Effective corrosion protection requires more than adding desiccant. Understanding the product, environment and supply chain is key to preventing costly moisture damage.
Why corrosion protection deserves more attention
For manufacturers shipping metal components, corrosion can become an expensive problem long before a product reaches its final destination. This is particularly relevant for components transported by sea or air freight, or placed into long-term storage, where changes in temperature and humidity can create condensation and moisture inside packaging.
The consequences can be significant. A corroded component may need to be written off and replaced, potentially delaying production, disrupting supply chains and creating problems for customers. This can be particularly serious in sectors such as automotive and aerospace, where components can be high value, and delays can have a much wider impact.
It is estimated that 2-4% of products shipped by ocean freight arrive damaged, costing around £50-60 billion each year. Of this damage, 10-2% is attributed to humidity or condensation-related water damage, representing an estimated £6-8 billion annual supply-chain loss.
The good news is that corrosion protection does not have to be complicated. The key is selecting the right combination of materials and applying them correctly.
- Understand what you are trying to protect
There is no universal corrosion-protection solution.
You need to consider the metal type, size, value, surface finish, and intended storage period. So too does the reason for using corrosion protection in the first place.
For example, a component transported across the world by sea will face very different conditions than one stored for a few weeks in a controlled warehouse.
Understanding the purpose of the packaging is therefore the first step. It helps determine the most appropriate materials and the required quantity, avoiding the risk of either under-protecting the product or spending unnecessarily on excess packaging.
- Calculate the right amount of protection
One common mistake is assuming that more desiccant automatically means better protection.
The quantity required depends on several factors, including the dimensions of the packaging, the weight and nature of the product, and how and where it will be stored and transported.
A packaging specialist can calculate the optimum amount for an individual application. This is preferable to simply using a standard quantity based on historical practice.
Getting the calculation right can improve protection while also helping to control material costs.
- Choose the right VCI or desiccant
Desiccants and VCI (volatile corrosion inhibitor) products work differently and choosing between them or deciding whether to use them together requires understanding the application.
Available desiccant materials include clay, silica and biodegradable alternatives such as Virdisorb. There is no single material that is right for every application.
For example, Virdisorb has been developed as a lower-energy alternative to silica gel. According to the supplied data, its production can reduce CO₂ output by 71kg per kilogram of silica gel, based on the same absorption rate. At pallet scale, this equates to around 30 tonnes of CO₂.
The choice should therefore consider both performance and the wider environmental impact of the packaging solution.
- Look at the whole process, not just the packaging
Sometimes corrosion appears to be a packaging failure when the real cause is elsewhere in the process.
One example involved metal components developing finger stains. Initial investigations suggested that the packaging material was at fault. However, a site investigation found that employees on a night shift had been cutting fingers off their gloves to improve grip. This transferred fingerprints to the metal, causing acid damage.
This shows why understanding the complete packaging and handling process matters.
Similarly, a company might use grease to protect a component and then add desiccant. The desiccant may contaminate the grease, which can compromise the original corrosion protection.
- Review the solution as supply chains change
The conditions a product encounters during transport should always influence the packaging specification.
Temperature and humidity are particularly important. Some silica-based desiccants can absorb moisture in cooler conditions but may release moisture again when exposed to very high temperatures. This can potentially create additional risks for the product.
Air freight also presents its own considerations. Packaging and desiccant may need to be clearly identifiable to security personnel. If packaging is opened during inspection, the protection provided by the desiccant can be compromised.
The packaging itself should therefore be considered as part of the entire supply chain rather than as an isolated component.
Don’t overlook the packaging combination
Whilst VCI and desiccants can work alone, the most effective solutions combine them with the appropriate films, boxes or other packaging materials.
In some applications, changing the packaging approach can also eliminate processes such as applying grease or oil. This can reduce labour and packing time as well as simplifying the overall process.
The objective should be to identify the most appropriate combination for the product, considering performance, cost, labour, and sustainability.
Storage of the protection materials also matters. Some desiccants begin absorbing moisture as soon as they are exposed to the atmosphere, so they need to be stored in airtight conditions to remain effective.
The takeaway: there is no one-size-fits-all solution
Corrosion prevention depends on understanding a product’s full journey from manufacturing and packing through storage, transport, and final delivery.
The five key considerations are:
- Understand the product and why protection is required.
- Calculate the correct quantity of protection.
- Select the appropriate VCI and/or desiccant.
- Examine the entire handling and packaging process.
- Review the solution as products, technology and supply chains change.
Technology continues to develop, so solutions used for years should not be the only option. A process involving oil or grease and traditional wooden crates, for example, may suit some applications, but modern VCI and desiccant technologies can offer alternatives that may reduce labour and improve packaging efficiency.
For manufacturers facing recurring corrosion issues, the starting point should be reviewing the complete packaging process rather than adding more protective material. Working with a packaging specialist can help identify where moisture enters the supply chain, calculate the required level of protection, and assess whether alternative materials or processes could provide a more effective solution.
This is where Antalis Packaging can support manufacturers with a consultative approach to corrosion protection. By considering the product, packaging, storage conditions and transportation environment together, the aim is to collaboratively develop a solution that provides protection while also considering cost, efficiency, labour and sustainability.
Ultimately, effective corrosion protection starts with asking the right questions. Rather than simply adding more material, manufacturers should consider the product, the environment and the complete supply chain, then select a solution based on those specific requirements.
To find out more or to discuss how the Antalis Packaging team can support your business, please call 0370 241 1466 or contact them here.
Jason Poxon, Head of Design, Antalis Packaging
Jason Poxon is Head of Design at Antalis Packaging, where he leads the development of innovative packaging solutions and brings extensive experience in packaging design and development. With a strong focus on design, materials and practical application, Jason works across a range of industries to create effective and sustainable packaging solutions. He is also an MPAS-certified designer, bringing specialist knowledge and experience that is particularly relevant to the aerospace and defence sectors.
Contact: [email protected]
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