A workshop that packs six panel thicknesses does not want six protectors. The usual answer is one size that covers the range with an acceptable fit at both ends, and the question is how much slack a U profile can take before it stops doing its job.
How much slack a U will tolerate
The profile grips by the two legs pressing on the two faces. A little slack still holds because the fold acts as a spring. Too much and the piece hangs on one leg and tips off when the panel is turned.
In practice, a channel sized to the middle of a range works where the range is narrow. Where the thickest panel is much thicker than the thinnest, one size will be wrong at one end and the range should be split.
Specification at a glance
The table shows a sensible split for a mixed workshop. It is a starting point, not a rule, because handling matters as much as thickness.
| Range | Sizes | Fit |
|---|
| 3-8 mm sheet | 1 size at 6 mm | Close at the thick end |
| 10-20 mm board | 1 size at 15 mm | Acceptable across the range |
| 3-25 mm mixed | 2 sizes: 6 and 20 mm | Proper fit both ends |
| 25-50 mm thick stock | 1 size at 38 mm | Loose at the thin end |
| Mixed, banded | 1 size may do | Band holds the fit |
| Mixed, unbanded | Split the range | Loose pieces fall off |
Splitting a range without doubling the stock
Two sizes usually cover a workshop range: a narrow one for sheet and thin board, a wider one for board and thick stock. That is two lines of stock instead of six, and both fit properly.
Where the volume is low, a slightly loose fit on the thin end is acceptable if the pack is banded, because the band holds the protector against the panel. On an unbanded stack it is not.
What to change when the range is split
Keep the leg constant across the two sizes and change only the inside width. Operators then handle one shape and the bundles look the same on the shelf.
Keep the wall constant too unless the duty differs. Mixing walls in one rack is how the wrong protector ends up on the wrong panel.
Questions buyers ask before ordering
Can one size cover 3-25 mm?
Not well. Two sizes, 6 and 20 mm, give a proper fit at both ends.
How much slack is acceptable?
A little, where the fold still springs. Beyond that the piece tips off when the panel is turned.
Does banding help a loose fit?
Yes. A band holds the protector against the panel, so a slightly loose size works on a banded pack.
Should the leg change with the size?
Keep it constant so operators handle one shape.
Can you supply a mixed pallet?
Yes, with each size labelled on the bundle.
Tell us the piece size, quantity per shipment and how it is handled at mona@hengnicepacking.com and we will advise on the board build.
