6 Straight Forward Steps to Get Rust Under Control

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

wear clean gloves when handling parts to control rust 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

pack only clean dry metals to control rust during storage 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

pack metals at room temperature to prevent condensation corrosion

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

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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.

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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

use enough VCI protection to get rust under control

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

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.

Read the Guide

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 served as Marketing Manager at ZERUST® for more than a decade, where she played a key role in shaping the company’s global brand strategy and executing integrated marketing initiatives across digital platforms, trade shows, and product marketing.

During her time at ZERUST®, Vanessa led numerous product launches and marketing campaigns that supported the growth of the company’s corrosion prevention portfolio, including Vapor Corrosion Inhibitor (VCI) packaging, rust preventative coatings, and corrosion management solutions. She worked closely with sales teams, technical experts, and international partners to ensure consistent messaging and effective market positioning across diverse industries and regions.

Vanessa was instrumental in strengthening communication with distributors and customers, helping to improve engagement, brand awareness, and overall market reach. Her efforts contributed to expanding ZERUST®’s presence in key industries such as manufacturing, transportation, and industrial supply chains, where corrosion prevention plays a critical role in protecting valuable assets and maintaining operational reliability.

With a strong understanding of both technical products and customer needs, Vanessa helped bridge the gap between product innovation and market adoption. Her work focused on delivering clear, value-driven messaging that highlighted the performance, reliability, and long-term benefits of ZERUST® solutions.

Although Vanessa has since moved on from ZERUST®, her contributions left a lasting impact on the company’s marketing strategy and global growth. Her work continues to influence how ZERUST® communicates its value and supports customers in implementing effective corrosion prevention solutions.

Explore ZERUST® Corrosion Prevention Solutions

Discover proven technologies designed to protect metal assets, improve reliability, and support long-term performance.

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