Definition
A flat sheet of corrugated board, plastic, or plywood placed on top of a palletized load before wrapping or strapping. Top caps distribute downward pressure from stacked loads, protect the top layer of products from dust and moisture, and provide a stable surface for stacking additional pallets on top. They are an inexpensive way to increase the stacking strength of a unit load and are widely used in distribution centers and warehouses.
Related Terms
Stacking Strength
The maximum weight that can be safely placed on top of a loaded pallet or palletized unit load without causing damage to the products or pallet below. Stacking strength depends on the pallet's structural design, the compressive strength of the products, and the stability of the load configuration. Edge boards, top caps, and interlocked stacking patterns all contribute to increased stacking strength. This specification is critical for warehouse floor stacking and container loading.
Edge Board
A right-angle protective strip made from laminated paperboard or plastic, placed on the edges and corners of palletized loads to prevent strap damage and reinforce stacking strength. Edge boards (also called corner boards or angle boards) distribute the pressure from strapping or stretch wrap across a wider area, preventing the strapping from cutting into the product packaging. They also increase the compressive strength of a palletized unit load.
Pallet Spacer
A flat board, frame, or layer placed between stacked palletized loads to distribute weight evenly and protect the products below. Pallet spacers prevent the bottom deck boards or legs of the upper pallet from creating point loads on the products of the lower pallet. They are especially important when stacking loads with uneven or fragile top surfaces. Spacers may be made from plywood, corrugated board, or plastic.
Pallet Wrap
A general term for materials used to secure and protect goods on a pallet during storage and transportation. The most common form is stretch wrap (stretch film), a highly stretchable plastic film that is wrapped around the loaded pallet to hold items in place. Other forms include shrink wrap, which is heated to form a tight seal, and pallet netting, which provides ventilation for products that need airflow. Proper pallet wrapping is essential for load stability and product protection.
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