How to Prevent Damage in Transit

Edge Protection & Dunnage Explained

Damage in transit is rarely random.

It usually comes from predictable forces: compression, shifting, vibration, impact, or strapping tension. If your product arrives crushed, scuffed, punctured, or broken, the issue is almost always insufficient protection — not bad luck.

Edge protection and dunnage exist to control those forces.

This page explains what they are, when you need them, and how to determine the right solution for your load.

What Causes Damage During Shipping?

Before choosing protection materials, it helps to understand the risks:

  • Vertical compression from stacking in trucks or warehouses

  • Strapping pressure cutting into cartons or product surfaces

  • Lateral shifting during acceleration and braking

  • Vibration over long distances

  • Forklift impact or puncture risk

  • Uneven weight distribution across the pallet

If you’re already asking about load security, you may also want to review:

→ When Do You Need Strapping Instead of Just Stretch Film?

→ How Much Stretch Film Do You Actually Use Per Pallet?

Protection works best when it’s layered — stabilization + cushioning + reinforcement.

What Is Edge Protection?

Edge protection (also called corner boards or angle boards) reinforces the vertical edges of cartons or palletized loads.

It serves three primary purposes:

  1. Prevents Crushing

    Vertical edge boards distribute top-load pressure when pallets are stacked.

  2. Protects Against Strap Damage

    Strapping can dig into corrugated cartons. Corner boards spread that tension across a wider surface area.

  3. Stabilizes the Load

    Edge boards add rigidity to the outer perimeter, improving stack integrity and reducing movement.


When You Likely Need Corner Boards

  • You’re double-stacking pallets

  • Your cartons show strap indentation damage

  • Your loads are tall or top-heavy

  • You ship appliances, furniture, or industrial cartons

  • Your freight is LTL and handled multiple times

If you’re unsure whether stacking is safe in the first place, review:

→ Are Standard Pallets Stackable? What to Know About Stability and Double Stacking

→ Are Your Pallets Safe for Racking?

What Is Dunnage?

Dunnage refers to materials placed inside a box, crate, container, or trailer to prevent movement and absorb shock.

Common types include:

  • Corrugated inserts or partitions

  • Foam blocking

  • Air pillows or inflatable airbags

  • Paper void fill

  • Wood blocking and bracing

While edge protection reinforces the outside of a load, dunnage protects the inside.

When Dunnage Is Critical

You likely need internal dunnage if:

  • The product has empty space inside the carton

  • The contents are fragile or high-value

  • You ship machinery, electronics, or components

  • You’ve seen damage from vibration or shifting

  • You export freight in ocean containers

If you’re shipping heavy equipment, you may also want to review:

→ Shipping Oversized or Heavy Loads? When You Need a Custom Pallet or Crate

→ Custom Pallets & Crates for Machinery and Industrial Equipment

In many industrial applications, wood blocking combined with a custom crate provides the highest level of protection.

Edge Protection vs. Dunnage: What’s the Difference?

While both protect your shipment, they solve different problems.

Edge Protection (Corner Boards)

Where it’s used:

On the outside vertical edges of a palletized load.


What it does:

  • Reinforces the perimeter of the load

  • Distributes compression from stacking

  • Prevents strapping from cutting into cartons

  • Adds rigidity to tall or unstable loads


Best for:

  • Double-stacked pallets

  • Loads secured with poly or steel strapping

  • Cartons showing crushed corners

  • LTL freight with frequent handling

Edge protection strengthens the structure of the load.


Dunnage

Where it’s used:

Inside cartons, crates, containers, or trailers.


What it does:

  • Prevents internal movement

  • Absorbs vibration and shock

  • Fills empty space (void fill)

  • Secures individual components

Best for:

  • Fragile or high-value products

  • Machinery and industrial equipment

  • Long-distance or export freight

  • Shipments with visible internal shifting

Dunnage protects the contents of the load.


The Practical Distinction

If your cartons are crushed or strapping is digging in → you likely need edge protection.

If your product is moving, breaking, or scuffing inside the packaging → you likely need dunnage.

In many industrial shipments, the correct solution is both:

  • Corner boards to stabilize the outside

  • Internal blocking or cushioning to protect the inside

Damage prevention works best when stabilization and internal protection are designed together.

How to Decide What You Need

Ask yourself:

  1. Is my product fragile or compressible?

  2. Will this pallet be stacked?

  3. Is strapping cutting into cartons?

  4. Does the product move inside the box?

  5. Is this LTL or long-distance freight?

  6. Is the load unusually heavy or uneven?

If you answer “yes” to any of these, protection upgrades likely make sense.

If your pallet design itself may be part of the issue, review:

→ How Much Weight Can a Pallet Really Handle?

→ Standard vs. Custom Pallets: Which Is Right for Your Load?

The Cost of Under-Protecting a Load

Skipping protection might save a few dollars per pallet.

But consider the real cost of damage:

  • Product replacement

  • Return freight

  • Lost customer trust

  • Insurance claims

  • Operational disruption

In most cases, properly specified edge boards or dunnage cost a fraction of a single damaged shipment.

When a Custom Solution Makes More Sense

If you ship:

  • High-value machinery

  • Export freight

  • Fragile assemblies

  • Irregular shapes

  • Loads over 2,000+ lbs

You may be beyond “add corner boards” territory.

In those cases, a properly engineered pallet or crate may be the right move:

→ How to Determine Specifications for a Custom Pallet or Crate

→ When Do You Need a Crate Instead of a Pallet?

Not Sure What’s Causing Your Damage?

Send us:

  • Product dimensions

  • Weight

  • Photos of damaged freight

  • Shipping method (LTL, FTL, export, parcel)

  • Whether you’re stacking or racking

We’ll help you identify whether the issue is:

  • Pallet strength

  • Load stabilization

  • Insufficient edge protection

  • Missing internal dunnage

  • Or a combination of factors

Preventing damage is almost always cheaper than replacing product.

If you’re evaluating protection options, request a quote and we’ll walk through the right solution for your operation.

Request a Quote

Or give us a call at (630) 765-5476.