Choosing and Using Edge Boards / Corner Protectors: A Beginner's Guide and Best Practices

Edge Boards / Corner Protectors are one of the easiest ways to improve packaging performance, but using them well requires a few simple decisions and correct placement. This beginner-friendly guide walks you through how to choose the right protector, best practices for application, and common mistakes to avoid. The goal is to keep goods safe, reduce claims, and make handling more efficient.

Step 1: Assess your load and transport conditions

• Weight and stack height: Heavier loads and high stacks need thicker, longer-legged edge boards to resist compression and preserve load geometry.
• Strap type and width: Steel, polyester, or polypropylene straps create different pressure levels. Narrow, high-tension straps cause more localized compression, so wider or reinforced edge boards are better.
• Handling and transit risks: Frequent forklift handling, long-haul transport, or rough road conditions increase the need for stronger protection.
• Environment: Moisture, humidity, and outdoor storage favor plastic or coated paperboard protectors over plain paperboard.

Step 2: Select the right material and profile

• Paperboard edge boards: Best for dry conditions and single-use shipments. They come in various ply counts and profiles; choose thicker boards for heavier loads.
• Plastic corner protectors: Good for wet or reusable situations. They maintain shape and can be returned and reused across shipments.
• Foam protectors: Use when cushioning and avoiding surface scratches are key, for example with glass or painted furniture.
• Reinforced or laminated options: For extra strength, laminations with thin metal strips or heavy board cores are available.

Step 3: Determine placement and quantity

• Full-edge vs corner-only protection: Full-edge boards run the entire stack height and provide consistent support; corner protectors are used for specific vulnerable corners or shorter stacks.
• Number of protectors per pallet: At minimum, use one protector on each exposed corner when straps are placed there. For heavy pallets, place protectors under each strap intersection to evenly distribute tension.
• Orientation: Place the protector so the longest leg faces the strap, maximizing contact area. Ensure the protector reaches from the pallet surface up to the top layer of the load for continuous protection.

Step 4: Apply strapping and tension correctly

• Pre-tension carefully: Tighten straps enough to secure the load without crushing boxes. Edge Boards / Corner Protectors allow higher tension without damage, but restraint is still necessary.
• Align straps properly: Position straps over protectors and centered along their length. Misaligned straps can slip off or concentrate force on an exposed edge.
• Avoid sharp edges: If packages have protruding elements, add additional padding before placing protectors to prevent puncturing.

Step 5: Use complementary stabilization methods

• Stretch wrap: Combine protectors with stretch film to reduce lateral movement and keep individual boxes in place.
• Top sheets and corner boards: Place a top sheet under the topmost strap to further distribute pressure; add internal dividers for fragile items.
• Slip sheets and anti-slip pads: Use these at pallet interfaces to reduce sliding between layers.

Inspection and maintenance

• Before shipment: Check that protectors are intact, correctly sized, and seated flush against edges. Replace any crushed or damaged protectors.
• During reuse: For reusable plastic protectors, inspect for cracks or deformation and clean any residue that could reduce friction.
• After arrival: Note any strap marks or damage to inform future protector selection and strap tensioning adjustments.

Common mistakes to avoid

• Using undersized protectors: Small or thin protectors can collapse under tension, leaving edges vulnerable.
• Over-tensioning straps: Even with protectors, excessive tension can still crush weak cartons or deform product packaging.
• Poor placement: Protectors that don’t reach the top or are misaligned with straps don’t provide intended protection.
• Ignoring environment: Paperboard in wet conditions will weaken; select a material suited to the environment.

Practical example

A beverage wholesaler was experiencing frequent punctured cartons and collapsed layers when pallet straps were tightened. Switching from thin paper edge strips to 60 mm kraft edge boards under each strap and aligning straps centrally reduced carton damage by 85% and lowered rework time. They also adjusted strap tension to a moderate level, relying on the protectors to maintain stability rather than extreme compression.

Quick checklist for beginners

1. Identify load weight, height, and strap type.
2. Choose material: paperboard for dry single-use, plastic for wet or reusable, foam for fragile surfaces.
3. Select leg length and thickness based on load height and strap width.
4. Place protectors under each strap contact point and ensure full contact with the load edge.
5. Tension straps moderately and inspect before dispatch.

Following these simple steps will make Edge Boards / Corner Protectors an effective, low-cost part of your packaging strategy. They are easy to use, reduce product damage, and help shipments remain safe throughout the supply chain.