Strapping is one of the most common ways to secure palletised goods for storage and transportation.
It helps hold cartons and products together so the load remains stable during handling.
But strapping can also cause damage.
A strap that presses directly against a carton corner may crush the packaging, leave deep marks or even cut through the outer material.
The problem becomes more serious when high tension is applied to a weak or unsupported edge.
For manufacturers and exporters, the solution is not simply to loosen every strap.
The load still needs to remain secure.
A better approach is to understand where strapping pressure is being applied and protect those areas correctly.
Eltete Edgeboard can be used between the strap and the package to help spread pressure across a larger area and protect vulnerable corners.
Why Does Strapping Damage Palletised Goods?
Strapping works by applying tension around the load.
That tension helps keep the shipment together.
However, the strap itself is relatively narrow.
When it passes directly over an exposed carton corner, the force may become concentrated on a small area.
Imagine pressing on a carton with your whole hand.
Then imagine applying the same force using only one finger.
The smaller contact area creates greater pressure on that point.
A similar effect can happen when a narrow strap presses against an unsupported package corner.
Eltete identifies several factors that can affect strapping pressure, including:
– Strap tension
– Product weight
– Carton strength
– Number of straps
– Strap position
– Edge shape
– Handling conditions
– Transportation conditions
The correct packaging setup should consider these factors together.
Common Signs of Strapping Damage
Strapping damage is not always a completely broken box.
Sometimes the first signs are smaller.
You may notice:
– Crushed carton corners
– Deep strap marks
– Torn outer packaging
– Dented edges
– Deformed cartons
– Damaged product corners
– Straps becoming loose during transport
These signs should not be ignored.
If a carton starts to collapse underneath the strap, the load can lose its shape.
Once the package compresses, the strap may also lose tension.
This can lead to more movement during transportation.
The original corner damage can therefore become a wider load-stability problem.
Too Much Strap Tension Can Crush Cartons
One of the most common causes of damage is excessive strap tension.
The strap must be tight enough to secure the load.
But tighter is not always better.
If the tension is too high, the strap can press heavily into the carton corners.
This may:
Crush the corner.
Deform the box.
Damage the product inside.
Reduce the structural strength of the carton.
The correct tension depends on the shipment.
A heavy industrial load and a pallet of lightweight cartons will not always require the same strapping configuration.
Eltete recommends considering the product weight, carton strength, strap type, transportation method, strap position and edge protection when setting up the strapping system.
Weak Carton Corners Increase the Risk
The strap is only one part of the problem.
Carton strength matters too.
If a carton is too weak for the product weight or stacking conditions, its corners may already be under pressure before the strap is applied.
Additional strapping tension can make the problem worse.
Damage can also occur when cartons are:
Overloaded
Poorly stacked
Misaligned
Hanging over the pallet edge
Exposed to unsuitable storage conditions
Compressed by other loads
Before adding stronger strapping, manufacturers should check whether the cartons themselves are suitable for the shipment.
Adding more tension to a weak packaging system may simply create more damage.
How Edgeboard Helps Protect Against Strapping Pressure
Eltete Edgeboard is a laminated paperboard profile designed to protect package corners and edges.
For palletised goods, Edgeboard can be positioned vertically along the exposed corners of the load before the strapping is applied.
The strap then presses against the Edgeboard instead of directly against the carton corner.
This changes the way the pressure reaches the package.
Without Edgeboard:
Narrow strap → concentrated pressure → vulnerable carton corner
With Edgeboard:
Narrow strap → Edgeboard → pressure distributed across a larger area
Eltete explains that the larger contact surface created by Edgeboard helps distribute strapping pressure instead of allowing the force to concentrate on one small section of the package.
Pressure Distribution Is the Key
The purpose of Edgeboard is not simply to cover the corner.
Its shape allows pressure from the strap to spread along the protective profile.
This can help reduce problems such as:
Crushed corners
Strap cuts
Torn cartons
Package deformation
Damage to exposed product edges
The Edgeboard also provides additional support along the vertical corners of a palletised load.
Eltete identifies corner protection, strapping protection, palletisation, stabilisation, unitisation and stacking strength among Edgeboard applications.
Protect the Full Vulnerable Corner
Correct placement is important.
On a palletised carton load, Edgeboard is commonly positioned vertically along the outside corners.
It should sit directly against the vulnerable edge.
The strapping can then pass over the protected section.
For a tall pallet load, the Edgeboard may extend across a large part or the full height of the load depending on the application.
This can help protect several carton layers rather than only the carton located directly underneath one strap.
The correct Edgeboard length should match the area that requires protection.
Edgeboard Must Be Under the Strapping
Placement matters.
The Edgeboard should protect the actual contact point between the strap and the load.
If the strap still presses directly onto an exposed carton corner, the pressure distribution benefit is reduced.
For palletised loads, the basic arrangement is:
Palletised cartons → Edgeboard on the vertical corners → strapping around the protected load
The Edgeboard acts as a protective layer between the carton and the strap.
Eltete states that its Edgeboard can be combined with plastic or steel strapping as part of a complete transport packaging system.
Choose the Correct Edgeboard Strength
Not every load requires the same Edgeboard.
A lightweight carton shipment has different requirements from a heavy industrial product.
The Edgeboard specification should be selected according to factors such as:
Product Weight
A heavier load may require stronger protection.
Strap Tension
Higher tension can create more pressure at the contact point.
Load Height
Tall palletised loads may need longer profiles to support and protect the full corner.
Edgeboard Thickness
The profile must be able to withstand the expected compression without collapsing.
Leg Width
Wider legs can provide a larger contact area for pressure distribution.
Product Shape
Standard cartons and irregular industrial products may require different protective arrangements.
Transportation Conditions
Long export journeys may involve repeated handling, vibration and changes in load pressure.
Eltete recommends matching Edgeboard dimensions and strength to the individual packaging application rather than using one specification for every load.
Edgeboard Can Also Support Load Stability
Strapping damage and load instability are often connected.
If carton corners start collapsing, the pallet load may begin losing its original shape.
Cartons may:
Move
Lean
Separate
Become misaligned
A stable rectangular load is generally easier to secure.
Vertical Edgeboard can help support the external corners and keep cartons aligned.
When combined with suitable strapping or stretch film, it can help multiple cartons behave more like one unitised load.
However, Edgeboard should not be treated as the only load-stability solution.
Eltete notes that stability also depends on factors such as carton strength, pallet condition, weight distribution, stacking pattern, load height and the securing method used.
Do Not Use More Strapping to Fix a Poorly Stacked Load
When a pallet feels unstable, the first reaction may be:
“Add another strap.”
That is not always the correct solution.
If the real problem is poor stacking, weak cartons or uneven load distribution, adding more straps can increase pressure without solving the cause.
For example, consider cartons that are not aligned properly.
Increasing strap tension may pull the outside boxes inward.
But it can also crush their corners.
The better approach is to fix the load configuration first.
Check:
Are the cartons aligned?
Is the weight distributed correctly?
Does the load overhang the pallet?
Are the bottom cartons strong enough?
Is the pallet suitable?
Is internal product movement causing instability?
Once the basic load is stable, strapping can secure it more effectively.
Protect Carton Corners from Stretch Film Pressure Too
Strapping is not the only material that applies pressure.
Stretch film also pulls against the corners of a palletised load.
When high wrapping force is applied directly against vulnerable cartons, the corners may deform.
Eltete explains that Edgeboard can be combined with stretch film so that some of the wrapping pressure is applied against the protective profiles rather than directly against the cartons.
This can help maintain a more consistent load shape.
A complete palletised packaging system may therefore use:
Cartons + Edgeboard + Stretch Film + Strapping + Suitable Pallet
Each component performs a different job.
Strapping and Stretch Film Are Not the Same
Strapping and stretch film may be used together, but they do not perform exactly the same function.
Strapping provides strong restraint around selected points of the load.
Stretch film helps contain the overall unit load and hold individual cartons together.
Some loads may require only one method.
Others may benefit from both.
Eltete recommends evaluating the complete packaging system rather than relying on excessive strapping when the real issue is weak packaging or poor load arrangement.
What About Steel Strapping?
Strapping damage is not limited to plastic straps.
Steel strapping can also create high pressure at contact points.
Eltete states that Edgeboard can be used beneath both plastic and steel strapping.
The Edgeboard specification should be appropriate for the pressure involved.
This becomes especially important with heavier industrial products.
A strong strap may successfully hold the product in place while still damaging an exposed corner if no suitable protection is used.
The securing force and surface protection must therefore work together.
Heavy Products Need Special Attention
Heavy products often require stronger restraint.
Examples may include:
Metal components
Machinery parts
Building materials
Automotive components
Industrial products
These products can create another challenge.
The strap may not only damage the packaging.
Direct contact can also scratch, dent or mark the product itself.
Eltete recommends using protective paper profiles between the strapping and vulnerable surfaces where appropriate.
The heavier the load and higher the strap tension, the more important the contact point becomes.
Strapping Damage Can Become More Serious During Export
A pallet may look fine when it leaves the factory.
But export shipments can remain secured for a much longer period.
The load may travel through:
Warehouses
Trucks
Ports
Containers
Distribution centres
Customer facilities
During that journey, vibration and repeated handling can change how the load behaves.
Cartons may also compress over time.
If a carton corner collapses, strap tension may change.
Eltete recommends using suitable cartons, Edgeboard beneath strapping, appropriate strap tension, stable pallet configurations and pre-shipment inspection for export loads.
Humidity Can Affect the Complete Packaging System
Exporters in Malaysia and Southeast Asia should also consider humidity and storage conditions.
Paper-based cartons may perform differently when exposed to unsuitable moisture conditions.
A carton that initially supports the load correctly may become less resistant to compression if the packaging environment is poor.
This is another reason why strap tension should not be considered in isolation.
The packaging design should account for the complete transport environment.
A Simple Strapping Damage Checklist
Before releasing a palletised shipment, inspect the load.
Check the Cartons
Are they crushed before strapping begins?
Are the corners aligned?
Are any cartons overhanging the pallet?
Check the Load
Is the weight distributed evenly?
Is the load leaning?
Can products move inside the cartons?
Check the Edgeboard
Does it cover the vulnerable vertical corners?
Is it straight?
Is the correct strength being used?
Check the Strapping
Is the strap positioned over the protected area?
Is the tension sufficient without crushing the package?
Are too many straps being used?
Check the Complete Unit Load
Does the pallet remain stable?
Does the load maintain its shape?
Can it withstand normal handling and transportation?
The goal is not simply to create the tightest possible load.
The goal is to create a stable and protected load.
What If You Already Have Strapping Damage?
Look at the location of the damage.
If crushing always appears directly underneath the strap, concentrated pressure may be part of the problem.
If the complete carton is collapsing, the carton strength or load configuration may need to be reviewed.
If straps become loose during transport, the packaging may be compressing or the product may be moving.
If damage occurs on only one side, the handling or stacking arrangement may also be involved.
Eltete recommends investigating the root cause instead of simply adding more packaging material.
Edgeboard Should Be Part of the Packaging Design
Edgeboard performs best when it is treated as part of the complete palletised packaging system.
It works together with:
The cartons
The pallet
The product arrangement
Strapping
Stretch film
Internal protection
Handling methods
Transport conditions
For one load, the main requirement may be protection against strap pressure.
For another, Edgeboard may also be needed to support stacking and improve pallet stability.
The specification should follow the application.
Protect the Corner Without Losing Load Security
Strapping is important because goods need to remain secure during handling and transportation.
The solution to damaged corners is therefore not simply to remove the straps or apply very low tension.
Instead, protect the area where that force meets the package.
Eltete Edgeboard creates a protective layer between the strapping and vulnerable package corners.
By increasing the contact area, it helps distribute pressure instead of allowing the strap to concentrate force on one small section of the carton.
When combined with suitable strapping tension, strong cartons, correct stacking and a stable pallet, it can form part of a stronger transport packaging system.
Secure the load. Distribute the pressure. Protect the corners.
For manufacturers and exporters experiencing crushed corners, strap marks or package deformation, Eltete Malaysia can recommend an Edgeboard specification according to the load, packaging and transportation requirements.
Learn more at www.eltete.com.my
