When should you use VCI plastic or VCI paper?
VCI Plastic vs. VCI Paper: Which material provides the best corrosion protection?
When choosing between VCI Plastic and VCI Paper, it is important to understand how these materials have evolved – and how they perform in practice. VCI (Vapor Corrosion Inhibitors) has been in use since the 1940s, but not all VCI solutions are equally effective. Here is an overview of the advantages and disadvantages, so you can choose the right solution for your packaging and corrosion protection needs.
The history behind VCI Plastic and VCI Paper
The first VCI products appeared in the 1940s with the introduction of Dichan. This chemistry was based on dicyclohexylamine nitrite, which releases rust-inhibiting vapors into the surroundings. Originally, this technology was applied to paper, but the early VCI papers had major limitations: the inhibitor dissipated too quickly due to high vapor pressure, flaked off the paper surface, and retained moisture when placed directly against metal. In the worst case, this could accelerate corrosion instead of preventing it. In addition, there were health concerns associated with the original chemistry, leading to a need for improvements.
A major breakthrough came in 1979, when Northern Technologies International Corporation developed a safer VCI system based on sodium nitrite. This technology was first implemented in plastic film, and in the early 1980s, also in paper products under the ZERUST® brand. These innovations changed the way we think about VCI Plastic vs. VCI Paper – and still influence the choice of packaging today.
VCI Plastic vs. VCI Paper: Advantages and disadvantages
Advantages of VCI Plastic
Superior moisture barrier VCI Plastic film provides a significantly better moisture barrier than VCI Paper. The film reduces water-vapor transmission and prevents ambient humidity from penetrating the packaging. This is crucial for preventing corrosion during storage and transport.
Easy to use and high visibility VCI Plastic packaging simplifies handling. Parts can be placed directly into VCI bags or crates lined with film, which are then sealed. Transparent film allows operators to quickly identify the contents without opening the packaging.
Protection against contamination VCI Plastic bags protect metal components against dust, dirt, and airborne particles during storage and transport. Regular plastic bags can block dirt, but do not provide the rust-inhibiting vapor protection that VCI Plastic does.
Long shelf life and durability VCI Plastic film typically has a long shelf life when stored in its original, airtight packaging – often up to three years. When used correctly, it provides long-term corrosion protection and keeps metal surfaces clean and dry.
Advantages of VCI Paper
Rapid vapor dispersion VCI Paper allows rust-inhibiting vapors to disperse quickly, which can be an advantage in applications where the vapors need to reach metal surfaces faster than plastic film can manage.
Cost-effective VCI Paper typically has a lower material cost than VCI Plastic film, making it attractive for high-volume or short-term packaging.
Flexible and formable VCI Paper can be easily shaped around complex forms and individual components, making it ideal for direct wrapping or stabilizing parts inside a container.
Cushioning effect during transport When VCI Paper is crumpled, it provides a slight cushioning effect that protects parts against movement and contact damage during transport.
Combine VCI Plastic and VCI Paper for optimal protection
The choice between VCI Plastic and VCI Paper does not have to be either-or. Many corrosion protection programs combine both materials to leverage their strengths. For example, containers can be lined with VCI Plastic bags, while individual components are wrapped in VCI Paper for added stability. VCI Plastic sheets or VCI Paper can also be used as dividers between layers in the packaging. This approach increases the VCI saturation inside the package and ensures that the vapors reach all interior spaces.
How to choose the right solution for your needs
The choice between VCI Plastic and VCI Paper depends on factors such as moisture exposure, storage duration, transport conditions, and the geometry of the parts. In many cases, a combination of both materials provides the most reliable result.
Real Marine AS helps manufacturers assess corrosion risk and implement effective, cost-efficient solutions. We can conduct site visits, including packaging audits, fluid analyses, and data logger studies, to identify potential improvements. The goal is to deliver the right products, processes, and procedures to achieve consistent corrosion protection.
This post was first published on the Zerust blog
Question for you: What challenges do you face regarding corrosion protection in your projects? Do you need help choosing the right corrosion protection? Do not hesitate to contact us!
