What to Do When Rust Prevention Fails?

In manufacturing, companies invest significant time and resources into protecting metal assets from corrosion during storage and transportation. However, even well-designed protection programs can sometimes fail. When this happens, many teams begin asking the same question: What to do when rust prevention fails? Many operations rely on volatile corrosion inhibitor (VCI) packaging, rust preventative coatings, desiccants, or a combination of these methods, yet corrosion can still occur if underlying process issues are present.

When corrosion appears, many companies immediately assume the rust prevention product itself is responsible. As a result, they begin searching for a different brand or type of rust preventative product in hopes that the new solution will fix the problem.

However, the more effective approach is to investigate the root cause of the corrosion issue before changing products.

Start With Root Cause Analysis When Rust Prevention Fails

When rust prevention fails, the first step should always be investigation. Understanding the factors that caused corrosion to develop allows manufacturers to implement a solution that actually addresses the problem.

Many companies are surprised to learn that the corrosion was not caused by the VCI packaging or rust preventative coatings they used. Instead, the issue often originates somewhere else within the manufacturing or handling process.

Common causes include:

• Improper packaging or sealing methods
• Residues left on metal surfaces after cleaning
• Contaminated metalworking fluids
• Environmental humidity or temperature changes
• Handling practices that introduce moisture or salts

Without identifying the root cause, simply changing corrosion inhibitors or packaging materials may only mask the problem rather than solve it.

Examine the Entire Manufacturing Process

Effective corrosion prevention requires evaluating the entire manufacturing process. Corrosion rarely occurs because of a single factor. Instead, it is often the result of several variables interacting across production, cleaning, packaging, and storage.

Manufacturers should review the full lifecycle of their metal parts, including:

• Raw material sourcing
• Machining and forming operations
• Metalworking fluids and coolants
• Washing and rinsing procedures
• Drying methods before packaging
• Packaging materials and sealing practices
• Storage environments
• Transportation and shipping conditions

For example, many manufacturing operations rely on metalworking fluids such as cutting fluids, coolants, wash detergents, and final rinse solutions. The chemistry of these fluids and the quality of the water used to mix them can significantly influence corrosion risk.

If fluid concentrations change or contaminants accumulate, parts may enter packaging already vulnerable to corrosion.

Evaluate Process Changes That Cause Rust Prevention to Fail

Another important factor to consider when determining what to do when rust prevention fails is whether something in the process has recently changed.

Manufacturing environments evolve over time. Suppliers may change, materials may be substituted, and production parameters may be adjusted to improve efficiency or reduce costs. Even small modifications can influence corrosion performance.

Examples include:

• Switching to a different metal alloy
• Changing a metalworking fluid formulation
• Increasing storage time before shipment
• Altering packaging design or materials
• Modifying wash chemistry or rinse water quality

When these types of changes occur, the rust prevention system that previously worked may no longer provide the same level of protection.

What to Do When Rust Prevention Fails in Manufacturing

If your team is trying to determine what to do when rust prevention fails, working with corrosion specialists can help identify the true cause of the issue.

ZERUST® implements a structured root cause analysis methodology called Z-CIS® (ZERUST® Corrosion Identification System). This approach evaluates the entire corrosion system, including manufacturing conditions, material compatibility, packaging methods, and transportation environments.

ZERUST® technical specialists can assist with:

• Root cause corrosion analysis
• On-site or virtual corrosion audits
• Laboratory testing and evaluation
• Packaging design recommendations
• Process adjustments that improve corrosion protection

By taking a systematic approach, manufacturers often discover that relatively small process improvements can significantly reduce corrosion risk.

Improve Results After Rust Prevention Fails

When rust prevention fails, the solution is rarely as simple as switching products. Corrosion is influenced by many variables throughout the manufacturing and supply chain process.

Instead of immediately replacing corrosion inhibitors or packaging materials, manufacturers should focus on identifying the root cause of the failure and addressing the underlying issue.

Many companies that implement the Z-CIS® methodology experience significant improvements in corrosion control. In some cases, operations achieve nearly 100 percent rust-free shipments while reducing costs associated with rework, rejected parts, and customer claims.

If your organization is dealing with corrosion challenges or trying to determine what to do when rust prevention fails, ZERUST® corrosion specialists can help evaluate your processes and recommend practical solutions tailored to your manufacturing environment.

Michael Malczewski

Michael Malczewski has been part of the VCI industry for more than 20 years and currently serves as Sales Director at ZERUST®. Based in the greater Chicago area, Michael supports customers throughout the north central United States, helping manufacturers implement corrosion prevention programs that protect valuable assets and improve operational efficiency. With his extensive knowledge of VCI technology and customer-focused approach, he provides tailored solutions across a wide range of industries, making him a trusted partner for long-term corrosion management strategies.

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