By replacing conventional rust-prevention oils and greases with VpCI® packaging, manufacturers can eliminate energy-intensive washing and drying stages while reducing hazardous waste and simplifying production processes.
Industrial manufacturers are under increasing pressure to reduce energy consumption and carbon emissions while maintaining efficient production processes. EcoCortec®, Cortec® Corporation’s European manufacturing facility, highlights how Vapor phase Corrosion Inhibitor (VpCI®) packaging can contribute to these objectives by eliminating some of the energy-intensive operations traditionally associated with corrosion protection.
Metal components are commonly protected during storage and transport with oils or greases. Before subsequent operations such as coating, these protective substances generally have to be removed through washing and degreasing processes. This can require heated chemical baths and forced-air drying systems, increasing the consumption of gas and electricity while also generating chemical waste.
VpCI® packaging provides an alternative approach by protecting metal components from corrosion without applying a heavy oil or grease coating. The technology forms a microscopic protective vapour layer on metal surfaces
inside the package. Once the package is opened, the protective vapours dissipate without leaving a film or residue, allowing components to proceed directly to subsequent manufacturing operations.
According to Cortec®, eliminating washing and forced-air drying can reduce the energy associated with heated tanks, drying ovens and high-volume air systems. Removing chemical solvent baths can also help reduce volatile organic compounds and hazardous waste in the production environment. At the same time, bypassing washing and drying stages can streamline production by allowing clean components to move directly into coating operations.
Located in Beli Manastir (Croatia), EcoCortec® manufactures VpCI® anti-corrosion packaging for international markets. The facility operates according to a closed-loop production model and incorporates its own recycling system, with the aim of reducing production waste. The company manufactures a range of packaging solutions for different applications and transport requirements. These include recyclable VpCI® films and bags in formats ranging from small bags for individual components to heavy-duty sheeting for large industrial equipment. The portfolio also includes products containing post-consumer recycled (PCR) material, as well as biodegradable and compostable film options.
VpCI® papers provide recyclable and repulpable corrosion protection for individual packaging, interleaving and layer separation. Available solutions include creped, reinforced, grease-resistant and ESD-safe papers, together with moisture-barrier alternatives to conventional wax or polyethylene coatings.
For applications requiring additional protection, the portfolio also includes VpCI® emitters and foam inserts designed to provide localised corrosion inhibition. Among these solutions is BioPad®, a USDA-certified product based on biobased non-woven materials.
By integrating corrosion protection directly into packaging, EcoCortec® states that manufacturers can reduce their reliance on conventional rust-preventive oils and the subsequent washing and drying processes required to remove them. This approach can help lower energy consumption and hazardous waste while simplifying material handling and supporting corporate carbon-reduction objectives.