How to Properly Pack Using VCI Packaging

Before packaging, metal parts must be clean, dry, and free from residues of emulsions, salts, or mechanical impurities. It is also recommended to equalize the temperature of the product with the surrounding environment to prevent moisture condensation inside the package.

The product should then be placed into a VCI film or bag in such a way that sufficient protective space is maintained around the entire product for the circulation of inhibitor vapors. The packaging must be sealed as tightly as possible — ideally by heat sealing, adhesive sealing, or a mechanical closure with minimal permeability to the surrounding atmosphere.

When packaging larger assemblies or export units, it is recommended to combine VCI materials with barrier packaging and desiccants to control relative humidity during storage and transportation. It is also important to minimize unnecessary opening of the package, as repeated exposure reduces the concentration of protective inhibitors inside the packaging.

How Do We Test the Effectiveness of VCI Protection?

At Bropack, we verify the effectiveness of anti-corrosion protection through laboratory testing in a condensation chamber that simulates extreme conditions of high humidity, temperature fluctuations, and water vapor condensation during transportation or long-term storage of metal parts. Testing is carried out in cooperation with Měříme s.r.o., enabling objective and independent evaluation of the protective properties of VCI materials according to standardized methods.

The principle of VCI (Volatile Corrosion Inhibitor) protection is based on the release of volatile corrosion inhibitors into the enclosed packaging space. The inhibitor molecules diffuse toward the metal surface, where they form an adsorbed protective layer that suppresses electrochemical corrosion reactions.

Corrosion of iron in the presence of water and oxygen proceeds, for example, according to the following reactions:

Anodic Reaction

Fe→Fe2++2e−Fe \→ Fe^{2+} + 2e^{-}Fe→Fe2++2e−

Cathodic Reaction

O2+2H2O+4e−→4OH−O_2 + 2H_2O + 4e^{-} \→ 4OH^{-}O2​+2H2​O+4e−→4OH−

Overall Formation Reaction of Ferrous Hydroxide

2Fe+O2+2H2O→2Fe(OH)22Fe + O_2 + 2H_2O \→ 2Fe(OH)_22Fe+O2​+2H2​O→2Fe(OH)2​

Subsequent Oxidation Producing Hydrated Iron Oxides (“Rust”)

4Fe(OH)2+O2→2Fe2O3⋅H2O+2H2O4Fe(OH)_2 + O_2 \→ 2Fe_2O_3 \cdot H_2O + 2H_2O4Fe(OH)2​+O2​→2Fe2​O3​⋅H2​O+2H2​O

VCI inhibitors interfere with these reactions by reducing the access of oxygen and moisture to the metal surface while simultaneously stabilizing the surface potential of the material. As a result, corrosion processes are significantly slowed down even at relative humidity levels approaching 100%.

Complete Custom Packaging Solutions with VCI Protection

We design technically optimized packaging solutions that protect products against mechanical damage, moisture, and corrosion during storage and transportation. Each packaging solution is developed individually according to the product dimensions, weight, sensitivity, and logistics chain requirements.

The solution may include rigid cardboard constructions, foam inserts, polyethylene foam separators, and ANTICOfol® anti-corrosion VCI films, which actively protect metal parts against oxidation using VCI (Volatile Corrosion Inhibitor) technology.

How Does the Packaging Design Process Work?

The design process begins with a technical analysis of the product and transportation conditions. We consider mechanical stress, handling methods, climatic conditions, and storage requirements. Based on these parameters, we design the packaging construction and protective elements to ensure maximum product fixation, protection, and logistics efficiency.

The goal is to minimize the risk of damage, optimize the packaging process, and reduce costs throughout the entire supply chain.