Corrosion has long been accepted as an unavoidable operational cost, but new research from Interpon Powder Coatings suggests it could represent one of manufacturing’s biggest opportunities for cost reduction and performance improvement. According to the company’s new Cost of Corrosion report, manufacturers worldwide could recover up to $875bn in preventable costs through improved corrosion protection strategies.
Published by AkzoNobel Powder Coatings, the study surveyed 1000 manufacturing leaders across multiple industries and regions to assess how businesses are balancing durability, sustainability and operational efficiency amid increasing regulatory and environmental pressures. The findings reveal that the hidden costs of corrosion extend well beyond equipment damage. Around 32% of respondents identified lost customers, product returns and reputational damage as the greatest financial impact, while 28% highlighted the environmental cost associated with waste and landfill.
The report also shows a growing recognition that corrosion protection is becoming strategically important to long-term business performance. Nearly half of manufacturers surveyed described anti-corrosion protection as essential to their operations.
Sector-specific insights indicate that EV manufacturers are leading the adoption of advanced powder coating technologies to improve durability and sustainability, while architectural manufacturers face increasing pressure to replace legacy systems with longer-lasting, environmentally compliant alternatives. Industrial equipment producers are also under pressure to modernise, although investment costs remain a challenge for some businesses.
“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.”
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