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  • A premier metal casting company located in Indiana was using a competitors VCI and were receiving their VCI products through a distributor located in Wisconsin. They reached out to Zerust®, as they ran into issues with their VCI supplier and distributor providing custom sized VCI in a reasonable timeframe. There were experiencing long lead-times for the product to be made and then had to wait additional time for the products to be shipped from the distributor’s warehouse in Wisconsin to their facility in Indiana.
    • Inventory Storage
    • Land Shipment
  • VCI Packaging
    The stamping company approached the VCI supplier they were using for help; that supplier had plenty of products but no solutions. On the recommendation from its sister stamping plant in Mexico, the plant contacted Zerust®. Zerust® immediately demonstrated a comprehensive approach to corrosion control. Numerous potential contributors to corrosion were identified and investigated by Zerust’s laboratory, e.g. chlorinated paraffins in the stamping fluid, water quality, pH and bacteria control, and cardboard contact in packaging. The scientific process was invaluable in resolving the corrosion problem.
    • Inventory Storage
    • Land Shipment
    • Work In Progress
  • Corrosion Causing Contaminants
    A large automotive transmission manufacturer located in the Midwest was experiencing rust and corrosion on torque converts during the storage and shipment to their end-user. They contacted Zerust® as they needed a corrosion control company to visit their facility and identify what was the reason for their parts corroding during the storage and shipment.
    • Inventory Storage
    • Land Shipment
    • Work In Progress
  • Reinforced Paper
    An industrial supply and packaging distributor looked to Zerust® for recommendations to help them better serve their customer, the end-user, a large steel processing company located in the Midwest. The steel processing company was looking for a more efficient and cleaner way to protect stacks of steel sheets from corrosion when they were stored in their warehouse and they wanted to move away from liquid rust preventative coatings. They were looking for a Vapor Corrosion Inhibitor (VCI) packaging option that was strong, durable, and excellent at preventing corrosion for up to a year in storage
    • Inventory Storage
    • Land Shipment
    • Work In Progress
  • VCI Pipe Sections
    A global offshore fabrication facility located close to the Gulf of Mexico needed to protect their pipe section inventory during the Oil and Gas downturn. This facility was accustomed to experiencing high levels of corrosion on their inventory. They were in need of an easy-to-use solution that allowed for minimal labor during the installation and removal process, while avoiding the deterioration of their expensive assets. They contacted Zerust® as they were referred by another major pipe fabricator that used Zerust® ICT® VCI Pipe Strips without any corrosion incidents for many years.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
    • Long Term Storage
  • VCI Cosmoline
    Newly manufactured rotary drills bits shipping from the U.S. to Saudi Arabia and are required to have no corrosion upon arrival and inspection by the customer. Cosmoline was the current corrosion prevention product being used, and the application process involved dipping the heavy and large awkwardly sized drill bits into a tank of the Cosmoline. The operators did not like the odor and the mess that it created during the removal from the dip tank.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
    • Long Term Storage
  • vci foam sheeting
    A global supplier of brake, chassis and drive components to the automotive industry was experiencing rust issues with components shipping within North America. Their method of protection when Zerust® was called in, consisted of the use of a competitor’s open cell VCI Foam layered within the dunnage. A local Zerust® representative visited the customer’s facility to review the issue the customer was having. During this visit, it was determined that the competitor’s VCI Emitter presented several issues regarding automotive corrosion protection requirements of clean, dry and corrosion free parts. The foam was “wet” with Vapor Corrosion Inhibitor which was displacing onto the surface of the components and was not providing enough Volatile Corrosion Inhibitor to protect the parts.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
    • Long Term Storage
  • VCI gearboxes
    A large steel roll supplier that recently shut down their facility contacted Zerust®, as they were looking for a corrosion control company to assist with the preservation of their assets. They were looking to preserve these assets in case the facility opens again, or should they need to transfer equipment to their other plants across the US. They were concerned about preserving the working and backup rolls, large gearboxes and electrical boxes along manufacturing line.
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • VCI gearbox
    A premier supplier of high-quality engineered equipment for the waste water industry faced challenges with shipping new products to a Southeast Asia country. They needed a solution to protect very large drive housings from rust and corrosion during their long ocean transit. Each drive housing also contained an enclosed worm gearbox which required additional protection as well since they would not be filling it with oil prior to shipping. They were looking for rust inhibiting solutions to protect the entire outer drive housing, which was 80” in diameter as well as the inner components of the worm gearbox. All components in question were ferrous metals made from cast iron or high carbon steel and are known to be highly susceptible to rust from exposure to ocean atmosphere.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
    • Long Term Storage
  • Corrosion Control Company
    A company that engineers and builds sand core production machines for various industries delivered machines to a foundry customer. Unfortunately, the machines rusted because the customer waited to install them and left them outside without proper rust preventatives. The customer asked the equipment manufacturer to remove the corrosion and apply a corrosion prevention coating that would protect the metal from rusting while indoors until they could be installed.
    • During Operation
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • dry to touch light rust preventative oil
    A premier supplier of high quality industrial and home improvement tools – hand files and rasps in Mexico faced corrosion protection concerns with shipping new products to its distributors in the US and nationwide. They needed a corrosion solution to extend the integrity of their files for a longer period and be able to deliver rust free products to their distributor chain. They contacted Zerust®, as they were looking for a corrosion control company to assist with extending the rust protection of their final product. The customer was receiving claims on a regular basis and the rust preventatives they were using were not performing as they needed any more. The customer was absorbing a substantial cost of corrosion associated with returned shipments and loss of sales to competitors. They were looking for rust inhibiting solutions to protect individual cases with 12 files and the goal they set is to find a better rust preventative that can protect the files from rust in a salt fog chamber for 60 + hours.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
  • Rust Preventative
    The world’s largest construction equipment manufacturer contacted Zerust®, as they were looking for a corrosion control company with expertise in protection against rust and corrosion. They needed to solve a corrosion problem with oil pans made in Mexico that were experiencing rust during the shipment to the United States. The issue arose at the border, as US customs were unpacking every piece to inspect its contents. After the inspection, the VCI packaging was not properly replaced, causing the equipment to corrode during transit.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
    • Long Term Storage
  • wax corrosion inhibitor
    A globally recognized manufacturer of pressure control equipment used in the oil and gas industry – gate valves, ball valves, surface and subsea BOPS, choke and kill manifolds, etc. were experiencing heavy corrosion on equipment being stored in their warehouse and during overseas shipments. They tried several grease and wax coatings to help mitigate the issue, but continued experiencing rust. An enormous amount of time and money was lost due to refurbishing and scrapping pieces of badly corroded equipment. They contacted Zerust®, as they were looking for a corrosion control company to assist with protecting the parts while in storage and shipment.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
    • Long Term Storage
  • VCI bags
    A Tier 1 automotive powertrain manufacturer started producing a new part that required Zerust® VCI protection during shipment to the end user. The manufacturer had an existing supply of Zerust® 2 mil Ferrous Yellow VCI bags. However, the VCI bags were too large for their new application and they found their employees were spending extra time on close winding the excess material into a twist, to seal the VCI bag closed in the returnable tote. They contacted Zerust® with the goal of finding a streamlined solution to make it easier for their employees to pack and close the VCI bags, allowing them to save on time and material cost.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
    • Work In Progress
  • long term engine storage
    A major agricultural machinery and diesel engine manufacturer approached Zerust® with a storage challenge. They had purposely produced a surplus of engines to meet anticipated demand. They required the engines to be stored rust-free for at least two years until they were needed for their long-term production use. Over 2,000 engines were to be stored in a non-climate controlled warehouse where the temperature and humidity varied. They were concerned this environment would cause rust. The storage location and ultimate destination of the engines were also located in two different countries to add to the complexity of the project.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
    • Long Term Storage
  • Music String Envelopes
    Music strings are shipped all around the world and are subjected to humidity, temperature changes, and long storage times which can cause corrosion. Strings are made of sensitive steel, phosphorus bronze, brass, and copper metals with proprietary coatings and require packaging that integrates corrosion protection. A leading music string manufacturer was using a competitor corrosion inhibitor with reoccurring corrosion issues. When they experienced the loss of an entire shipping container of strings to corrosion they called the Zerust® technical services team for help.
    • Export Shipment
    • Inventory Storage
    • Land Shipment
    • Long Term Storage
  • VCI Film Aluminum
    A large power generator manufacturer located in Minnesota was experiencing corrosion issues with their aluminum drip pans supplied from India. Due to the time spent on an ocean liner, the drip pans would arrive at the manufacturer in Minnesota with corrosion along the edges of the pan. The manufacturer needed this corrosion issue resolved, however they could not use any kind of oil rust preventative and were in need of a dry corrosion protection solution.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
  • VCI Coil
    A large aluminum rolling mill needed to supply aluminum coils to a high-end cookware manufacturer and were required to provide 100% corrosion-free shipments. Since the aluminum was going to be made into cookware, they required a safe alternative to typical rust preventatives such as oils and coatings to protect the coils from corrosion during storage and shipping.
    • Inventory Storage
    • Land Shipment
    • Long Term Storage
  • Outdoor Corrosion Protection
    A major supplier of equipment to the mining industry had a sharp increase in demand for their large-scale rock crushing components, they needed to be able to ramp up production and store them on-site for up to two years. They no longer had sufficient inside storage for the additional inventory and needed to be able to store them outside exposed to the elements.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
  • Waste Water Corrosion Protection
    A water treatment plant wanted to find a corrosion inhibiting solution to protect electrical components and control panels at their facility. With the extreme corrosive environment at their facility, they found themselves replacing controllers that were no longer operational due to corrosion every year. Not only are these controllers expensive, but the cost from the downtime while these controllers were being replaced was becoming a very costly expense for the plant.
    • During Operation
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • vci emitter diffusers
    A major manufacturer of military aircrafts needed fuselage electronics, tooling sets, wing sections, and even complete aircrafts to arrive without corrosion. However, when using oils and greases to protect metals, the manufacturer’s engineers noticed corrosion in various areas. After working with the Zerust® corrosion management team, the company applied Zerust® corrosion prevention solutions to stop corrosion during shipment. Using Zerust® helped them proactively meet their stringent contract and industry standards while safely managing corrosion.
    • During Operation
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • Rust Remover
    A leading manufacturer of service parts found over half of the inventoried steel parts rusting due to improper packaging and a leaky roof. Since inventory was tight, the company contemplated shipping these less than perfect parts out to private and municipal customers and, in so doing, run the risk of disappointing its customers.
    • During Operation
    • Work In Progress
  • Cold Seal VCI Film
    A leading manufacturer of axles and other automotive parts wanted to find a faster, more efficient corrosion inhibiting packaging solution to protect gears, axles, and differential units during service and inter-plant shipment. Typically, these parts are wrapped with VCI film and secured with tape. However, this process is very labor intensive, taking an average of four minutes to wrap and tape a single part.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • Anti-Tarnish VCI Film
    An OEM service and parts organization needed to distribute 40,000 sensors crucial to the operation of the equipment they sold over the last 10 years as part of their warranty coverage. These parts were in inventory storage for many years and were no longer produced. When samples of these sensors were inspected before shipment, the sensors were found to have black copper oxidation on exposed areas of the gold plated contact leads. All 40,000 sensors were deemed unusable for their purpose and no replacement was found.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • VCI Packaging
    A contract manufacturing and packaging house were looking to reduce costs. They were hand-packing thousands of parts a day in VCI kraft packaging paper and sealing them with tape. Unfortunately, there were no machines available to make the process more efficient that was compatible with VCI kraft packaging paper.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • Corrosion Control
    An international crating company needed to find a better corrosion control solution than their current method of desiccants with sealed barrier packaging. Finding an effective solution was crucial to the company since their worldwide shipments pass through temperature and humidity swings that can accelerate corrosion. The company was unhappy with the desiccant-barrier packaging method because the desiccants became saturated and needed to be replaced at least every six months, increasing material and labor costs. Also, the barrier packaging frequently became punctured and moisture rapidly filled the desiccants making them ineffective. Once the desiccants became saturated, they became a source of corrosion by emitting moisture back into the package.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • Marine Corrosion Protection
    Corrosion damage is especially prevalent in marine environments, where salty air, often combined with high temperatures and humidity levels make corrosion prevention a challenge. A major naval organization faced serious corrosion issues on ship aids to navigation, bail-out pump motors, and small engines. Corrosion in these areas cause malfunctions and reliability problems that are not only costly to repair, maintain, or replace but also puts the people that rely on this equipment at risk. The naval organization’s efforts to combat corrosion included methods such as oiling, scraping, and painting. All of these methods were inefficient, ineffective, and costly.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • foggable water-based rust preventative
    A Russian automaker experienced corrosion on stamped metal surfaces during CKD (complete knock-down) shipments from Russia to Ecuador. They used various oils as their corrosion protection method, which proved to be ineffective as well as an environmentally hazardous means of protection. The auto manufacturer needed a different solution that would work efficiently and without the contamination and the clean-up that comes with using oil.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • VCI film
    When a major international automobile manufacturer switched to a cheaper corrosion-inhibiting solution for overseas CKD shipments, it didn’t anticipate the cost-cutting decision to cause a negative effect on its bottom line. Prior to reducing spending, the company used Zerust® VCI corrosion-inhibiting packaging film and had no corrosion problems. Soon after switching to a generic product, the company learned the true costs of preventable corrosion. It wasn’t long before complaints of corrosion were reported by customer plants in the U.S. The lower-cost corrosion-inhibiting products, while promoted as “similar” to Zerust® VCI film, actually performed less effectively than plain polyethylene packaging that contained no corrosion inhibitors! Complaints and part replacements were costing the company over $200,000 USD—with no end in sight.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • automotive corrosion protection
    A large US auto manufacturer was plagued by auto parts arriving at assembly facilities corroded. To add to the challenge, the parts had to be packed hot which created condensation. The manufacturer could not use oils and the parts had a storage period prior to use. The Zerust® team of corrosion technicians were invited to diagnose the problem and create a packaging solution.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
  • Spray-On Corrosion Protection
    A leading US manufacturer of heavy-duty road construction machinery required corrosion protection for its equipment in challenging conditions. High-value, fully assembled machinery needed protection during international shipping and outdoors at the jobsite. The company needed a product that is safe for paint while protecting bare metal, exposed wiring, and electrical boxes in shipping, operations, and during downtime at construction sites.
    • Export Shipment
    • Inventory Storage
    • Long Term Storage
    • Work In Progress
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