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Triple packaging

Three layers

On this page11
The absorbent has to take the entire contents. Not some of it.

The primary receptacle

The thing the sample is in. A tube, a vial, a bottle, a cup. This is the layer a container catalog can supply and the only one we do.

The secondary packaging

A leakproof enclosure around the primary receptacle. Its job is to contain the sample if the primary fails, which means it is a containment device rather than a wrapper.

The absorbent, between the two

"Absorbent material must be placed between the primary receptacle and secondary packaging" and "must be of sufficient quantity to absorb the entire contents of the primary receptacles."

Read entire contents literally

Not enough to mop up a dribble. Enough that if every primary receptacle in the parcel emptied, the absorbent holds all of it. That is a quantity you calculate from the volumes you are shipping.

Which is the step most often done by eye

A pad in the bag looks like compliance. Whether it absorbs 4 millilitres or 40 is a specification, and with multiple primaries in one parcel the total is what counts.

The rigid outer packaging

Rigid is the word. It carries the markings, it takes the handling, and it is what the drop test is performed on.

Why three and not two

Because the failure modes are different. The primary fails by leaking, the secondary catches it, and the outer survives being dropped, crushed and stacked without either of the inner layers being exposed.

An itemised list of contents goes between the layers

Which is part of the system rather than a courtesy. Somebody opening a damaged parcel needs to know what was in it before they find out.

The system is tested as a system

Which is why buying the three parts separately from three suppliers and assembling them is not the same as buying a tested packaging. The test result belongs to the assembly.

So for Category B, buy the kit

From a supplier who sells and certifies the complete packaging. We can tell you what the inner layer has to do; we cannot sell you the thing the regulation describes.

References

49 CFR 173.199, Category B infectious substances. "A Category B infectious substance must be packaged in a triple packaging consisting of a primary receptacle, a secondary packaging, and a rigid outer packaging." Absorbent material "must be placed between the primary receptacle and secondary packaging" and "must be of sufficient quantity to absorb the entire contents of the primary receptacles". "The primary receptacle or the secondary packaging must be capable of withstanding without leakage an internal pressure producing a pressure differential of not less than 95 kPa." "The packaging must be capable of successfully passing the drop test in 178.609(d) of this subchapter at a drop height of at least 1.2 meters (3.9 feet)." "At least one surface of the outer packaging must have a minimum dimension of 100 mm by 100 mm (3.9 inches)." By aircraft, each primary receptacle may not exceed 1 L and each outer packaging 4 L for liquids, or 4 kg for solids. law.cornell.edu
Written from 49 CFR 173.199 and 173.134, and from the catalog as it stood on 19 October 2026. Nothing here is offered as a compliant primary receptacle for a regulated shipment: the pressure and drop requirements attach to a tested assembly, not to a bottle. Category A infectious substances are a different packaging instruction entirely and are not summarized. Sterility is not claimed for any product, and what a laboratory will accept is the laboratory's to say.