This quality problem has plagued me through three different employers in the last ten years. It is worse now that my current employer is selling parts to China.

Here in the Midwest, we have a 'rust season' that lasts from the end of May, through August. When the weather turns dry, it is less of a problem. My last employer expected bearing metal products to sit on the shelf with a thin film of sprayed rust preventive, and not rust for months. That didn't work out too well.

At my current employer, we are now in the start of our local 'rust season', and we are shipping a high-carbon steel product to China. Our local customer for this product purchases it, and it sits on their dock for an unspecified period of time. Then it ships to a US port city, and waits to be loaded in a shipping container. It spends upwards of three weeks 'on the water', and then waits in a Chinese port city to go to the end user.

The end user found the rust, took pictures, and made a complaint to our local customer who forwarded the information to us. There will be no non-conformance, or corrective action requested.

I should think not, given the obvious state of the Chinese warehouse in the pictures. The Chinese end user said the parts were in their warehouse for several weeks prior to attempting to use them.

The punch line is that I need to come up with a way for our parts to arrive ready to use at this Chinese factory. We store them vacuum packed with VCI antioxidant paper in an air conditioned warehouse. Our inventory turns over almost as fast as we can make the parts. I have no idea what kind of rust protectant will protect these parts (completely rust free) for such a trip.

I would appreciate any suggestions.

The part is a valve component. It is high carbon steel that is highly polished in one area. The slightest rust and it is useless.

Maybe a parafin dip, like what they use on gages. It would also protect the polished surface.

I have seen a water based product that drys out to a thin white film used on some parts as well. No idea the name.

Maybe desacant bags, we toss in a 1 pound bag in each tub of parts we ship.

This quality problem has plagued me through three different employers in the last ten years. It is worse now that my current employer is selling parts to China.

Here in the Midwest, we have a 'rust season' that lasts from the end of May, through August. When the weather turns dry, it is less of a problem. My last employer expected bearing metal products to sit on the shelf with a thin film of sprayed rust preventive, and not rust for months. That didn't work out too well.

At my current employer, we are now in the start of our local 'rust season', and we are shipping a high-carbon steel product to China. Our local customer for this product purchases it, and it sits on their dock for an unspecified period of time. Then it ships to a US port city, and waits to be loaded in a shipping container. It spends upwards of three weeks 'on the water', and then waits in a Chinese port city to go to the end user.

The end user found the rust, took pictures, and made a complaint to our local customer who forwarded the information to us. There will be no non-conformance, or corrective action requested.

I should think not, given the obvious state of the Chinese warehouse in the pictures. The Chinese end user said the parts were in their warehouse for several weeks prior to attempting to use them.

The punch line is that I need to come up with a way for our parts to arrive ready to use at this Chinese factory. We store them vacuum packed with VCI antioxidant paper in an air conditioned warehouse. Our inventory turns over almost as fast as we can make the parts. I have no idea what kind of rust protectant will protect these parts (completely rust free) for such a trip.

I would appreciate any suggestions.

The part is a valve component. It is high carbon steel that is highly polished in one area. The slightest rust and it is useless.

That is a tough problem. It seems to me the responsibility for rust should pass down the line with the parts. I have never done a study but I am guessing the vacuum packing described should provide enough protection for the trip. Is someone down the line changing that condition?

It could be that you need an additional rust inhibitor prior to vacuum sealing. There is a hot wax dip on the market called "Sheath" (I think) that scored awfully high when we did rust prevention test for our products. Our testing didn't include ocean transport so I can't speak to over seas containers.

Good luck with your search. I would be interested to know how you end up.

Dave

Thank you both. I am in full product research mode today. It will probably be a couple of weeks before I am testing. The big cheese is on vacation, and he will likely have some words for the local customer who shipped the parts. I don't see how we are responsible either, since the product sat at the local customer's location for a while, and shipped in various trucks, and at least one boat. We have no control over the packing in the overseas shipping container. Of course - this is why they aren't asking for a corrective action. They just want rust free parts next time. I'm sure it's gonna cost them.

Thank you both. I am in full product research mode today. It will probably be a couple of weeks before I am testing. The big cheese is on vacation, and he will likely have some words for the local customer who shipped the parts. I don't see how we are responsible either, since the product sat at the local customer's location for a while, and shipped in various trucks, and at least one boat. We have no control over the packing in the overseas shipping container. Of course - this is why they aren't asking for a corrective action. They just want rust free parts next time. I'm sure it's gonna cost them.

Good luck in your venture, our customer expect a defect free part regardless of how long it sits on the shelf. I look forward to hearing what you finally ending up doing.

:)

I don't know how readily available it still is or how cost effective it might be, but have you ever considered cosmoline?

There's another substance I remember using when I was in the Navy called, "Break Free CLP (Cleaner, Lubricant, Preservative)." This substance I believe is held to MIL-L-63460 standard. It is manufactured by Break-Free Corporation located in Santa Ana, California.

Hope this helps. :)

Well, here is how it turned out. Flexing of our light film vacuum pack on our light duty backer board caused the film to open and moisture got in. Sitting in warehouses that are not environment controlled for weeks at a stretch did the rest. Of course the local customer & the chinese end user want us to upgrade our packaging.

I give the big boss here much credit. He pulled out the PPAP and the contract with the local customer and pointed out how the packaging requirements were specified. He told the local customer if they want upgraded packaging they will have to agree to the necessary cost increase. The silence is deafening... I expect the job to go to china as soon as they figure out how to make it.

Cosmoline! Wow..., haven't seen that stuff in twenty years. We used to pack everything in it in the army.

Thank you everyone for the advice.

Rich

I give the big boss here much credit. He pulled out the PPAP and the contract with the local customer and pointed out how the packaging requirements were specified. He told the local customer if they want upgraded packaging they will have to agree to the necessary cost increase. The silence is deafening... I expect the job to go to china as soon as they figure out how to make it.

Good spot on the packaging requirements! I had that happen to me once, too. Good lesson learned - always verify the packaging requirements!

There are many options for corrosion protection, one of which is used for overseas shipments is the Volatile Corrosion Inhibitors (VCI's) bags - plastic bags with corrosion inhibiting built in.

Here is one site I dug up quick on the internet - there are many more (find a supplier near you!):

http://www.champlincompany.com/Commercial/Packaging_Materials/Packaging_Materials_CorrosionProtection.htm

You want to use "cosmolene"

http://www.corrosionsource.com/

Rich,

Thanks for dropping in for the update!!!!