4 Simple Steps to Stop and Prevent Corrosion

Corrosion, rust, oxidation, degeneration.  No matter how you say it, one thing is certain, it’s costing you money.  Quite possibly even more than you’re aware of.  The annual cost of corrosion in the production and manufacturing industry is estimated at a staggering $17.6 billion each year according to the study, “Corrosion Costs and Preventive Strategies in the United States.”  That’s just a fraction of the estimated $276 billion lost due to corrosion in the United States.  Even more alarming, the estimated indirect costs of corrosion is equal to the direct cost.  So, what steps do you need to take to ensure your products are being adequately protected from corrosion?

4 Simple Steps to Stop and Prevent Corrosion

1)  Educate Yourself  – What Exactly is VCI?

First and foremost, it’s important to understand what VCI are and how they work.  The term “VCI” stands for Volatile Corrosion Inhibitors.  Volatile Corrosion Inhibitors (VCI) are a type of corrosion inhibitors that are used to protect ferrous and nonferrous metals against corrosion, also known as rust.   Corrosion inhibitors compounds vaporize from the paper or film.  They are attracted to the charged surface of the metal due to polar orientation.

 

 

As seen in the images above, the VCI molecules align on the surface which creates a barrier that prevents oxidation.  Simply put, corrosion is stopped.  The molecules continue to build up on to the barrier surface until a continuous barrier has formed on the metal surface.

2)  So Many Choices…

It’s hard not to feel overwhelmed when you start looking at the different options available to prevent corrosion.  Paper, film, bags, and more…Oh, my!  Once you understand what choices are available to you, and what benefits each provides, the next step will be a piece of cake.  Our vendor partners at Daubert Cromwell, offer a large selection for all your VCI needs.

  • VCI Paper: Easy to use, scratch and abrasion resistant, high heat resistance and set up VCI protection quickly.   VCI Paper can also easily be converted into sheets, bags, and wraps for individual parts, to name a few.
  • VCI Films/Bags: Heat sealable, durable and stretchable, economical, high water resistance, and can be applied automatically and removed quickly.  VCI Films and Bags are easily customizable to meet all your needs.

Why Must There Be So Many Choices

  • VCI Liquids: Ideal for use to prevent rust on exposed metals and unpainted metals at all stages of their lifecycle, for lay-up and preservation of engines.
  • VCI Devices: Devices give off, or emit VCI compounds and protect recessed areas within a package.  They are ideal for hard to reach areas and enhance protection by giving a ‘boost’ of available VCI.
  • Rust Remover: Used when it’s necessary to remove rust from metal before packing, storing or shipment.  Daubert Cromwell offers a liquid and gel form of rust removers.

3)  Selecting the Right VCI

When selecting the right VCI for your application, it’s crucial to know that the VCI protection is a function of what metals are in need of protection, corrosion inhibiting chemicals used, and the ratio of chemicals in the formulation just to name a few.  It’s important to note that VCI formulations that work under one set of conditions may not work under another.   All aspects of the process, metals composition, packaging, storage and shipping conditions should be considered in order to select the right packaging media and VCI formulation.

 

With the help of your R.V. Evans Packaging Solutions Specialists, and a Site Needs Analysis, we can assist you with selecting the appropriate VCI product by taking the following into consideration:

  • Type of metals in need of protection
  • Duration of protection required
  • Domestic or export shipping
  • Climate conditions
  • Size and weight of product
  • Value of product
  • Current packaging requirements
    • Handling
    • Automatic or manual
  • Chemical or oil residue on the metal
  • Processing and cleaning methods
  • Packing station location relative to other processes

4) A Few Final Thoughts

You’ve gone through the motions of learning what VCI are, the types of VCI and how to select it.  So, it only seems fitting you know how to properly use it.  First and most important:  Employees that are packaging your products should ALWAYS wear gloves while handling metal parts.  

safety

  • Parts should be clean and free of fingerprints before wrapping.
  • Package your clean products as quickly as possible.
  • The metal part should be no more than 12″ from the VCI product.  The closer to the metal, the better the corrosion protection.
  • As a general rule, use 1 sq. ft. of VCI for every 1-3 sq. ft. of the metal surface.  Use at least 1 sq. ft. of VCI for every cubic foot of void space.
  • The duration of protection depends on the VCI paper and packing method used.
  • Packages may be opened and resealed without affecting the corrosion protection. (Avoid touching metals during an inspection.)
  • Do not inventory more than a six month supply of VCI paper or film.

Feeling Prepared?

Whether you’re new to the world of corrosion prevention or looking to add to your current corrosion prevention application, you’re now one step closer to stopping and preventing corrosion.  Are you still uncertain about what VCI application best suits your needs?  R.V. Evans company can assist you in determining and implementing the best solution for your requirements.

If you’re interested in learning more about VCI products or any of our other Packaging Solutions, please contact us to schedule your Site Needs Analysis with one of our Packaging Solutions Specialists.  To learn more about all of our Packaging and Fastening Solutions, visit us online at www.rvevans.com.

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Pregis IntelliPack SmartBAGGER® Foam-In-Bag System Prevents Damages During Shipment

Pre-Solution Application

The client, a manufacturer of power transmission equipment industry, was packaging their product on a corrugated sheet contained in shrink film before placing them into a corrugated carton.  This resulted in a high rate of returns dues to damages received during shipment and a decline in customer satisfaction.

The R.V. Evans’ Value Added Solution

After performing a Site Needs Analysis and thorough review of the application, an R.V. Evans Packaging Solutions Specialist determined the appropriate value added solutions.  The recommendation: The Pregis IntelliPack SmartBAGGER® Foam-In-Bag System

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Key Benefits of the Pregis IntelliPack SmargBAGGER® Foam-In-Bag System

  • Cellular Telemetry
    • Remotely monitor and adjust system performance through proprietary PX3 system
    • Proactive preventative maintenance program minimizes downtime, supports optimal productivity
  • Bar-Coding
    • Machine dispenses the precise amount of liquid foam and film
    • Ensures consistent package protection every time
  • Equipment Design
    • Ergonomic design
    • User-friendly, intuitive control panel

Measurable Savings Realized

With the installation of the Pregis IntelliPack SmartBAGGER® Foam-In-Bag System, our client was able to significantly reduce the amount of damages during shipment and has seen their customer satisfaction increase.  The Foam-In-Bag system also provides a reusable packaging system for the customers to return any product in need of warranty repairs.

To see the Pregis IntelliPack SmartBAGGER® Foam-In-Bag System in action, check out this video.

 

If you are interested in learning more about the Pregis IntelliPack SmartBAGGER® Foam-In-Bag System, please visit our website at www.rvevans.com.  If you would like to set up an on-site review of your current packaging processes, R.V. Evans can help.  Schedule a Site Needs Analysis by contacting us today.

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AirPouch® FastWrap™ Provides Product Protection & Saves Space for E-Commerce Retailer

Pre-Solution Application

The client, a farm supply store with multiple retail locations, was preparing to launch their E-Commerce business and required a protective packaging solution for shipping their products.  They required a product that would protect, take up minimal storage space and a system that was easy to operate.

The R.V. Evans’ Value Added Solution

After performing a Site Needs Analysis and thorough review of the application, an R.V. Evans Packaging Solution Specialist determined the appropriate value added solutions.  The recommendation: The AirPouch® FastWrap™ Bubble-On-Demand from Automated Packaging Systems.

 

Key Benefits of AirPouch® FastWrap™ Bubble-On-Demand

  • Flexible: One System produces bubbles and tubes on-demand for wrapping, interleaving and block-and-brace applications
  • Fast, All-Electric System: Tabletop, all-electric system operates at 65 feet per minute and does not require compressed air to operate
  • Reduce Costs: Better air retention and improved yield cost per cubic foot
  • Low Maintenance: Reliable equipment designed for easy maintenance and serviceability
  • Reduce Storage Space: High-yield, boxed material reduces storage and transport requirements of paper, foam and pre-filled bubble materials
  • Easy to Use: Operator friendly controls are regulated through intelligent design, managing heat, air and speed for consistent fill level and seal quality
  • Eliminate Waste: Inflates and seals the protective wrap and tube material from start to stop, eliminating waste

Measurable Savings Realized

With the implementation of the AirPouch® FastWrap™ system, our client was able to ensure that orders would be properly protected and arrive without damages.  With the addition of overhead hoppers, we have been able to streamline their pack stations and free up valuable square footage in their warehouse facility.

If you are interested in learning more about the AirPouch® FastWrap™ system or other packaging solutions, please visit our website at www.rvevans.com.  If you would like to set up an on-site review of your current packaging processes, R.V. Evans can help.  Schedule a Site Needs Analysis by contacting us today.

Connect with R.V. Evans Company for new packaging and fastening updates, tips, application solutions and more!

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Rising Turnover Costs in Manufacturing: Mitigation Through Automation

Employee turnover can be expensive. In fact, Josh Bersin of Deloitte believes the cost of losing an employee can range from tens of thousands of dollars to 1.5–2.0x the employee’s annual salary. These costs include hiring, onboarding, training, ramp time to peak productivity, the loss of engagement from others due to high turnover, and higher business error rates. (Altman, 2017).

In a time when speed-to-market, low defect rates, and low cost-per-unit levels drive profitability more than ever, manufacturers are particularly affected by employee turnover. In 2016, manufacturers experienced turnover rates of 16%. (Bares, 2017). Doing the math, one can see that if their company turns over 16% of their operating workforce, and turnover costs are 2x the lost workers’ salaries, then annual turnover costs can equal up to 32% of your total operating payroll per year (assuming equal wages for simplicity’s sake). The “learning curve” effect also plays its part in higher defect rates and lower productivity, decreasing product quality and speed-to-market (Argote and Epple, 1990). In other words, turnover can severely affect profitability, especially in manufacturing.

So, what can manufacturers do about it? The psychology and social science on this subject has been published for many years, yet turnover rates are still high and have risen consistently over the past five years. Let R.V. Evans Company take a different approach. If you’re a manufacturer, do any of these activities fall under any of your workers’ job descriptions?

  • Forming cases and boxes
  • Closing and stapling boxes/cases
  • Sealing/taping cases
  • Bagging parts
  • Stretch-wrapping pallets
  • Printing images, date and batch codes, or barcodes on products or cases
  • Applying labels
  • Manually creating void-fill protective packaging for cases
  • Manually shrink-wrapping products
  • Applying strap to bundles, boxes, pallets, etc.

If you answered yes to any of those, there is room for automation.

Automation doesn’t always come in the form of complete robotics; there are ways to semi-automate as well. Semi-automation reduces the amount of laborers required to perform certain tasks in the manufacturing process, particularly in packaging processes. Examples of automation and semi-automation include:

  • Incorporating a WFPS 3290 Combo to allow a single operator to form, pack, and seal up to 30 cases per minute
  • Using an AutoBag 550 to allow a single operator to bag up to 45 parts per minute
  • Install an Orion Flex Series stretch wrapper to wrap pallets much faster than by hand
    • with a 260% pre-stretch that can save up to several thousand dollars in stretch wrap per year
  • Implementing a Samuel Model P715 automatic plastic strapping machine to apply plastic strap to your packages at speeds of up to 60 straps per minute- without an operator
  • Connecting many of these systems and others via conveyor equipment
  • Much, much more

There are numerous ways R.V. Evans and its team of packaging solutions representatives can help you reduce turnover by eliminating some of those high-turnover positions entirely. This is not a recommendation to replace your good, high-quality people that make your operation great. This is a recommendation to allow R.V. Evans to help you find ways to eliminate positions that are difficult to keep occupied due to high turnover. Equip your good workers with the means to produce more and add more value- at a lower total cost. Automating, semi-automating, and/or streamlining your processes can increase your speed to market, decrease your cost-per-unit, lean out your labor force, and make you more money. 

Why R.V. Evans? Because we are a team of experts whose core competencies are creating packaging solutions and giving great customer service. We spend every day staying up to date with the latest technology, studying that technology, and creating ways to implement it in various manufacturing environments. You are the expert in your operation, and we are packaging solutions experts. Team up with us so we can create a packaging solution that is right for you. We will forever follow up with great service.

Here is how to get started. 3 options are included below.

  1. Click here to schedule a site needs analysis with one of our packaging experts
  2. Click here to request general information about a specific product or product line
  3. Call 800-252-5894 to speak to one of our wonderful customer service representatives

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Unitizing and Stabilizing Your Products: Strapping

Strapping, also known as banding or bundling, is a common way to unitize, stabilize, and secure products. The strapping process involves applying straps (or bands) to a unit or collection of units in order to hold those units in place, or to further secure boxes or crates in which products are packaged or stored. An example of a strapped pallet of products is shown in Figure 1.

 
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Figure 1

 

Many applications involve strapping individual boxes for further package integrity. An example of such is shown in Figure 2.

 

Image result for plastic strapped box

Figure 2

 

The straps help hold the boxes in place, providing stability and therefore protection for the products inside the boxes. Combining strapping with stretch wrapping and corner board provides for a well-protected pallet of product. An example of such is shown in Figure 3.

 

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Figure 3

Types of Strap

There are many different types of strap. However, these many types fall under two primary categories: steel and plastic.

Steel Strap

Steel strap is used for medium- and heavy-duty applications. Steel strap is manufactured with many different widths, thicknesses, tensile strengths, etc.- all designed for a certain set of applications. Determining an appropriate type of steel strap is best performed by an R.V. Evans solutions representative. 

Plastic Strap

Plastic strap is used for light- and medium-duty applications. There are three primary types of plastic strap: nylon, polyester, and polypropylene. Additionally, each of these three material categories have been included in many different products designed for different applications. Determining the appropriate plastic strap for your application is best determined by an R.V. Evans solutions representative.

Strapping Equipment

Strap can be applied with manual hand tools, battery-operated hand tools, pneumatic tools, or semiautomatic and automatic strapping machines. Each type, size, and model of strapping tools provide a unique set of benefits. Finding the best one for you is, of course, best performed by an R.V. Evans solutions representative.

 

For more information on strapping applications, click here!

Shrink and Stretch Wrapping: Differences and Applications

“Go ahead and shrink wrap that pallet”, my boss said before he walked out of the warehouse. I leaped into action only to waste 15 minutes searching for a shrink wrapper in the warehouse. There wasn’t one. As my boss returned, he said to me in an annoyed voice, “Ok, what was confusing about shrink wrapping the pallet?”. “I noticed there isn’t a shrink wrapper here, sir”, I said. He stared at me for a second before replying, “Ok…I guess it is hard to miss”, then he grabbed the pallet jack and wheeled the pallet over to a large, conspicuous stretch wrapper just 20 feet away.

There is a common confusion regarding shrink wrapping and stretch wrapping. These two applications have something in common: they are both methods of packaging something in plastic. However, these applications package things much differently and for different purposes.

Shrink Wrapping

Shrink wrapping is the process of using shrink film, a material comprised of polymer plastic, and heat to seal products inside of the shrink film. The heat application process can be done via either a heat gun or a shrink tunnel. Packaging manufacturers like Seal-A-Tron produce shrink wrapping systems for industrial applications. A shrink-wrapped item will look something like this:

Image result for shrink wrapped product

In some cases, entire pallets of produce can be shrink wrapped to provide a form of product protection in transit and/or storage. However, most applications involve individual products, especially food products.

Stretch Wrapping

Stretch wrapping is the process of wrapping stretch film, a highly stretchable and elastic plastic film, around products. The elasticity of the stretch film pulls the products together and keeps them secure. This process is often performed with a turntable stretch wrapping machine like Orion’s Flex CTS Twin Station Stretch Wrapper, although many options are available for different user needs. A stretch-wrapped pallet looks something like this:

Image result for stretch wrapped pallet

This particular pallet was also strapped and equipped with corner board, a form of protective packaging, for optimal protection and security in transit and in storage.

Which One Should You Use?

This question is best answered by requesting more information from the R.V. Evans team. However, to get you started, a brief breakdown of a couple advantages and applications is shown below.

Stretch Wrapping Applications/Advantages Shrink Wrapping Applications/Advantages
· Wrapping boxes and pallets of products

· Cost-effective (particularly with pre-stretch)

· Protection from dust, dirt, and moisture

· Typically used to secure single products

· Best choice for food products

R.V. Evans Co. would be happy to provide you with any additional information you need at 1-800-252-5894 or via the website.

Inflatable Air Cushions “Fulfill” Protective Packaging Needs of E-Commerce Company

Storopack AIRplus air bags with integrated EZ feed packing station.

Storopack AIRplus air bags with integrated EZ feed packing station.

Pre-Solution Application

The client, a member of the e-commerce fulfillment industry, was previously using a paper dunnage form of protective packaging and void fill in their packaging and shipping process.

The R.V. Evans’ Value Added Solution

After performing a Site Needs Analysis and thorough review of the application, an R.V. Evans’ Packaging Specialist determined the appropriate value added solution.  The recommendation: Storopack AIRplus airbags with integrated EZ feed packaging station.

Key Benefits of the Storopack AIRplus Airbags

  • AIRplus films combine reliable protection and multiple uses with cost-saving features and sustainability for the ideal in-the-box packaging solution.
  • Their lightweight properties lower shipping costs
  • Create inflatable packaging materials on demand resulting in minimal use of storage space and handling
  • Provides consistent and controlled protective packaging
  • Low labor requirements – ease of use in production
  • Clean, dust-free characteristics
  • Minimal or no capitol expenditure for equipment with material commitment
  • Variety of film configurations for various packaging needs:
    • Cushion – absorbs shock and protects products
    • Void-fill – fills empty space and keeps products from rattling in the box
    • Block & Brace – holds heavy items or singe objects in place inside the box
    • Wrap – covers product surfaces to avoid contact damage and provides optimal protection against scuffing and scratching
  • Additional protective packaging solutions & benefits can be found at www.rvevans.com

Measurable Savings Realized

The Storopack AIRplus solution has enabled the client to experience a number of improvements including less abrasion, as well as increased yields and reduced shipping costs.  The integrated EZ feed packing station has reduced the overall footprint of their packaging area and reduced labor through minimized product handling requirements.

For more information on fastening & packaging solutions available from the R.V. Evans Company, visit www.rvevans.com or contact R.V. Evans for an on-site review of your specific fastening or packaging application.

Connect with R.V. Evans Company for new packaging and fastening system updates, tips, application solutions, and a little fun stuff too!

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