Common Mistakes and Best Practices When Using Edge Boards / Corner Protectors

Edge boards / corner protectors are straightforward in concept, but common mistakes in selection and application can reduce their effectiveness. This article outlines frequent errors beginners make and offers practical best practices to maximize protection, save money, and improve packaging performance.

Common mistakes

• Wrong material selection — Choosing corrugated edge boards for damp or frozen environments leads to rapid deterioration. Conversely, using expensive metal protectors for disposable shipments increases cost unnecessarily.
• Insufficient coverage — Applying protectors only at a couple of corners while leaving other edges exposed invites damage during handling. All load corners and exposed edges should be assessed and protected as needed.
• Too-thin profiles for heavy loads — Thin or single-wall edge boards under heavy straps will crease, allowing straps to dig into packaging. This results in crushed corners or ripped pallet wraps.
• Improper installation sequence — Installing straps before placing protectors or not securing protectors so they shift can negate protection benefits. Protectors must be positioned before strapping and stabilized during the strapping process.
• Ignoring strap type and tension — High-tension strapping without adequate edge protection will cut into goods. Using wrong strap materials (steel vs polypropylene) without matching protector thickness is another frequent oversight.
• Poor storage and handling of protectors — Storing corrugated protectors on the floor where they absorb moisture or crushing them in transport damages their effectiveness.

Best practices

• Match protector strength to load conditions — For heavy, tall, or stacked loads, choose double/triple-wall corrugated, plastic, or metal protectors. For light retail packages, single-wall corrugated or foam may suffice.
• Protect all exposed edges — Make a habit of inspecting each pallet or stack and apply edge boards / corner protectors to every vulnerable side, not just the easily visible ones.
• Secure protectors before strapping — Use stretch film, tape, or temporary clips to hold protectors in place while straps are applied to avoid slippage and misalignment.
• Pair strap type with protector material — Steel straps need robust protectors; plastic straps work well with corrugated or plastic protectors. Reduce strap tension to the minimum required to secure the load and rely on protectors to distribute pressure.
• Educate packers and handlers — Standardize packaging instructions and train staff on why and how to use edge boards / corner protectors. Visual job aids on the line help reinforce correct application.
• Inspect and maintain reusable protectors — For plastic or metal protectors, inspect for cracks, wear, and deformation. Remove damaged protectors from service to avoid compromised protection.

Cost optimization tips

• Use corrugated edge boards for most single-use shipments to balance performance and recyclability.
• Implement a return-and-reuse program for plastic protectors on regular returnable pallets to amortize higher purchase cost.
• Run damage-cost analysis: track damage claims before and after implementing protectors to quantify savings. Often the reduced claims justify an increase in packaging spend.

Sustainability and compliance

• Choose recyclable or reusable materials where possible. Corrugated edge boards are widely recyclable and align with circular packaging goals.
• For international shipments, verify that the protector material meets import regulations (e.g., ISPM-15 does not apply to cardboard, but wooden components may require treatment).

Real-world examples and lessons learned

• A consumer appliances company switched from applying protectors to only the top corners to protecting all four corners and reduced cosmetic damage claims by 30% within three months.
• An exporter who initially used corrugated edge boards in ocean shipments moved to plastic protectors for pallets exposed to salt spray and wet stacking. The change eliminated soggy, weakened protectors and reduced rework at destination.
• A manufacturer tightened strap tension to ‘secure’ loads but increased product breakage. Training on correct strap tension combined with thicker edge boards resolved the issue and improved load security.

Quick checklist for best outcomes

• Select protector material and thickness matched to load and environment.
• Cover all exposed edges and corners.
• Secure protectors before strapping and check for slippage.
• Train staff, document procedures, and inspect packs before shipment.
• Monitor damage claims and adjust protector strategy as needed.

By avoiding common mistakes and following these straightforward best practices, edge boards / corner protectors become a highly effective, low-cost way to reduce damage, enhance pallet stability, and improve overall packaging performance in your supply chain.