Client Background
Type: Tier-1 supplier to a Japanese automotive brand
Product: Automatic transmission valve bodies (aluminum + steel)
Annual supply: Over 2 million units
Export markets: North America, Europe, Southeast Asia
Previous packaging: Standard PE film + rust-preventive paper + desiccant
Challenge
Cold cracking: During winter shipments in freezer containers (-25°C), standard PE film became brittle, tearing at bolt hole edges due to vibration – 2.3% of parts required rework per container.
Inadequate rust protection: Rust-preventive paper lost effectiveness in humid conditions; slight rust spots caused a 1.5% drop in assembly line yield.
Complex procedure: Three-layer packaging (film + paper + desiccant) took ~8 minutes per unit, high labor cost.
Solution
3-layer co-extruded VCI anti-rust film: Outer layer with low-temperature PE (brittleness temperature < -40°C), middle EVOH barrier (OTR < 2), inner VCI masterbatch releasing anti-rust vapor continuously.
Custom bag design: 3D-shaped bags to conform tightly to the valve body’s complex geometry.
Eliminated paper and desiccant: VCI film alone provides both rust prevention and barrier, simplifying the process.
Results (Quantified)
Transport damage rate dropped from 2.3% to 0.05% (98% reduction)
Rust protection passed 100% – client eliminated post-cleaning before assembly, reducing per-unit cost by ~8%
Packaging time reduced from 8 to 3 minutes per unit (62% efficiency gain)
Passed IATF 16949 on-site audit; now referenced as global packaging standard
Client Testimonial “We never thought packaging could be this simple and reliable. Their VCI film stays tough at -30°C, and our North American plant’s complaint rate is nearly zero.” – Quality Manager
