Ultimate VCI Guide: Anti-Rust Protection for Metals and Servers in Your Industrial Wood Packaging

Alfredo Vázquez
Nov 20
4 min read

Empaque Industrial de Madera para servidores con un ejemplo de inhibidor de corrosión — **Conceptual Example of a Physical Corrosion Protector (paper or plastic)**

At Kayak Packaging, corrosion protection is a non-negotiable priority. For critical industries such as electronics (yes—thinking about your servers!), automotive, heavy machinery, and export packaging, rust is simply not an option. That’s why we created this comprehensive guide on VCI technology (Volatile Corrosion Inhibitors). You’ll learn what it is, how it works, and how to choose the ideal VCI for your applications—including its integration into our specialized wooden packaging, server crates, and server boxes.

🔬 How does VCI technology work?

VCIs are advanced chemical compounds that volatilize inside the closed environment of a package and adsorb onto metal surfaces. There, they form an invisible molecular layer that inhibits the electrochemical mechanisms of corrosion. This protective layer interferes with both anodic and cathodic reactions, blocking electron exchange and therefore preventing the formation of oxides or sulfates.

It’s an invisible shield that actively protects your metals.¹

Key Advantages of VCI

Non-contact protection: Ideal for complex geometries and internal cavities.
No manual application required: Eliminates the need for oils, greases, or post-processing degreasers.
Residue-free: Your parts remain clean and ready for the next process once the wooden industrial packaging is removed.
Highly compatible: Works well with automated processes and is adaptable to eco-friendly packaging.

🛋️ Types of VCI Products and Their Application in Industrial Wooden Packaging

The versatility of VCI allows it to be integrated into various formats to optimize protection:

VCI Paper

Kraft paper treated with specific inhibitors (such as sodium nitrite or amine-based blends).
Ideal for: Wrapping individual components, tools, or loose parts inside wooden boxes or server crates.
Recommended for: Enclosed spaces requiring short- to medium-term protection (up to 9 months, depending on formulation).²

VCI Plastic (film, bags, stretch film)

Unlike conventional plastic, it incorporates volatile inhibitor additives that protect nearby metals.
Provides both physical protection (moisture barrier) and chemical protection in a single layer. Complies with standards such as ASTM E96 (vapor barrier) and MIL-PRF-22019D (military specification).³
Recommended for: Large parts, assembly lines, export packaging, or sensitive equipment stored inside specialized wooden industrial packaging.
Durability: Up to 24 months under stable conditions.

VCI Foams and Emitters

Devices or foams that release the inhibitor inside closed environments.
Used for: Passive protection of electronic devices (such as servers), cabinets, motors, or the interior of server boxes.
Commonly made from polyethylene or polyurethane foam, treated with compatible inhibitors.⁴

🧮 Comparative Table: Common Metals and Their Recommended Inhibitors

Metal Type	Recommended VCI Inhibitors
Carbon Steels	Sodium nitrite, sodium benzoate, amine blends
Aluminum or Zinc	Sodium benzoate, dicyclohexylamine, triazole derivatives
Copper & its alloys	Benzotriazole, tolyltriazole
Mixed Metals	Multifunction formulations (amine blends + organic salts + selective triazoles)

🧰 Key Considerations for Selecting the Right VCI

Choosing the correct VCI is an art that requires detailed analysis:

Metal Type

Carbon steels: Compatible with nearly all VCI chemistries.
Aluminum or zinc: Require specific inhibitors (sodium benzoate, dicyclohexylamine, or triazole derivatives) to prevent galvanic corrosion and white rust.
Mixed metals: Use multifunction VCI formulations.

Storage or Transit Duration

< 3 months: VCI paper may be sufficient.
3–24 months: Prefer VCI plastic with airtight sealing and additional VCI emitters.

Packaging Type and Design

Wooden crates or server crates: Use interior VCI film + emitter, or a fully sealed VCI bag.
Sensitive electronics (e.g., servers): Use VCI foams + sealed VCI plastics (avoid PVC to prevent chemical reactions).

Destination Climate

High humidity: Reinforce with desiccants or additional vapor-barrier layers.
Dry climates: VCI paper or simple emitters may be sufficient.

⚠️ Important Compatibilities and Warnings

Although VCIs are highly effective, it is crucial to consider their compatibility with downstream industrial processes⁵:

Some inhibitors (especially amine derivatives) may interfere with welding, coatings, or paint adhesion.
Not all VCI chemistries are compatible with sensitive plastics, optical components, or certain elastomers.

For this reason, at Kayak Packaging, we always recommend conducting pilot tests before full-scale implementation and verifying specific compatibility with your materials and processes.

🚀 Kayak Packaging: Your Expert Partner in VCI Protection

At Kayak Packaging, we have extensive experience in corrosion analysis, material compatibility, VCI selection, and the design of specialized wooden packaging and certified server crates. Our goal is to ensure your products arrive perfectly protected, no matter the conditions. 📚 References

ASTM International. (2021). ASTM E96/E96M-22: Standard Test Methods for Water Vapor Transmission of Materials. ASTM.

ASTM International. (2022). ASTM D882-22: Standard Test Method for Tensile Properties of Thin Plastic Sheeting. ASTM.

U.S. Department of Defense. (2020). MIL-PRF-22019D: Packaging, Volatile Corrosion Inhibitor, Activated. Defense Logistics Agency.

Kharshan, M. (2016). Application of Vapor Phase Corrosion Inhibitors (VCIs) in the Automotive Industry. Materials Performance, 55(9), 32–37.

Shreir, L. L., Jarman, R. A., & Burstein, G. T. (Eds.). (1994). Corrosion: Volume 2. Butterworth-Heinemann.

Mansfeld, F. (2018). Role of VCI in Long-Term Corrosion Protection. Corrosion Science and Engineering, 76(2), 109–115.

Hawkins, R. (2019). Corrosion Inhibitors: Principles and Applications. Materials Performance Journal, 58(4), 42–48.