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- What is the shelf life of Zerust/Excor ICT products?
Most Zerust/Excor ICT products have a shelf life of up to two years when the product is stored in an external bag or box, out of direct sunlight and under shelter.
- How long does Zerust/Excor VCI corrosion protection remain effective?
Most Zerust/Excor ICT products have an in-life of up to five years when protecting clean metal surfaces and when used as recommended by Zerust/Excor representative.
Corrosion protection lasting more than 10 years is possible if the packaging is designed such that the Zerust/Excor active substances cannot escape from the packaging. The more airtight the transport packaging is, for instance using a sealed wooden or metal box, the longer the corrosion protection lasts if the packaging is required to provide effective protection for over two years Zerust/Excor should be involved in its design.
- How much Zerust/Excor VCI must be placed in the packaging?
The component part or volume needing protection must be completely enclosed by a Zerust/Excor active material. If complete Zerust/Excor packaging is being used no additional VCI material is required. However, this also depends on the nature of the packed merchandise. If there are difficult to access areas, it is advisable to use Zerust/Excor VCI protection.
- Can Zerust/Excor bags be reused?
All Zerust/Excor products can be reused if they are dry, clean, and undamaged. The material specific differences between VCI film, foam, and paper. If the bags are still in good condition without holes or tears. Bags that have an excessive number of holes or tears, have large holes or tears, or have begun to crack or lose strength due to excessive exposure to direct sunlight will not provide adequate corrosion protection and should not be reused.
- How well sealed does Zerust/Excor VCI packaging have to be?
The more tightly sealed the packaging the better the corrosion protection. Damage to the film wrapping can be sealed with adhesive tape. It is not necessary to extract air or weld the film together. However, water must be prevented from penetrating the packaging.
If the rip is small, you can cover the rip or hole with a high quality piece of tape that is designed to adhere to low energy surfaces like polyethylene (please contact Zerust's Technical Service Department for more information). Or, you can fold over and staple the area shut and then seal over the holes made by the staples with the recommended tape. If you have a large rip that you cannot close easily with tape or staples, you should replace the bag with a new one. The best seal is always a heat seal.
- Does an effective distance or direction have to be considered?
Almost all Zerust/Excor products are active on both sides, i.e. either side can be oriented toward a metal surface. This increases the effectiveness of the protection. No attention needs to be paid to a possible effective distance.
- What happens after VCI packaging has been removed?
After removal of Zerust/Excor packaging, the VCI substances present on the metal surface disperse within one to two hours.
- Is VCI paper better than VCI film? What are the differences between them?
Both products contain identical Zerust/Excor VCI substances, tailored to the different substrates. The differences are material specific: paper releases VCIs more rapidly than VCI film but does not retain a depot for as long. VCI film acts as a barrier to water vapor, whereas dry paper readily absorbs moisture. The application should be oriented toward the goods to be protected and the details of the manufacturer's packaging operations. A Zerust/Excor representative can advise you on this.
- Can I use my Zerust/Excor ICT bags in conjunction with oil coatings?
A light oil coating on the metal part is fine to use with Zerust/Excor ICT bag. A heavy oil coating may affect the performance of the ICT bag by keeping the corrosion inhibiting vapor molecules from reaching the metal surface. Please contact Zerust/Excor to determine the suitability of the oil and application.
- How do I know which of your products to use for my type of metal?
Ferrous: Iron, steel and cast iron metals are protected using Zerust/Excor Ferrous Packaging.
Non-Ferrous: Aluminum (and aluminum alloys containing copper and/or manganese), copper, brass, bronze and fully galvanized steel are protected using Zerust/Excor Non-Ferrous Packaging.
Multimetal: Products that contain combinations of the Ferrous and Non-Ferrous metals listed above can be protected Zerust/Excor Multimetal Packaging.
Silver: Is protected from tarnishing with clear Zerust/Excor Silver Packaging. Although Zerust/Excor products are usually sold in the above standard colors to help our customers distinguish they type of metal protection they are using, we are able to custom produce most Zerust/Excor products in any color of your choice.
- How can I tell whether my products require VCI protection?
In case of doubt we advise consulting Zerust/Excor representative. Zerust/Excor possesses wide-ranging testing capabilities which quickly enable us to determine the optimum method of protecting a given part. With small parts customers can conduct their own tests. Try packing identical parts at the same time and under identical conditions, one part in normal film and one in Zerust/Excor film. Next store these parts for several days undercover but open to the elements. If the part packed in normal foil shows signs of corrosion, while the one packed in Zerust/Excor film shows none, it can be assumed that the part requires VCI protection.
- My product has been produced, but I have to wait for "Quality Control Testing". What is this?
Each order is tested by Zerust's Quality Control Department to ensure that it meets our high quality standards for corrosion protection. Part of the quoted lead time is used for this quality testing. If you'd like to waive this quality testing on your product, you must sign a Quality Testing Waiver Request form. Please contact us for more information.
- Does NTIC conform to ISO Standard?
Yes, NTIC's management systems conforms to the ISO 9001 Quality Management Standard.
- Can used Zerust ICT films be recycled?
Yes. Zerust ICT films made of polyethylene and polypropylene have been recycled for years. Zerust ICT products, themselves, are produced using only virgin materials to assure a high level of quality and consistency for our customers.
- How can I purchase Zerust ICT products?
To purchase Zerust ICT products, you can either call 1-800-328-2433 or 1-763-225-6600 to speak with a customer service representative, or send an email to email@example.com.
- How do I know that I am measuring length, width, and height correctly?
For flat bag, sheet, sleeve, and round bottom bags.
Width is measured from edge to edge. If it is a slit seal bag, measure inside seal to inside seal or inside seal to fold. Bag length is measured from top of bag to top of bottom seal or fold. Sleeve or sheet length is measured from cut edge to cut edge.
- What are NTIC's standard lead times for Zerust ICT non-stocked products?
NTIC's standard lead times vary depending on the product and quantity. For specific product inquiries, please contact out Customer Service Team at 1-763-225-6600.
- What is corrosion?
Corrosion is the chemical or electrochemical reaction between a material, usually a metal, and its environment that produces a deterioration of the material and its properties. Usually corrosion is the oxidation of metals in the presence of water or water vapor, and is known as rust (iron, steel) while rust (galvanized steel), and other terms of corrosion failures such as tarnish, pitting and flaking.
There are many different types of corrosion including atmospheric corrosion, corrosion in waters, corrosion in soils, corrosion in chemical environments, mechanically assisted corrosion, high-temperature corrosion, microbiologically influenced corrosion, etc. From an economic safety and aesthetic standpoint, atmospheric corrosion is one of the most important types of corrosion. Atmospheric corrosion is enabled by atmospheric humidity and stimulated by pollutants in the atmosphere such as acid gases [sulfur dioxide (SO2), hydrogen sulfide (H2S), and carbon dioxide(CO2)], nitrogen oxides (NO and NO2), ozone (O3), and salts (chlorides and sulfides).
- How is corrosion prevented?
There are many different ways to prevent corrosion, including modifying the atmosphere by dehumidification, nitrogen purge, evacuation, etc, and creating a barrier on the metal surface to prevent the permeation of moisture. This barrier can be formed by liquid coating, such as oil, or via packaging products that contain VCI or Vapor Corrosion Inhibitors. Vapor Corrosion Inhibitors work by diffusing corrosion inhibiting molecules from a source (packaging film or paper for example) to metal surfaces. These molecules settle on metal surfaces and form a protective corrosion inhibiting layer that inhibits the electro-chemical reactions that cause corrosion to form.
NTIC combines the use of vapor corrosion inhibitors with material sciences and process management expertise to implement custom corrosion solutions for a customer or throughout an entire supply chain. We call this our Zerust/Excor Integrated Corrosion Technologies or ICT.
- How do Zerust ICT products prevent corrosion?
Zerust ICT products prevent corrosion in several ways:
1. By acting as a protective barrier from external dirt and abrasion, and also as a barrier to help block the diffusion of corrosive acid gas pollutants from outside of ICT packaging material (such as sulfur dioxide or hydrogen sulfide) - thereby preventing contact of these corrosive gases with enclosed metal surfaces.
2. By vapor corrosion inhibitors that passivate the electron flow between the anodic and cathodic areas on metal surfaces and interrupt the electro-chemical corrosion process.
3. By adding water repulsion properties to the metal surface, which inhibit water from permeating the metal surface and providing the electrolyte for corrosion reactions.
The vapor corrosion inhibitor portion of Zerust ICT products is made of proprietary chemical formulations that are invisible, odorless, non-toxic, non-reactive, non-flammable and non-allergenic. These chemical formulations release a corrosion inhibiting vapor that diffuses throughout an enclosure that either contains ICT formulations or is made from ICT materials, and settles on exposed metal surfaces to form a microscopic corrosion inhibiting layer.
This protective layer will remain on the surface of the metal as long as there is no significant, continuous exchange of air within the enclosure. Ideally, there should be less than one air exchange per day (for example, when an electrical cabinet or package is opened briefly and occasionally). Once the metal part is removed from the enclosure, the corrosion inhibiting layer is no longer kept in place by equilibrium with the ICT source, and it dissipates from metal surfaces (typically within about an hour) leaving the metal part clean, dry and corrosion-free.
The vapor diffusing properties of our corrosion inhibiting formulations offer an important advantage over conventional inhibitor coatings since the traces of these gas molecules penetrate into inaccessible crevices, gaps, and slots, reaching the surfaces of complex-shaped articles that are difficult to coat. They are adsorbed onto the surface of the metal to form a corrosion inhibiting protective layer that is just a few molecules thick. Zerust ICT products may also include acid gas absorbing chemicals in the packaging material to act as a barrier and add another dimension to the protection of the metal content. These "scavenging" chemicals react and neutralize the polluted air that may diffuse through the Zerust ICT material. Also used are various combinations of physical barrier properties that optimize the corrosion prevention and physical protection needs of our customers. These may range from plain low density polyethylene (LDPE) material to combinations of higher strength, higher tear resistance, higher resistance to sunlight or UV, static charge dissipation, and lower diffusion for moisture or acid gas molecules.
Zerust ICT products offer corrosion protection without having to be in direct contact with or coated onto the parts that are being protected. Metal parts merely need to be enclosed in or with a Zerust ICT product (where airflow is minimized) for protection to occur. With Zerust, it is no longer necessary to apply messy oils, greases and other corrosion protection compounds and incur the cost of their removal.
- How does moisture in a package affect the performance of Zerust ICT packaging products?
Depending on the design of the corrosion prevention solution, some Zerust ICT packaging products may be produced from low and high density polyethylene resins and to a large extent, are resistant to vapor penetration. Some atmospheric moisture will eventually find its way into a closed package. The presence of moisture in a package can be expected during shipments across areas of high humidity.
When moisture permeates through the Zerust ICT plastic packaging products (flexible and rigid) the moisture is affected by the vapor corrosion inhibitors that are present in the ICT product. The Zerust ICT product still inhibits corrosion despite a low level of moisture passing through the plastic. Corrosion problems arise when moisture is allowed to enter a package unimpeded by the Zerust ICT packaging products, e.g. through an incorrect closure or a significant hole in the package. When there is a significant hole in the package, for example, the corrosion inhibiting molecules are allowed to escape, breaking up the protective corrosion inhibiting molecular layer that had formed on the surface of the metal. An unimpeded airflow into the package must be avoided.
- What can be anticipated when parts that are already corroded are packaged in Zerust ICT products?
When parts in an already corroded condition are packaged in Zerust ICT products, the corrosion process is slowed. However, our packaging products cannot remove corrosion that has already formed.
- What can be anticipated when wet parts are packaged in Zerust ICT products?
When wet parts are packaged in Zerust ICT products, a certain amount of corrosion can be anticipated to take place. The amount of corrosion will be a function of the time it takes for the active corrosion inhibiting molecules to saturate the package enclosure, the corrosion inhibiting effectiveness of the designed ICT system, the amount of moisture on the part, and the pH and contamination of the water itself.
- How long can parts be expected to remain free of corrosion after removal from a Zerust ICT package?
Tests performed with electron spectroscopy for chemical analysis (ESCA) show that 2-4 hours after a steel panel is removed from a Zerust ICT package, all traces of the corrosion inhibiting molecular layer are gone from the surface of the part.
The period of time before one can expect corrosion to occur on a part depends on the cleanliness of the part and the environment around the part (relative humidity, presence of pollutants or wood, temperature, etc.)
- How long does it take for the interior of a Zerust ICT package to reach its designed corrosion prevention capability?
The time required for active corrosion inhibiting molecules from ICT product to saturate a package is a function of the volume and temperature of the package. Protection begins as soon as corrosion inhibiting molecules reach the metal surfaces, and maximum protection is achieved when the entire environment of the package is saturated with the corrosion inhibiting molecules.
- Does Zerust ICT have any effect on electrical or electronic components?
Test data show that Zerust ICT products do not adversely affect electrical and electronic components. In fact, the corrosion inhibiting molecules actually help improve the reliability of electrical and electronic components by preventing corrosion that is too small to be seen by the naked eye. It is absolutely safe to use Zerust ICT packaging products to prevent corrosion of any instruments, devices and equipment which contain electric and electronic components.
- Are there any inhalation or contact risks with Zerust products?
Test data and review of corresponding scientific literature show that there are no inhalation or contact risks with Zerust ICT products. Zerust ICT products have been reviewed and cleared for use by factory, government and military personnel by the appropriate occupational health departments, including those of all major automotive manufacturers worldwide.
- What is the best way to store Zerust ICT products before use?
NTIC recommends keeping Zerust ICT packaging products clean, out of direct sunlight and away from water while in storage. Simply keep the products in their original shipping cartons, bags or containers. If a carton is opened, cover the products with a sheet or bag of plain polyethylene to protect the products from dust and dirt. It is also recommended that Zerust ICT products be stored in moderate temperatures, typical of most indoor workplace conditions to minimize exposure to excessive temperatures and outside elements such as direct sunlight, rain or snow. Storing Zerust ICT products correctly ensures that the products will meet or exceed their estimated shelf life.
- What is VCI and VCI film?
VCI stands for Volatile Corrosion Inhibitors. Zerust applies VCI technology to inhibit corrosion on metal. VCI film is packaging that generally consists of polyethylene film that has been impregnated with chemical formulations that are unique to each manufacturer. While the underlying formulations can vary significantly, the finished products all function similarity in that they release very low concentrations (typically in parts per ten-thousandth) of invisible corrosion inhibiting vapors into the surrounding air. The vapor molecules subsequently condense onto exposed metal surfaces and form a molecular corrosion shield that can protect against rust and other forms of corrosion for up to five (5) years, and even longer in some cases. When the VCI packaging is later removed, all vapor corrosion inhibiting molecules rapidly evaporate. This leaves the metal parts clean and ready for immediate use.