Jumbo Sizes

Jumbo Cornerboards as
Edge Protectors Options

Jumbo Sizes
National Motor Freight Classification
Jumbo Sizes
Side View
Jumbo Sizes
End View
Jumbo Sizes
Thick vs Thin
Jumbo Sizes
Reinforced Corners
Jumbo Sizes
Full Sided Doublewall

Tuff Angle's jumbo cornerboards meet National Motor Freight Classification requirements for edge protectors that must have at least 3 plies of corrugated and measure at least one inch thick.

The thickness requirement of edge protectors, for the majority of approved packs by the Commodity Classification Standards Board (CCSB) is either 3/4" or 1" thick.

Some packs are specifically three ply. Some packs come with 1/2" as a minimum requirement.
Keep in mind that minimum requirements are just that - minimum requirements.
(CCSB) only list the "minimum" requirement, while a better product or packaging technique may never get a mention. Thus a certain impetus is granted to possibly the "worst" product because simply being named by (CCSB), it gains a certain amount of credibility over better products.

Anything better than the "minimum" packaging requirement is ALSO approved. Tuff Angle edge protectors are available in many calipers or thickness. Depending on the need and function, both jumbo cornerboards and very thin cornerboards are available.

Two factors contribute to corner board thickness: the number of plies and thickness of those plies.

Tuff Angle's patented folding design aligns and folds three sheet layers of corrugated atop one another before folding all three layers again in order to make the 90 degree angle.
The three layers obviously effect the eventual measurement, but so does the thickness of the sheet being folded. Three thicknesses of a 1/8" inch thick corrugated sheet will approximately yield a 3/8" finished edge protector.

Tuff Angle's folding design is an efficient way to achieve thickness requirements. For instance, 1" hard angleboards probably aren't even available.

The thickest is 1/2" which are relatively expensive because they are laminating very thin non-fluted pieces of paper on top of each other until the desired thickness is achieved.

The result is a very strong edge protector that isn't very thick, with good stacking strength (if you can align the small footprint of these cornerboards with each other when multi-stacking boxes in the warehouse and truck), but has very little cushioning to protect from material handling and shipping damage.

Fluted paper obviously has an advantage over a flat sheet when the goal is to achieve a thick edge protector. It doesn't take as many layers of paper to achieve height.
Most fluted edge protectors employ the same general production technique. They stack and glue individual layers together until they are as thick as needed.

Fluted layers obviously have a cost advantage over flat layers of paper, in that it doesn't take as many layers. Fluted edge protectors also have a cushioning advantage over hard cornerboards, but not as much as you would think. Yes, the product is softer due to the corrugated fluting; but the process to make them is essentially the same.

Both processes stack and glue layers of paper until they achieve the thickness they want; but the design really doesn't do much to make the cornerboard tougher.

It really just provides a certain number of plies to get through before the product is damaged. Though frequently used as innerpack, the stacking strength of fluted edge protectors is much less compared to hard angleboard.
Tuff Angle edge protectors are different. They don't merely layer paper. They fold and refold the corrugated sheet. Tuff Angle's layers are produced by scoring and folding a single corrugated (fluted) sheet into three interlocking layers.

Each panel is glued prior to folding. All three layers are then refolded to make a ninety degree angle.
Each bend serves to reinforce the corner, making it ultra strong and extremely protective from impact damage. Multiple bending of a single sheet also provides tremendous stacking strength.

Fold and refold a magazine and then stand it upright to have an idea of the stacking strength produced with this design configuration.

Tuff Angle edge protectors come in a variety of calipers. Both extremely thin and jumbo cornerboards are available.

Jumbo Cornerboards

Sheet thickness is mainly a product of the height of the corrugated flutes. Flutes come as thin as a McDonald's hamburger clamshell box and cosmetic packaging, or as thick as triplewall bulk containers used at grocery stores. Tuff Angle's jumbo cornerboards are approximately 1 1/8" thick.
Tuff Angle edge protectors achieve thickness by folding three layers of a single sheet with the appropriate flute height. Three layers of a 1/8" sheet yields approximately a 3/8" sheet (plus glue which isn't much).
Folding a single sheet into three layers and then refolding all three layers, provides tremendous reinforcement to the corner; while at the same time achieving tremendous stacking strength. You simply can't obtain either the corner reinforcement, or the stacking strength with the traditional approach of gluing individual pieces of fluted paper into layers.

Most fluted corner boards are not made from a double-sided sheet. They are made with layers of single face sheets turned upside down on each other.
Some of the flutes nest within each other, while other flutes sit directly on top of the other. Unreliable and varying thickness is the result.

Tuff Angle edge protectors are made from a full double-sided sheet. When folded, each panel has a flat surface to adhere to. Yet another reason that Tuff Angle edge protectors offer more protection from shipping and warehouse damage.

Tuff Angle edge protectors offer jumbo cornerboards too. They are manufactured from a doublewall sheet.

A doublewall sheet has two different types of flute on a single sheet. The two different flutes are bonded to either side of a flat sheet. The sheet used is stated as A/C flute. One of these sheets measures approximately .34" thick.

Tuff Angle's resulting jumbo cornerboards, when folded into three layers are approximately 1 1/8" thick. The result is an extra strong edge protector with reinforced corners, a great deal of stacking strength; and a 1 1/8" footprint for improved utilization of the available stacking strength.

Tuff Angle's jumbo cornerboards efficiently achieve thickness by utilizing fluting. Reinforcing folds provide true strength to the corners and reduces product damage.

Corrugation direction, paper grade, multiple folding, bonding glue, and a larger footprint all contribute to the tremendous stacking strength of these jumbo edge protectors.