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Zerust® VCI Film Eliminates Corrosion on Metal Auto Components in Overseas Shipping

Export Shipment
Inventory Storage
Long Term Storage
Work In Progress

Who?

Large automotive manufacturer

What?

Corrosion management for CKD overseas shipments.

Why?

Increase process yields, reduce labor and costs.

How?

Switching to Zerust® ICT® 510-C VCI Film protects overseas shipments from corrosion and eliminates messy oils.

foggable water-based rust preventative

high strength vci film

VCI film

Problem

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.

Solution

Zerust’s international team of corrosion experts recommended Zerust® ICT®510-C Ferrous and Multimetal VCI Film for the protection of steel and galvanized steel during transportation and storage. After a successful trial shipment to Ecuador, Zerust® VCI films were officially approved for use.

Automotive parts protection from rust & corrosion
For years

Amount saved by Zerust® VCI film
$858,000 USD per year

Customer Satisfaction
100%

Results

The manufacturer found that using Zerust® Vapor corrosion inhibiting (VCI) products paid-off. Corrosion stopped completely on stamped parts and anywhere else Zerust® products were used. The company eliminated oil as a means of corrosion protection in many production areas, helping to improve CKD shipment process yields. Using Zerust® also reduced costs by eliminating the internal logistics and manpower necessary to remove the oil and clean the parts before they can be used. By using Zerust® products, they saved US$858,000 per year! Contact a Zerust® Representative for a comprehensive corrosion management solution most effective for your metal assets.

multimetal VCI film — Zerust® VCI film

By packaging our products in Zerust® VCI film, we were able to save $858,000 a year.

Plant Manager

More Case Studies

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.

View Case Study

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.

View Case Study

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.

View Case Study

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.

View Case Study

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