Problem
A Midwest automotive stamping company that supplies small stampings for various OEMs had an unexpected spike in customer rejects due to excessive rust. The corrosion began to form within 24 hours of stamping and became so severe that corrosion costs, including overtime, de-rusting, air freight, and scrapped parts, totaled more than $50,000 per month. In addition, stampings routinely sent to a third-party wash source four miles from the stamping facility exhibited corrosion upon arrival. The company’s sister plants in Michigan and Mexico were also affected by this increase in corrosion.
Solution
The stamping company approached the VCI supplier they were using for help; that supplier had plenty of products but no solutions. Then, 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.
In addition to root-cause analysis from corrosion experts, ZERUST® provided VCI Packaging products for numerous live trials. Results showed that ZERUST® VCI Packaging products were as good or better than the incumbent products with lower minimum order quantities and a lower price. In addition, ZERUST® helped the stamping company realize additional savings by properly sizing bags to eliminate excess material. Also, testing proved that the incumbent’s foam pad emitter offered negligible corrosion protection and could be eliminated.
