US

MX CN

Product Catalog

6 Straight Forward Steps to Get Rust Under Control

By: Vanessa Gilbert

Opening a container and discovering corrosion on metal parts is frustrating. It leads to rework, missed deadlines, warranty claims, and strained supplier relationships. If you are trying to get rust under control, the first step is identifying where corrosion begins.

Corrosion rarely has one single cause. Instead, it often results from a combination of handling practices, moisture exposure, packaging design, and environmental conditions. The good news is that there are practical steps you can take today to control rust and protect your metal assets during storage and shipment.

One of the best places to start is with part handling and packaging practices.

Step 1: Wear Clean Gloves

Get Rust Under Control Are workers using clean gloves? Are they using gloves at all?

Hands and dirty gloves transfer salts, oils, and contaminants directly onto metal surfaces. These residues accelerate corrosion, especially in humid environments.

To get rust under control:

Provide clean gloves at packing stations
Train workers on why glove changes matter
Replace gloves regularly or when visibly soiled

This simple change often produces immediate improvement.

Step 2: Pack Only Clean and Dry Metals

Get Rust Under Control Water and metalworking fluids are two of the most common contributors to corrosion.

If parts are packed while wet or contaminated with machining residues, they are already at risk. Even small amounts of trapped moisture can initiate corrosion inside enclosed packaging.

Before packaging:

Ensure parts are fully dry
Remove metalworking fluids and debris
Verify surfaces are free of contaminants

If you want to control rust long term, clean and dry surfaces are non-negotiable.

3. Pack Metals at the Same Temperature as the Room Temperature

Packaging warm parts is a common mistake.

When hot metal cools inside packaging, condensation forms on the surface. That moisture becomes an immediate corrosion source.

Instead:

Allow parts to cool to ambient room temperature
Avoid sealing warm assemblies
Monitor humidity in packing areas

Reducing condensation risk is a critical step to get rust under control during shipment.

Using VCI Packaging to Control Rust

<br />

If you are using VCI packaging, proper application is essential.

VCI stands for Vapor Corrosion Inhibitor. VCI products release corrosion-inhibiting molecules into an enclosed space. These molecules form a thin protective layer on exposed metal surfaces. As a result, moisture and airborne contaminants cannot react with the metal.

VCI packaging is available in multiple formats, including:

When used correctly, Vapor Corrosion Inhibitor Technology (VCI) helps you get rust under control without applying messy oils or coatings.

The following three steps maximize performance.

Explore ZERUST® Corrosion Control Products

Ready to get rust under control? Browse our full range of VCI packaging, rust preventatives, and corrosion protection solutions designed for industrial environments.

View All Products

Step 4: Tightly Close Packages

VCI only works inside an enclosure.

If bags are left open or loosely folded, protective vapor escapes. That reduces corrosion protection effectiveness.

To control rust with VCI packaging:

Fold or roll bags closed securely
Use tape, ties, or heat seals
Confirm zipper closures are fully engaged
Ensure water cannot enter from above

A properly sealed enclosure is fundamental to success.

Step 5: Use Enough VCI Protection

VCI molecules must reach all metal surfaces.

For densely packed parts or multi-layer dunnage systems, protection may need to be distributed throughout the package.

Consider:

Adding VCI sheeting between layers
Using VCI diffusers for large enclosures
Consulting a packaging engineer for layout design

Adequate VCI placement ensures consistent vapor distribution and helps you get rust under control across the entire load.

Step 6: Prevent Contact with Cardboard and Wood

Get Rust Under Control

Cardboard and wooden pallets often introduce moisture and acids.

Even if your metal parts are clean and dry, direct contact with untreated corrugated or wood can trigger corrosion.

To control rust caused by packaging materials:

Line containers with VCI gusset bags
Separate metal from corrugated surfaces
Use VCI poly film or VCI kraft paper barriers

Shielding metals from reactive materials reduces hidden corrosion risks.

Learn How to Use ZERUST® VCI Products Correctly

Proper application is critical to get rust under control. Review best practices for using ZERUST® VCI packaging and diffusers to maximize corrosion protection performance.

Additional Resources to Help You Get Rust Under Control

These six steps address common corrosion triggers in manufacturing and packaging environments. However, if corrosion continues, a broader evaluation may be needed.

If your goal is to get rust under control across your operation, consider reviewing:

Handling procedures
Wash chemistry
Drying processes
Packaging design
Storage humidity levels

ZERUST® corrosion specialists can assess your current process and recommend a complete prevention strategy tailored to your parts and environment.

Take the Next Step to Control Rust

If you would like to share these best practices with your team, contact ZERUST® Marketing to request a laminated corrosion prevention poster for your shop floor.

If your corrosion issue extends beyond packaging, your ZERUST® representative can:

Conduct a corrosion risk assessment
Recommend VCI packaging or rust preventative solutions
Design a system to get rust under control
Provide samples and validation testing

Proactive corrosion prevention protects quality, delivery timelines, and profitability.

Ready to Get Rust Under Control?

If corrosion is affecting your production, storage, or shipments, our specialists can help. Contact ZERUST® for a corrosion risk assessment and a customized protection strategy designed to control rust and protect your metal assets.

Contact ZERUST®

Vanessa Gilbert

Vanessa Gilbert was ZERUST®’s Marketing Manager for more than a decade, where she helped shape brand strategy and execute integrated campaigns across digital, events, and product marketing. She led numerous product launches, strengthened distributor and customer communications, and supported global growth initiatives for VCI packaging, rust preventatives, and corrosion management solutions. Although Vanessa has since moved on from the company, her contributions played a key role in elevating ZERUST®’s market presence and customer reach.

Related Products

VCI Film

ZERUST® ICT®510-C VCI Film

ICT®510-C VCI Film provides cost-effective and versatile protection against rust and corrosion damage for metal assets in shipping and storage. Additionally, it’s available in ferrous, non-ferrous, and multimetal formulations, as well as various-sized rolls, sheets, tubing, and bags.

Assortment of ZERUST ICT510-C corrosion inhibitor bags for various metal types

ZERUST® ICT® VCI Bags

ICT® VCI Poly Bags provide convenient and proven protection against corrosion damage for metals in shipping and storage. In addition, they are available in ferrous, non-ferrous, anti-tarnish, and multimetal protection types and various zipper, flat, and gusseted sizes.

Metal gears in a box showcasing advanced corrosion protection packaging.

ZERUST® ICT® Gusset VCI Bags

ICT® Gusset VCI Bags provide convenient and proven protection against corrosion damage for metals in shipping and storage. In addition, they are available in ferrous, non-ferrous, anti-tarnish, and multimetal protection types and gusseted sizes ranging from two inches up to 150 inches.

Large metal gear in a ZERUST Flat VCI Bag inside a storage box.

ZERUST® ICT® Flat VCI Bags

ICT® Flat VCI Poly Bags provide convenient and proven protection against corrosion damage for metals in shipping and storage. In addition, they are available in ferrous, non-ferrous, anti-tarnish, and multimetal protection types.

Cast parts packaged in ZERUST Zipper VCI Bags for optimal corrosion protection during storage and shipping.

ZERUST® ICT® Zipper VCI Bags

ICT® Zipper VCI Bags provide convenient and proven protection against corrosion damage for metals in shipping and storage. In addition, they are available in ferrous, non-ferrous, anti-tarnish, and multimetal protection types.

Diverse rolls of corrosion protection film in yellow, blue, and green, suitable for various metals.

ZERUST® ICT®510-C VCI Poly Sheeting

ICT®510-C VCI Sheeting provides cost-effective and versatile protection against rust and corrosion damage for metal assets in shipping and storage. Additionally, it’s available in ferrous, non-ferrous, and multimetal formulations, as well as various-sized sheeting.

Roll of ICT420 for versatile corrosion protection

ZERUST® ICT®420 VCI Kraft Paper Rolls

ICT®420 is an acid-free, pH-neutral, and non-abrasive VCI kraft paper that merges the practicality and cost-efficiency of paper-based packaging with advanced corrosion protection. Consequently, it streamlines the preservation of metals during work-in-progress, shipping, and storage.

Sheet of ICT420-35P illustrating corrosion protection

ZERUST® ICT®420-35P VCI Poly Kraft Paper

ICT®420-35P VCI Poly Kraft Paper is an acid-free, pH-neutral, and non-abrasive kraft paper coated with a one-mil thick ZERUST® ICT® polyethylene layer containing Vapor Corrosion Inhibitors (VCIs). As a result, providing the kraft paper with increased tear and moisture resistance, making it an efficient and cost-effective solution for the corrosion protection of ferrous metals during work-in-progress, shipping, and storage.

Roll of ICT427 for comprehensive metal protection

ZERUST® ICT®427 Premium VCI Paper

ICT®427 is an acid-free, pH-neutral, and non-abrasive premium VCI paper formulated to provide robust corrosion protection for demanding situations—such as high humidity and challenging metal parts during work-in-progress, shipping, and storage.

Roll of ICT432-35P showcasing versatile packaging for metal protection

ZERUST® ICT®432-35P Poly VCI Kraft Paper

ICT®432-35P is an acid-free, pH-neutral, and non-abrasive VCI kraft paper coated with a 3/4 mil plain polyethylene layer. As a result, providing the kraft paper with increased tear and moisture resistance, making it an efficient and cost-effective solution for the corrosion protection of multiple metal types during work-in-progress, shipping, and storage.

Roll of ZERUST ICT430-35SR showcasing its reinforced structure.

ZERUST® ICT®430-35SR VCI Scrim Paper

ICT®430-35SR VCI Scrim Paper is an acid-free, pH-neutral, and non-abrasive VCI kraft paper that’s scrim-reinforced (3/4 mil polyethylene layer and fiberglass scrim). As a result, providing effective corrosion protection with the convenience and affordability of a paper wrapping product with superior strength that avoids ripping and tearing during work-in-progress, shipping, and storage.

Metal gear secured with ZERUST VCI paper for corrosion protection

ZERUST® ICT® VCI Paper Sheets

ZERUST® VCI Kraft Paper Sheets are available in various product types, including ICT®420, ICT®420-35P, ICT®427, ICT®430-35SR, and ICT®432-35P, ensuring an ideal packaging solution. Whether in storage or transit, ZERUST® VCI Kraft Paper Sheets deliver unparalleled performance.

Overview of ZERUST Vapor Capsule series for diverse applications

ZERUST® Vapor Capsules

Vapor Capsules are portable VCI emitter diffusers containing proven ZERUST® Vapor Corrosion Inhibitors (VCI). They protect metals in hard-to-reach areas of control panels, electrical cabinets, or other enclosed spaces from corrosion, even when they are in operation. Additionally, use these VCI emitter diffusers as a supplement to other ZERUST® VCI packaging products for added protection.

Moisture Control Packets

ZERUST® ActivDri™ PWA Packets

ActivDri™ PWA Packets are patent-pending, economical, effective, and easy-to-use dual-action, moisture control Vapor Corrosion Inhibitor (VCI) packets that protect against environmental contaminants and humidity that aggressively corrode metal parts, components, electronics, and electrical components/equipment

Close-up of two ActivDri CAP-50A Capsules side by side

ZERUST® ActivDri™ CAP-50A Capsule

ActivDri™ CAP-50A is a dual-action moisture control capsule designed for enclosed industrial and electrical applications. It incorporates ZERUST® Intelligent Counter-Corrosion Technologies (ICT®) that offer slow and fast-releasing Vapor Corrosion Inhibitors (VCI) that settle on exposed metal surfaces to protect them against environmental contaminants and humidity that aggressively corrode metals during operation, shipping, and storage.

ActivPak material change from brown to white displayed

ZERUST® ActivPak®

ActivPak® is a versatile and powerful fast-acting VCI sachet designed to address flash rust and corrosion concerns in demanding scenarios, including overseas shipping and polluted factory environments.

Overview of current and new ActivPak(LS) showing material update

ZERUST® ActivPak®(LS)

ActivPak®(LS) Flash Corrosion VCI Emitters offer fast-acting corrosion protection in challenging conditions, such as factories, marine environments, waste treatment facilities, and power plants.

ICT420-170 in 1-inch and 2-inch sizes scattered on a clean surface.

ZERUST® ICT®420-170 VCI Chips

ICT®420-170 are acid-free, pH-neutral, and non-abrasive 170# VCI kraft paper sheets cut into 1” x 1” and 2″ x 2″ VCI chips. Additionally, their small, thin shape makes them perfect for protecting critical surfaces within narrow or hard-to-reach areas of parts or equipment or as a supplement to other ZERUST® VCI packaging products for added protection.

Variety of ZERUST Z-PAKs for different corrosion protection needs

ZERUST® Z-PAK®

Z-PAK® is an economical, effective, and easy-to-use vapor corrosion inhibitor (VCI) diffuser packet that can be used alone or, more typically, with other ZERUST® packaging products to provide robust temporary corrosion protection for ferrous metals during shipment, storage, or work-in-progress.

Stack of ZERUST ICT870-OC for corrosion protection

ZERUST® ICT® Open Cell VCI Foam Pad

ICT® Open Cell VCI Foam Emitter Pads are a convenient way to provide added corrosion protection in packaging or an effective way to improve protection in demanding environments and on lightly contaminated parts.