Corrosion has long been seen as an unavoidable 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 shows that up to $875 billion* in preventable costs could be recovered through smarter protection strategies, and highlights the industries turning this long-standing challenge into a driver of innovation and performance. 

Published by AkzoNobel’s Interpon Powder Coatings, the global study surveyed 1,000 manufacturing leaders across key industries and regions. Featuring a wealth of global and regional insights, it explores how manufacturers are balancing protection, cost, and sustainability amid rising environmental and regulatory pressures. The extensive detail and insights that lie within this landmark study reinforce Interpon’s position at the forefront of advancing corrosion protection. 

Global insights include: 

• Hidden costs are significant: Almost a third (32%) say their biggest expense comes from lost customers and product returns, and damaging reputations. Another 28% emphasize 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 by sector and region: 

• EV manufacturers are setting new standards, with over half already using advanced powder coatings to boost durability and sustainability. 
• Architectural manufacturers are caught between legacy systems and tougher regulations demanding more sustainable, longer-lasting protection. 
• Industrial equipment producers face rising pressure to modernize, though many hesitate due to initial investment costs. 
• North America and South Asia & Australasia show readiness to leap ahead with advanced technologies, while Europe’s new regulations drive a wave of innovation across markets. 

These global contrasts reveal a clear shift: corrosion protection is no longer just about preventing damage, but creating long-term value. 

Today’s powder coating technologies extend product life, cut waste, reduce energy use, and help manufacturers meet 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 a highly-detailed investigation into 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.