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

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

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

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:

• VCI gusset bags
• VCI film sheeting
• VCI Kraft paper
• VCI bags
• VCI diffusers and emitters

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.

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

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.

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.

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.

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