Custom Edge Protectors

Measuring Custom Edge Protectors for Your Loads

For pallet corners, measure the height of the loaded pallet from the top of the deck boards to the top of the goods. The protector is usually cut a little shorter than that, so it does not stand proud of the load and catch on anything. If pallets vary in height, ordering two or three standard lengths covers most loads without waste.

Leg size depends on the strapping and the carton. A common pallet board has legs of 35 mm or 50 mm; heavier loads and wide straps suit 50 mm to 60 mm. Wall thickness typically runs from 3 mm for light-duty use to 5 or 6 mm for heavy goods. If you are not sure, tell us the pallet weight and how it is strapped, and we will suggest a profile.

For panels and furniture, measure the thickness of the item and the length of the edge you want to cover. Channel profiles are sized so the item slides in snugly without being forced. Our steps for measuring loads before ordering apply to pallets as well as boxes.

Material and Moisture

Edge protectors are made from layers of kraft paper laminated together and formed under pressure into a rigid angle. The result is surprisingly strong for its weight and does not splinter like timber.

Goods that sit in cold stores, open yards or damp trailers benefit from a moisture-resistant outer layer, which helps the board keep its stiffness when humidity is high. White-faced protectors give a cleaner look for retail-ready pallets and take printed messages well. The grades and their moisture tolerance are explained in our guide to board grades and moisture.

Printing on the Board Face

A printed edge protector does more than protect. Warehouse staff see the corners of every pallet, so a logo running up all four corners is an easy way to make your loads recognisable at a busy distribution centre. Simple handling messages such as do not stack, this way up or fragile can sit alongside the brand name.

Print is usually one or two colours on kraft or white, repeated along the length. Keep the design bold and simple; fine detail is lost on a narrow leg. Matching the colour to your shipping boxes and tape gives a joined-up look from the dock to the shelf.

Printed boards are also useful for traceability. A pallet that arrives with a damaged corner board but intact goods is clear evidence that the protection did its job, and a branded board makes it obvious whose pallet it was when loads are split across several bays. Some firms print a short contact line or returns instruction so that empty boards and pallets find their way back. Loads that need a reference on each corner can carry pallet labels for the same load.

Placing and Using Edge Boards Well

Put protectors on before stretch wrapping, so the film holds them in place, and then strap over the top. On the top layer, horizontal pieces under each strap stop the strap cutting into the carton edges. For pallets that will be double stacked, a top sheet or layer pad combined with vertical edge boards gives the most stable result.

Store protectors flat and dry, ideally on a rack near the wrapping station so staff use them every time rather than only for awkward loads. A consistent habit does more to cut damage claims than an occasional heavy-duty fix.

It is also worth checking how your carrier handles pallets. Groupage networks move loads through several hubs, and each transfer is another chance for a corner to be clipped, so a mixed load on a shared network deserves more protection than a dedicated delivery straight to one customer. Boards are held in place by stretch wrap film over the boards before strapping.

Measure the Pallet Height and the Strap Tension

Edge boards are specified from two things: the height of the stacked load and how hard the straps pull. Measure the load from the pallet deck to the top of the stack, because a board that stops short lets the strap crush the top layer, and tell us whether the straps are hand-tensioned or machine-tensioned, since machine straps need a thicker wall. Choose the leg size by the box edge: 35 mm legs for most cartons, 50 mm for heavy sacks and panels. Say if the boards go into a cold store or sit outside, because moisture-resistant board is specified at the quote stage. Printed boards need a vector logo and the repeat spacing along the length, which the free proof shows. A custom quote comes by email within one working day, minimums are low and quoted per job so you can trial a profile on a few pallets, and boards are cut in four to seven working days after approval. Delivery is free and tracked to UK mainland sites in bundled flat stacks. The cartons inside the load are sealed with our tear strip tape for the cartons.