Redefining Sustainable Corrosion Protection

Case Study

Case Study – Redefining Sustainable Corrosion Protection

Industry – Automotive / Metal Components Manufacturing

Application – Corrosion protection for metal parts using VCI packaging during storage & transit

Load per bag: 10–14 kg

The Challenge : Bridging the Performance Gap in Compostable VCI

Metal components and precision-machined parts require high-performance Volatile Corrosion Inhibitor (VCI) packaging to prevent oxidation during extended storage and humid transit conditions. Historically, conventional plastic VCI films were the industry standard due to their proven chemical stability and mechanical durability.

As global industries transitioned toward sustainable packaging, a significant demand emerged for compostable VCI solutions. However, early market alternatives often failed to deliver the reliability required for industrial applications. Extensive trials revealed systemic limitations, including inconsistent VCI molecule release, poor moisture barrier properties, and a limited shelf life. Furthermore, these materials often lacked the physical integrity to withstand the rigors of heavy handling, leading to a widespread industry perception that compostable films were unsuitable for long-term corrosion protection.

TGP’s Integrated Technical Approach

TGP recognized that effective corrosion protection is not derived from chemicals alone; it requires a synergy between chemical formulation and material science. To challenge the status quo, TGP developed an integrated VCI solution that balances high-efficacy, non-toxic chemical compounds with robust polymer engineering.

Key Technical Challenges Addressed:

Standardization: Achieving consistent efficacy in alignment with the rigorous German TL 8135 standard.
Load Capacity: Meeting high-density requirements of 10–14 kg per packaging unit.
Physical Durability: Preventing puncture-induced failures caused by sharp-edged automotive components.
Cost Neutrality: Replacing 120-micron LDPE film without increasing costs or compromising protection.

Cost Neutrality: Replacing 120-micron LDPE film without increasing costs or compromising protection.

TGP developed a high-performance compostable VCI film that mirrors the mechanical stability of conventional plastics while ensuring long-lasting corrosion inhibition. By optimizing both the VCI formulation and the film’s molecular structure, TGP ensured effective molecule release and retention over extended transit periods.

The resulting material features enhanced puncture resistance and tear strength, specifically designed to withstand the sharp edges of automotive bolts, nuts, and fasteners. Even under rough handling and variable environmental conditions, the packaging maintains its integrity, ensuring the metal contents remain pristine.

Quality Control and Compliance

To ensure batch-to-batch consistency, TGP implemented high-performance compounding techniques and a centralized quality management system.

Key Manufacturing Advantages:

In-House Masterbatch Production: Direct control over the chemical composition ensures strict quality across every batch of VCI bags.
Tailored Formulations: Development of multiple VCI chemical grades customized to specific client requirements.
Advanced Testing: An in-house facility compliant with German TL 8135 standards validates the performance of every final product.
Environmental Safety: Stringent controls eliminate toxic substances such as nitrites and heavy aromatic amines.

By ensuring all base carriers and modifiers remain fully compliant with ISO 17088, TGP has successfully scaled production without compromising environmental or material performance. This innovation proves that sustainable packaging can meet the highest industrial standards for long-term corrosion protection.