The far-reaching value of sustainable manufacturing and why coatings choices matter

For manufacturers under pressure to cut waste, improve efficiencies, meet tighter environmental expectations and protect hard-won customer trust, corrosion has become a much broader strategic issue.

The scale of the challenge is hard to ignore. Corrosion costs more than $3tn globally every year, and up to 35% of that cost is considered preventable through better protection strategies. That means the real cost of corrosion is not limited to maintenance bills or premature failures. It shows up in reduced product lifespans, unnecessary material consumption, operational inefficiencies, customer dissatisfaction and reputational damage.

Corrosion’s cost reaches beyond maintenance

The ‘value drain’ stretches well beyond the factory floor. Around 40% of newly produced steel is used to replace corroded material contributing an estimated 3.2% of global CO₂ emissions**. Corrosion is therefore not simply a durability challenge; it is also a significant sustainability issue. When products or components fail early, manufacturers face not only the direct financial burden of replacement, but also the environmental impact of more raw material extraction, more energy use and more waste.

That broader picture is reinforced by Interpon’s global Cost of Corrosion report, which surveyed 1,000 manufacturers across various sectors. The findings reveal that corrosion-related costs are felt in environmental and reputational terms, not just operational ones. 

In the UK, nearly one in five (19%) manufacturers say the main cost of corrosion is environmental, driven by the need to replace equipment too early. Protective coatings play an important role in addressing this challenge by helping products last longer and reducing the need for premature replacement. Increasingly, manufacturers are looking at coatings not simply as a finishing process, but as a way to support durability, efficiency and sustainability goals.

Regulation is raising the stakes

At the same time, the regulatory landscape is making coatings decisions more strategic. In Europe, and in countries such as the UK where Europe is an important export market, manufacturers face growing pressure to prove that products are durable, resource-efficient and lower in carbon impact. Measures such as the Carbon Border Adjustment Mechanism (CBAM) and the Ecodesign for Sustainable Products Regulation (ESPR) are focusing attention on product longevity, recyclability and embodied carbon. The UK is set to introduce its own CBAM measures from January 2027.

Against this backdrop, corrosion protection is becoming more central to compliance, export readiness and customer confidence. As expectations around durability, resource efficiency and carbon impact continue to grow, coating choice is becoming a more strategic manufacturing decision. By supporting product longevity and business performance, the right coating system can enable manufacturers to own their impact, both environmentally and commercially.

Why powder coatings are gaining ground

Among the coating technologies helping manufacturers meet these evolving demands, powder coatings are attracting growing interest.

In industries such as white goods, HVAC, lighting, shelving, racking, shop fittings and electrical enclosures, powder coatings are already well established, with half (50%) of respondents reporting that they use them. The attraction is not only about corrosion resistance, but also manufacturing efficiency, which 49% cite as a key driver in coating choice. There is a clear sense that powder coatings are increasingly aligned with the needs of manufacturers trying to balance durability, throughput and environmental performance.

The durability credentials are particularly important. 75% of the manufacturers agree powder coatings provide a durable, long-lasting finish, while 73% say they deliver superior edge coverage. Those qualities matter because corrosion often starts where protection is weakest, particularly around edges, joins and exposed surfaces. If manufacturers can strengthen protection in those vulnerable areas, they are better placed to reduce maintenance demands, extend product lifespan and avoid early replacement.

Powder technology is also advancing. At the high-performance end, Interpon Redox primer systems are designed to deliver robust corrosion protection for demanding environments. Building on that technology, Interpon Redox One Coat combines corrosion protection and a durable finish in a single powder coat, helping simplify the coating process without compromising performance.

Innovation is also improving manufacturing efficiency. Interpon XTR enables thinner film builds that can help reduce powder consumption without compromising performance or finish quality, while Interpon Low-E powder coatings cure faster and at lower temperatures, helping manufacturers reduce energy consumption within the production process.

Together, these advances demonstrate how powder coatings can deliver benefits beyond protection alone, supporting more efficient manufacturing while helping extend product life.

For manufacturers in these markets, coatings are expected to do more than provide an aesthetically pleasing finish. They need to contribute to long-term protection, provide ease of cleaning, offer UV and heat resistance, and enable lower maintenance demands.

Even so, legacy systems still hold significant ground. Powder coatings are the most used option by industrial manufacturers at 50%, with liquid coating remain close behind at 41%, and hot-dip galvanizing continues to play a role at 21%. 

Many manufacturers already understand the benefits that powder coating systems can bring. The difficulty lies in making change practical within real production environments. In the industrial sector, a quarter (25%) say the cost of adapting existing lines is a barrier to adoption, while 39% are concerned about compatibility with current processes. Those are not minor concerns. Switching coating systems can involve capital expenditure, disruption risk, workflow changes and questions around throughput.

So, the decision is rarely a simple sustainability choice. It is a manufacturing choice that must stack up commercially as well as technically. As a result, the most attractive solutions are therefore not just the most sustainable on paper, but the ones that can also deliver stronger protection, support efficiency and improve operational performance.

That is why corrosion protection can no longer be treated as a narrow cost-control issue. The manufacturers that move early towards solutions combining durability, efficiency and sustainability will be better placed to reduce waste, extend product life, strengthen competitiveness, protect reputation and ultimately own their impact. Coatings choices matter far more than they once did as manufacturers look to improve not product performance as well as the long-term environmental and commercial resilience of their business.

Tomasz Kluczewski is regional commercial director, North Europe at AkzoNobel Powder Coatings

www.akzonobel.com