How to Prevent Corner Damage During Transportation
Corner damage is one of the most common problems that can occur during product handling, storage and transportation.
The corners and edges of a package are often the first areas to experience impact, compression, strapping pressure or movement during transit. Once a corner becomes crushed or damaged, the overall strength and stability of the package may also be affected.
Businesses can reduce corner damage by using suitable packaging materials, protecting exposed edges with edgeboard, securing the load correctly and ensuring that products do not move during transportation.
What Causes Corner Damage During Transportation?
Corner damage can happen at different stages of the supply chain, including during packing, forklift handling, warehouse storage, container loading and final delivery.
Understanding the cause of the damage is the first step towards choosing the correct packaging solution.
Common causes of corner damage include:
Impact during handling
Excessive strapping pressure
Poor load stability
Product movement during transportation
Incorrect stacking
Weak carton boxes
Pallet overhang
Improper forklift handling
Insufficient protective packaging
Uneven weight distribution
Moisture or humidity exposure
Packages may also experience a combination of these problems during a single journey.
Why Are Package Corners Easily Damaged?
The corners of a box or palletised load are highly exposed.
They may come into contact with warehouse walls, forklift equipment, other pallets or the internal surface of a truck or shipping container.
Corners also carry part of the vertical pressure when products are stacked. When the packaging is weak or the weight is not distributed evenly, the corners may become crushed.
Strapping can create additional pressure. When a strap is placed directly against a carton, it may cut into the corner or deform the packaging.
Once a corner has been damaged, the package may lose its original shape and become less stable.
How Can Corner Damage Affect a Business?
Corner damage may appear to be a small packaging issue, but it can create additional costs throughout the supply chain.
Possible consequences include:
Damaged products
Rejected deliveries
Product returns
Replacement costs
Repacking work
Delivery delays
Customer complaints
Reduced stacking stability
Unsafe warehouse conditions
Damage to the company’s reputation
Even when the product inside remains usable, visibly damaged packaging may create a negative impression for the customer.
How to Prevent Corner Damage During Transportation
Use the Correct Packaging Size
The outer packaging should fit the product correctly.
A box that is too large may allow the product to move during transportation. A box that is too small may place excessive pressure on the product and packaging walls.
Correctly sized packaging reduces unnecessary movement and helps distribute pressure more evenly.
Businesses should consider:
Product dimensions
Product weight
Product shape
Fragility
Stacking requirements
Transportation method
Handling process
The packaging should be designed around the product and its complete journey.
Use Edgeboard for Corner Protection
Edgeboard is a protective packaging profile placed along the corners and edges of boxes, palletised products or other unit loads.
It creates an additional protective layer between the product packaging and external pressure.
Edgeboard can help protect corners from:
Impact
Compression
Strapping pressure
Stretch film pressure
Stacking pressure
Handling damage
Movement during transportation
It can be placed vertically along the corners of a pallet load or horizontally along exposed edges.
The correct position, size and strength of the edgeboard will depend on the load and packaging requirements.
What Is Edgeboard?
Edgeboard is commonly made from multiple layers of laminated carton board formed into an angle profile.
The profile normally has two legs that fit around the edge or corner of a package.
Edgeboard can be used externally on palletised loads or internally inside boxes. Its function may include protecting corners, strengthening packaging, improving load stability and supporting stacking performance.
It can be used together with stretch film, shrink film or strapping as part of a complete transport packaging system.
How Does Edgeboard Prevent Corner Damage?
Edgeboard helps distribute external pressure across a larger area.
Without edge protection, strapping or impact pressure may be concentrated on a small section of the carton corner. This concentrated pressure can crush, tear or deform the packaging.
When edgeboard is placed between the strap and the carton, the pressure is distributed along the length of the protective profile.
Edgeboard also reinforces the vertical corners of the load. This can help the load maintain its shape during handling, storage and transportation.
Its main functions include:
Protecting exposed corners
Distributing strapping pressure
Supporting vertical edges
Improving load stability
Strengthening carton packaging
Reducing package deformation
Supporting stacking performance
Edgeboard should be selected according to the product weight, load height, stacking conditions and transportation environment.
Place Edgeboard Correctly
Correct placement is important for effective protection.
For palletised cartons, full-length edgeboards are normally placed vertically along the outer corners of the unit load.
The edgeboard should:
Cover the vulnerable section of the corner
Remain straight against the load
Extend across the required load height
Be held securely by stretch film or strapping
Avoid blocking important labels
Remain correctly positioned during handling
Short edge protectors may be used directly underneath straps when full-length vertical protection is not required.
Horizontal edgeboards may also be positioned along the top or bottom edges of a load when additional protection is necessary.
The arrangement should be tested before being used for regular shipments.
Use the Correct Strapping Tension
Strapping helps secure a load, but excessive tension can damage carton boxes and product corners.
When straps are tightened too strongly, they may cut into the packaging or crush the corners.
When straps are too loose, the load may move during transportation.
The correct strapping tension should be based on:
Product weight
Carton strength
Load dimensions
Type of strap
Transportation method
Number of straps
Position of straps
Edge protection used
Edgeboard should be placed underneath the strapping to help distribute the pressure and prevent the strap from directly contacting the carton corner.
Strapping equipment should also be checked and calibrated regularly.
Stabilise the Pallet Load
An unstable load is more likely to shift, lean or collapse during transportation.
Movement can cause the corners of boxes to strike other products, pallet edges or the inside of a vehicle.
To improve load stability:
Use a consistent stacking pattern
Align boxes correctly
Distribute weight evenly
Place heavier products at the bottom
Avoid unnecessary gaps between cartons
Use edgeboard on vertical corners
Apply suitable stretch film
Use strapping when required
Avoid excessive pallet overhang
Check the load before dispatch
The correct load-stabilisation method depends on the size, shape and weight of the products.
Avoid Pallet Overhang
Pallet overhang occurs when boxes extend beyond the outer edge of the pallet.
Overhanging boxes are more exposed to impact from forklifts, warehouse equipment and other palletised loads.
The unsupported section may also become crushed because the pallet does not provide a stable base underneath it.
Products should be arranged within the dimensions of the pallet whenever possible.
The pallet should also be selected according to the dimensions of the load rather than forcing the product onto an unsuitable pallet size.
Reduce Empty Space Inside the Packaging
Empty space allows products to move inside a box.
When a product moves during transportation, it may strike the internal walls and corners of the packaging.
Suitable internal packaging may include:
Paper-based cushioning
Honeycomb board
Dividers
Partitions
Void fillers
Internal edge protectors
Custom inserts
Support blocks
The internal packaging should hold the product securely without creating excessive pressure.
Use Strong and Suitable Cartons
A weak carton may collapse even when external corner protection is used.
The carton specification should be suitable for the product weight, stacking height and transportation environment.
Businesses should evaluate:
Board grade
Carton dimensions
Product weight
Stacking duration
Warehouse humidity
Transportation conditions
Number of handling points
Packaging design
Reusing damaged or weakened cartons may increase the risk of corner crushing and package failure.
Inspect cartons before packing and replace any boxes that are wet, torn, crushed or deformed.
Use Suitable Pallets
A damaged or incorrectly sized pallet can affect the entire load.
Broken pallet boards, uneven surfaces or protruding nails may damage cartons placed above them.
Before loading products, inspect the pallet for:
Cracks
Broken components
Uneven surfaces
Protruding nails
Moisture damage
Incorrect dimensions
Insufficient load capacity
The pallet should provide a flat and stable base for the complete load.
Prevent Product Movement
Products should remain stable from the time they leave the warehouse until they reach the customer.
Movement can occur because of:
Vehicle vibration
Sudden braking
Sharp turns
Uneven roads
Forklift movement
Container movement
Incorrect stacking
Insufficient securing materials
Stretch film, strapping, edgeboard, dividers and suitable void-filling materials can be combined to reduce movement.
The packaging system should secure the product without creating damaging pressure.
Protect the Top and Bottom Corners
Corner damage does not only happen along the vertical sides of a load.
The top corners may be damaged by stacking, strapping or contact with other products.
The bottom corners may be damaged by pallet surfaces, forklift handling or load movement.
Additional protection may include:
Top edgeboard
Bottom edgeboard
Corner caps
Top covers
Protective sheets
Honeycomb board
Paper-based pads
The correct solution should be based on where the damage normally occurs.
Control Moisture and Humidity
Paper-based cartons may lose some of their strength when exposed to excessive moisture or humidity.
Moisture can come from:
Warehouse conditions
Condensation inside containers
Wet pallets
Outdoor handling
Temperature changes
Long transportation periods
Packaging materials should be selected according to the expected transportation environment.
Products should also be stored away from wet floors and exposed areas before shipment.
For demanding conditions, businesses should discuss suitable moisture-resistant packaging options with their packaging supplier.
Train Warehouse and Forklift Operators
Good packaging may still become damaged when products are handled incorrectly.
Forklift impact is a common cause of damaged pallet corners and cartons.
Operators should be trained to:
Approach loads carefully
Use the correct fork position
Avoid striking cartons
Avoid pushing loads against walls
Control lifting and lowering speed
Place loads on level surfaces
Follow stacking limits
Inspect damaged loads
Clear handling procedures can reduce both product damage and workplace safety risks.
Test the Packaging Before Implementation
A packaging design should be tested before it is used for large or repeated shipments.
Testing may include:
Compression testing
Stacking evaluation
Strapping testing
Load-stability testing
Handling trials
Vibration testing
Drop or impact evaluation
Warehouse trials
Test conditions should reflect the actual product, load weight, transportation method and storage environment.
Testing helps identify weak corners, unstable stacking arrangements and unsuitable packaging materials before the products are sent to customers.
Conduct a Packaging Damage Assessment
Businesses experiencing repeated corner damage should record when and where the damage occurs.
Useful information includes:
Location of the damage
Type of product affected
Frequency of damage
Transportation route
Carrier used
Carton specification
Pallet condition
Strapping position
Stretch film application
Stacking height
Warehouse conditions
Photographs of damaged shipments
This information can help determine whether the main cause is packaging, handling, transportation or load design.
A damage assessment should focus on solving the root cause rather than simply adding more packaging material.
Where Should Edgeboard Be Placed?
The correct edgeboard position depends on the packaging problem.
Vertical Corner Protection
Edgeboards are placed along the vertical corners of a palletised load.
This arrangement can help protect the corners, maintain the load shape and improve overall stability.
Strapping Protection
Short or full-length edgeboards are placed between the strap and the carton.
This prevents the strap from applying concentrated pressure directly onto the packaging.
Top Edge Protection
Edgeboards may be placed along the top edges of the load to protect the cartons from strapping or stacking pressure.
Internal Box Reinforcement
Edgeboards can be placed inside a carton to reinforce its corners and provide additional stacking strength.
Protection for Long Products
Edgeboard or wrap-around profiles may be used to protect the exposed edges of long or irregularly shaped products.
The packaging design should be customised according to the product and handling requirements.
Which Products Can Use Edgeboard?
Edgeboard can be used for many different types of products and packaging applications.
Examples include:
Carton boxes
Palletised consumer goods
Food and beverage products
Electronics
Furniture components
Automotive parts
Metal products
Paper rolls
Building materials
Household appliances
Industrial components
Long products
Bagged goods
The required edgeboard strength and dimensions may differ for lightweight cartons and heavy industrial products.
Can Edgeboard Improve Load Stability?
Edgeboard can help improve load stability by supporting the vertical corners and helping the palletised load maintain its shape.
When combined with correctly applied stretch film or strapping, it can help hold individual boxes together as one unit.
However, edgeboard should not be treated as the only load-stabilisation method.
Load stability also depends on:
Product arrangement
Carton strength
Weight distribution
Pallet condition
Stretch film application
Strapping position
Load height
Transportation conditions
The complete packaging system should be evaluated together.
Edgeboard and Stretch Film
Stretch film is used to hold products together and secure them to the pallet.
When edgeboard is added to the corners, the stretch film can apply pressure against the protective profiles instead of directly compressing the carton corners.
This combination may help:
Maintain a rectangular load shape
Protect exposed corners
Reduce carton deformation
Improve unit-load stability
Distribute wrapping pressure
The amount and tension of the stretch film should be appropriate for the load.
Edgeboard and Strapping
Strapping is commonly used for heavier loads or products that require stronger securing.
Edgeboard creates a protective barrier between the strap and the carton.
This can help prevent:
Strap cuts
Crushed corners
Torn cartons
Localised pressure
Package deformation
The straps should be correctly positioned, and their tension should be tested before regular use.
Common Packaging Mistakes That Cause Corner Damage
Using cartons that are too weak
Allowing products to overhang the pallet
Applying excessive strapping tension
Placing straps directly on carton corners
Using insufficient stretch film
Using too much stretch film pressure
Leaving large gaps between products
Stacking heavy products on top of lighter products
Using damaged pallets
Ignoring moisture conditions
Failing to test the packaging
Using edgeboard with the wrong dimensions
Not training forklift operators
Avoiding these common mistakes can significantly improve transport packaging performance.
Frequently Asked Questions
What causes corner damage during transportation?
Corner damage may be caused by impact, excessive strapping pressure, unstable stacking, product movement, weak cartons, pallet overhang, forklift handling or insufficient protective packaging.
How do you protect the corners of a box during shipping?
Box corners can be protected using edgeboard, corner protectors, suitable internal packaging, correctly applied stretch film and controlled strapping tension.
What is edgeboard used for?
Edgeboard is used to protect package corners and edges, distribute strapping pressure, strengthen cartons, improve load stability and support stacking performance.
Where should edgeboard be placed?
Edgeboard is normally placed vertically along the outer corners of a palletised load. It can also be placed underneath straps, along horizontal edges or inside boxes for additional reinforcement.
Does edgeboard prevent strapping damage?
Edgeboard can help prevent strapping damage by creating a protective layer between the strap and the carton. It distributes the strapping pressure across a larger area.
Can edgeboard improve stacking strength?
Edgeboard may help support the vertical corners of a package and improve stacking performance. The result also depends on the carton strength, product weight and overall packaging design.
Can edgeboard be used inside a carton?
Yes. Edgeboard can be placed inside a carton to reinforce the corners, support the package structure and provide additional protection.
Can edgeboard be used with stretch film?
Yes. Edgeboard is commonly used together with stretch film. The stretch film holds the edgeboard in position and helps stabilise the complete load.
Can edgeboard be used with strapping?
Yes. Edgeboard can be positioned underneath plastic or steel strapping to protect the package corners and distribute pressure.
Is edgeboard suitable for heavy products?
Edgeboard can be produced in different sizes and strengths for different applications. Heavy products require a technical assessment to determine the appropriate profile and packaging arrangement.
How can businesses reduce transport damage?
Businesses can reduce transport damage by using correctly sized packaging, stabilising the load, protecting exposed corners, controlling strapping tension, using suitable pallets and testing the packaging system.
Why Choose Eltete Edgeboard?
Eltete Edgeboard is a paper-based transport packaging solution designed to provide corner protection, stability and stacking support.
It can be used externally around palletised loads or internally inside packaging.
Eltete Edgeboard can also be combined with:
Stretch film
Shrink film
Plastic strapping
Steel strapping
Carton boxes
Paper pallets
Honeycomb board
Other protective profiles
The appropriate edgeboard design can be selected based on:
Product dimensions
Load weight
Package height
Required strength
Strapping method
Storage conditions
Transportation environment
Corner protection requirements
Every load is different. Selecting the correct edgeboard specification helps businesses avoid using too little protection or unnecessary excess packaging.
Conclusion
Preventing corner damage requires more than simply adding extra packaging material.
Businesses should first identify why the damage is occurring. Common causes include impact, strapping pressure, unstable loads, weak cartons, pallet overhang and incorrect handling.
Edgeboard provides an effective way to protect exposed corners, distribute pressure and strengthen palletised loads.
For the best result, edgeboard should be combined with correctly sized packaging, suitable pallets, controlled strapping tension, proper stretch film application and safe handling procedures.
A complete packaging assessment can help determine the right materials and design for the product’s weight, dimensions, transportation method and destination.
Contact Eltete Malaysia
Are your products experiencing crushed corners, damaged boxes or unstable pallet loads during transportation?
Eltete Malaysia can assess your current packaging and recommend a suitable edgeboard and transport packaging solution.
Contact Eltete Malaysia to discuss your packaging requirements or request a quotation.
