Metal parts rust, surfaces tarnish, components are damaged in transit — corrosion causes enormous economic losses every year. VCI masterbatch is the raw material that solves this problem directly within the packaging: as the basis for VCI protective films that actively release volatile corrosion inhibitors into the packaging atmosphere and reliably protect metal surfaces. BRANOpac manufactures VCI masterbatch in-house — and also offers it as a contract manufacturing product for individual requirements.
The most important facts about VCI masterbatch at a glance
- VCI masterbatch is the precursor material for VCI corrosion protection films — manufactured from PE granulate and volatile corrosion inhibitors (VCI substances).
- The substances are released in a controlled manner, pass into the gas phase and form a protective molecular layer on metal surfaces.
- BRANOpac manufactures VCI masterbatch in-house using planetary roller extruders — for gentle, uniform processing of temperature-sensitive substances.
- In addition to in-house production, BRANOpac offers contract manufacturing of individual VCI masterbatches — tailored to metal type, protection duration and carrier material.
What is VCI Masterbatch? – Definition and Mode of Action
VCI masterbatch is a plastic granulate into which VCI substances — so-called Volatile Corrosion Inhibitors — have been incorporated. It serves as a precursor material for the production of VCI corrosion protection films and other VCI moulded parts. The granulate is dosed in proportion to a base polymer — typically polyethylene (PE) — and subsequently processed into films or other products.
How do VCI additives work within the film?
The substances incorporated into the masterbatch are released in a controlled manner after processing, pass into the gas phase and distribute themselves throughout the packaging atmosphere. They adsorb onto the metal surface and form a protective molecular layer that reduces corrosive reactions. The protection acts without direct contact between the film and the metal surface, provided that a sufficiently enclosed packaging space is present.
Which metals are protected by VCI masterbatch?
Depending on the formulation of the VCI masterbatch, ferrous metals such as steel and cast iron, non-ferrous metals such as copper, brass and bronze, or combinations of different metals can be protected. BRANOpac develops and manufactures both metal-specific and multi-metal formulations tailored to the respective application.
Manufacturing VCI Masterbatch: The Production Process at BRANOpac
BRANOpac manufactures VCI masterbatch entirely in-house. The necessary mixture of PE granulate and VCI substances is melted in an extruder, pressed into strands, cooled in a water bath and subsequently granulated. The finished granulate can be used directly for the production of VCI films and other VCI products.
Melt, strand, granulate – how VCI masterbatch is made
The manufacturing process begins with the precise dosing of PE granulate and VCI substances. Inside the extruder, the mixture is melted at a controlled temperature and thoroughly blended. After exiting the die, the strands are cooled in a water bath and cut into uniform granulate pellets. These pellets form the finished VCI masterbatch, ready for further processing.
Advantages of planetary roller extruder technology
BRANOpac uses planetary roller extruders in its manufacturing process, which offer particular advantages. Compared to conventional single-screw extruders, they provide a very uniform blending of components as well as precise temperature control. This is especially important, as many VCI substances are temperature- and heat-sensitive and may be impaired in their effectiveness at excessively high temperatures. Planetary roller extruder technology enables these substances to be incorporated gently and evenly into various polymers.
Would you like to use VCI masterbatch or enquire about contract manufacturing? Florence Lachat from our project management and sales team will be happy to advise you — from the initial enquiry through to your individual solution.
Get in touch nowFields of Application: Which Industries Use VCI Masterbatch?
Wherever metal parts need to be stored or transported without requiring cleaning or treatment prior to further use, VCI films — and therefore VCI masterbatch as their basis — are employed. Typical industries include the automotive sector, mechanical engineering, the electrical industry, the steel industry and metal parts manufacturing. Contract packagers working for various industrial customers also make regular use of VCI films.
VCI film as end product: protection for transport and storage
Corrosion protection films manufactured from VCI masterbatch offer a practical advantage over other protective methods: packaged metal parts can be put to immediate use after unpacking, without the need for cleaning or degreasing. At the same time, the film is transparent, so packaged parts remain identifiable at all times. Within the context of temporary corrosion protection, VCI film is one of the most user-friendly solutions available.
Further products: VCI hollow-chamber panels, trays and caps
VCI masterbatch is not only the basis for films. The granulate can equally be processed into VCI hollow-chamber panels, trays, caps and other moulded parts. This enables the realisation of tailored packaging solutions that enclose complex components with a precise fit whilst actively protecting them against corrosion.
Contract Manufacturing of VCI Masterbatch: Individual and Customer-Specific
In addition to its own production, BRANOpac offers the contract manufacturing of individual VCI masterbatches. Customers who produce their own films or moulded parts and require a tailored corrosion protection batch can work together with BRANOpac to develop a formulation precisely matched to their requirements — with regard to the metals to be protected, the desired protection duration, the carrier material used and the processing parameters. All process steps, from formulation development through compounding to quality control, are handled by BRANOpac.
VCI masterbatch is a plastic granulate with incorporated VCI substances, used for the production of VCI films and moulded parts. VCI paper, by contrast, is a coated paper product. Both release volatile corrosion inhibitors, but differ in carrier medium, processing form and field of application.
Depending on the substances used, VCI masterbatch formulations can be designed for ferrous metals (steel, cast iron), non-ferrous metals (copper, brass, bronze) or as multi-metal protection. BRANOpac offers tailored formulations for each specific application.
VCI masterbatch is typically processed into VCI films by extrusion. The granulate is dosed together with PE or PP base granulate and processed into blown films, tubular films or moulded parts such as hollow-chamber panels and trays.
Yes. BRANOpac offers contract manufacturing of customer-specific VCI masterbatches. All process steps — from formulation through extrusion to quality assurance — are precisely tailored to the customer's requirements.
The protective effect of VCI films depends on the formulation, the type of metal and the storage conditions. Depending on the product, protection durations of several months to several years are possible. BRANOpac provides advice on selecting the appropriate formulation.