE; minimum 2.0 mil (51 µm); sealed or folded closed after loading
Kraft paper liner	Not acceptable as sole moisture protection; acceptable as void-fill supplement only

All poly bags and liners must be sealed — twist-tie closure is not acceptable as sole seal method. Heat seal preferred; fold-and-tape acceptable for master carton liners. Seal integrity: no open seams, pinholes, or tears at time of pack.

16.4 Inner Pack & Cushioning

Articles must be packed to prevent relative movement that could cause abrasion, scuffing, or crushing. Void fill required when articles occupy less than 85% of master carton volume. Acceptable: paper cushion, molded fiber pads, air pillows (LDPE), EPE foam sheets. Not acceptable: loose packing peanuts (polystyrene or starch) unless enclosed in a contained bag. Stacking orientation must be marked (THIS SIDE UP / ↑) when article orientation is critical. Maximum stack height / weight must not exceed the carton's stated ECT or BCT rating.

Critical16.5.1 Critical — Delivery Packaging Failures▼

Master carton crushed, punctured, or collapsed — articles inside damaged or may be damaged
Evidence of water ingress (wet liner, wet articles, watermarks on inner surfaces)
Poly liner absent where required by §16.3.1
Desiccant absent from fabric pouch or EVA case shipments where required by §16.3.2
Humidity indicator card (HIC) shows red / triggered condition at receipt
Visible mold, mildew, or biological growth on any article or inner packaging surface
Contamination (oil, chemical, pest evidence) inside the master carton

Major16.5.2 Major — Delivery Packaging Non-Conformances▼

Poly liner present but not sealed — folded open or torn at seal
Desiccant present but incorrect type, size, or placement
Humidity indicator card missing from ocean shipments
Insufficient void fill — articles freely shifting >25 mm within carton
Stacking orientation markings absent when required
Individual article poly bags missing, unsealed, or torn prior to receipt
Master carton shows significant moisture damage without evidence of article impact

Minor16.5.3 Minor — Delivery Packaging Observations▼

HIC present but partially triggered (1 of 3 spots) with articles dry and undamaged
Void fill present but insufficient to prevent minor shifting (<25 mm)
Poly bag present but not heat-sealed — fold-tape closure intact and effective
Minor external carton scuffing with no impact on articles inside

16.6 Documentation & Traceability

Requirement	Detail
Packing list	Required with every shipment; must reference PO number, item numbers, quantities, and lot/batch numbers
Moisture protection statement	Supplier to confirm method used on packing list or COA for ocean shipments
Desiccant lot traceability	Supplier name and lot number to be recorded; available upon request
Carrier damage documentation	Noted on delivery receipt at time of delivery; photographed before unloading
Supplier response time	Wahl notifies within 5 business days; supplier responds with root cause and CA within 10 business days
Records retention	2 years from ship date

APPAppendix — Illustrations

Technical reference illustrations for inspection criteria referenced throughout this specification. Illustrations marked Original are from the approved Rev05 source document. Illustrations marked AI Reference are generated technical references for sections without an existing illustration.

Illus. 1 Panel Classification — Panels A, B, and C Original

Panel A, B, C classification die-line for POS folding carton

Panel A — Major/primary panels containing legal copy or critical design elements. Panel B — Secondary panels (sides, interior). Panel C — Hidden panels (dust flaps). Referenced in §5.1 and §6.1.

Illus. 2 Glue Joint Closure Original

Ideal glue joint closure — 1/8 inch from glue tab score to board edge

Glue joint closure too wide vs. too small comparison

Left: Ideal glue joint — 1/8" from glue tab score to edge of board. Right: Glue joint too wide (max 3/8" double wall or <175# single wall; max 5/16" for >175# single wall) vs. too small (max 1/16" overlap). Referenced in §7.3.

Illus. 3a Fishtailing Original

Fishtailing defect — gap width difference from score line ±1/8 inch (3.2mm)

Fishtailing occurs when slot cuts are angled, creating a gap width difference between the largest and smallest slot opening. Tolerance: ±1/8" (3.2 mm) from score line. Referenced in §7.3.

Illus. 3b Gap Resulting from Fishtailing Original

Gap resulting from fishtailing — maximum gap 8.7mm at assembled box corner

Gap at the assembled box corner resulting from fishtailed slot cuts. Maximum allowable gap: 8.7 mm. Referenced in §7.3.

Illus. 4 Slot Movement — Horizontal & Depth Original

Horizontal slot movement — ideal vs slot offset max ±1/8 inch from score line

Slot depth movement — ideal vs deep slot max +3/16 inch and shallow slot max -3/16 inch

Left — Horizontal Slot Movement: Slot offset from score line must not exceed ±1/8" (±3.2 mm). Right — Slot Depth Movement: Deep slot max +3/16"; shallow slot max −3/16" from score line. Referenced in §7.3.

Illus. 5 Zone A — Plastic Lid / Thermoformed Tray Original

Zone A — the entire front face product and graphic area of a plastic blister or thermoformed tray

Zone A encompasses any product or graphic area on the front face of the blister or thermoformed tray. Stricter defect criteria apply within Zone A per §11.3. Zone B is the surrounding border/flange area.

Illus. 6 Notching Example Original

Notching example — physical sample showing a notch defect at a folding carton board edge

Notching is a defect at the cut edge or corner of a board where material has been removed or torn, creating an indentation. Notching >1.5 mm on Panel A or B is a Minor defect per §5.5. Structural notches at stress points may elevate to Major.

Illus. 7 Molded Fiber Warp / Flatness Measurement Reference AI Reference

Molded fiber tray warp and flatness measurement — deviation measured from flat reference plane

Warp deviation is measured as the maximum gap between the part surface and a flat reference plane placed across the span being measured. Dry Press: Maximum deviation ≤ 3.0 mm across any 100 mm span (§13.3.1). Wet Press: Maximum deviation ≤ 1.5 mm across any 100 mm span (§13.4.1). Test per TAPPI T 412 or equivalent.