TechMagazín
Is Your VCI Packaging Not Working? 7 Mistakes That Can Cause Corrosion Even in Properly Packaged Products
VCI packaging offers a simple and effective way to protect metal products during storage and transport. It does not require oiling, leaves no greasy film on the surface, and parts can generally be used immediately after unpacking. However, for the protection to work properly, it is not enough to simply place the product in an anti-corrosion bag or wrap it in VCI film. The condition of the product, the appropriate choice of material, and the correct packaging procedure are also important.
What mistakes can significantly reduce the effectiveness of anti-corrosion packaging?
1. Packaging damp or contaminated parts
VCI packaging serves to prevent corrosion. However, it cannot remedy the condition of a product that is already wet, corroded, or contaminated with aggressive substances at the time of packaging.
Particular risks include traces of water, sweat, salts, dust, or unsuitable process fluids. A problem can arise, for example, when a worker handles a metal part without gloves, leaving fingerprints on its surface. These contain moisture and salts that can promote localized corrosion.
Therefore, before packaging, the product must be clean, dry, and cooled to ambient temperature. When handling sensitive parts, it is advisable to wear clean gloves.
2. Insufficiently Sealed or Damaged Packaging
VCI substances are gradually released from the packaging material into the enclosed space, creating a protective environment around the metal. If the packaging remains open, is not sealed properly, or has holes, the protective atmosphere can escape, allowing ambient air and moisture to enter.
Special attention must be paid to sharp edges on products, which can tear the film during packaging or transport. Protective profiles, spacers, or the use of more mechanically resistant film can help. Bags and sacks must be thoroughly sealed in an appropriate manner depending on their design, for example, by heat sealing, adhesive sealing, or by folding the edges tightly and taping them shut.
3. Too Much Space Between the VCI Material and the Metal
The active ingredients must reach the required concentration inside the packaging. If a metal part is placed in packaging that is too large, or if there is insufficient VCI material relative to the package’s volume, it may take longer to create a protective environment, or the protection may be inadequate.
It is therefore advisable to adjust the size of the pouch, bag, or film to fit the packaged product. For large crates, machine assemblies, and palletized units, it may be necessary to supplement the protection with VCI paper, VCI emitters, or other anti-corrosion elements. The specific solution should always be based on the product’s dimensions, storage duration, and shipping conditions.
4. Incorrect Choice of Protection for a Given Metal
Not all metals react to the surrounding environment in the same way. Steel, cast iron, copper, brass, aluminum, and galvanized surfaces have different protection requirements. Therefore, VCI material intended primarily for ferrous metals may not automatically be suitable for all non-ferrous metals and their alloys.
Before selecting packaging, it is important to precisely identify the material to be protected. For products composed of multiple metals, it is necessary to choose a solution suitable for combined, or multimetal, use. Choosing the right ANTICOfol® VCI film or MULTIferro® anti-corrosion paper helps prevent not only red rust on steel but also oxidation and changes in the appearance of non-ferrous metals.
5. Combination with Unverified Packaging Materials
The result is not influenced solely by the VCI packaging itself. Inside the combined packaging, there may be cardboard, wooden components, foam, adhesives, labels, or fastening materials. Some of these may contain elevated moisture levels or release substances that impair metal protection.
Potential risks include, for example, insufficiently dried wood and cardboard, or untested materials placed in close proximity to a sensitive surface. For export and long-term packaging, it is therefore advisable to evaluate the entire packaging system, not just a single film or bag. If you are unsure about the compatibility of individual materials, it is advisable to test the proposed composition in advance.
6. Packaging a Hot Product
Metal parts are often hotter than the surrounding environment after machining, washing, or other manufacturing operations. If such a product is immediately sealed in packaging, moisture condensation may occur as it cools. This creates an environment inside the packaging that increases the risk of corrosion.
Parts should therefore be packaged only after their temperature has equilibrated with the ambient environment, in a dry and, if possible, stable operating environment. For export, ocean transport, or significant temperature fluctuations, VCI protection can be supplemented with barrier film, desiccant packets, and a moisture indicator, depending on the specific conditions.
7. Improper Storage of VCI Packaging Before Use
Even unused VCI material requires proper storage conditions. If a roll of film or a package of paper remains open for an extended period, exposed to high temperatures, direct sunlight, humidity, or airflow, it may gradually lose its effectiveness.
It is recommended to store VCI packaging in its original sealed packaging, in a dry place, and away from heat sources. Only the amount needed for the current task should be removed, and the remaining material must be resealed. At the same time, it is necessary to observe the recommended storage period specified by the manufacturer.
Corrosion protection works as a system
A reliable result is not achieved by a single packaging material alone. The entire process is crucial—from the cleanliness of the product, through the selection of the correct VCI solution, to the sealing of the packaging, storage, and shipping conditions.
If corrosion occurs even in packaged products, this does not necessarily mean that VCI technology is not working. The cause may be a minor error in the packaging procedure, an inappropriate combination of materials, or conditions that the original solution did not account for.
Bropack Solution helps customers design anti-corrosion packaging tailored to the specific product, type of metal, duration of protection, and mode of transport. The solution may also include packaging validation and testing under demanding conditions. A properly designed system helps reduce corrosion, the number of complaints, and the costs of cleaning and repackaging.
Do you need to verify whether your current anti-corrosion packaging is properly designed? Contact us. We’ll help you select the appropriate materials and procedures for the safe storage and transport of your products.