Cost of Corrosion report identifies hidden billion-dollar opportunity

Phil Black - PII Editor 05/11/2025

383 2 minutes read

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Independent research of 1,000 manufacturers reveals how smarter protection turns costs into competitive edge

Corrosion has long been viewed as the inevitable cost of doing business, but a new global study reveals it's fast becoming one of manufacturing's biggest untapped opportunities.

The new Cost of Corrosion report from Interpon reveals that as much as US$875 billion in preventable costs could be recovered through smarter protection strategies and shines a light on the industries turning this long-standing challenge into a driver of innovation and performance.

The global study, published by AkzoNobel's Interpon Powder Coatings, questioned 1,000 manufacturing leaders across key industries and regions. Containing a plethora of global and regional insights, it investigates how manufacturers are balancing protection cost and sustainability amid an increase in both environmental and regulatory pressures. The depth and insights contained within this landmark study reinforce Interpon's position at the very forefront of advancing corrosion protection.

Global insights include:

Hidden costs are considerable: nearly one-third, 32%, say their most significant expense is comprised of lost customers and product returns and damaging reputations. Another 28% emphasizes the environmental cost of waste and landfill.

Protection is mission critical: There is universal understanding that anti-corrosion protection is important, and nearly half, 44%, view it as essential to their business operations.

The landscape varies depending on sector and region:

EV manufacturers have set new standards, and more than half are already incorporating advanced powder coatings to enhance durability and sustainability.
Architectural manufacturers are caught between the legacy systems and tougher regulations demanding more sustainable longer-lasting protection.
The production of industrial equipment has increasing pressure to modernize, though many are cautious due to initial investment costs.
While North America and South Asia & Australasia are poised to leap ahead with advanced technologies, new regulations in Europe power a wave of innovation across markets.

These contrasts around the world outline one thing: a shift in corrosion protection as a means to prevent damage and to create long-term value.

Today's powder coating technologies extend product life, cut waste, reduce energy use and help manufacturers meet their sustainability goals-all while improving performance and profitability.

“Corrosion protection was once seen mainly as a way to prevent product failures and financial loss,” says Jorrit van Rijn, Marketing Director at AkzoNobel Powder Coatings. “Today, it plays a far bigger role – helping manufacturers cut waste improve efficiency and deliver longer-lasting higher quality products that customers trust and value. Smarter protection strengthens performance and relationships and that’s the change we’re proud to drive with our customers worldwide.”

The Cost of Corrosion report provides an in-depth investigation of how protection performance and sustainability are converging across industries and regions. It's designed for manufacturers ready to stay ahead of changing standards and turn smarter protection into progress.

Download the full report here