Corrosion has often been treated as a technical issue for engineers and coatings specialists. But for Indian manufacturers, that view is becoming too narrow. Corrosion costs industry more than US$3 trillion a year, with up to US$875 billion preventable with the right protection strategies, according to the Association of Materials Protection and Performance. This makes corrosion far more than a surface-finish problem.

Coatings sit on the manufactured surfaces and components which the chemical-sector make or supply into wider value chains, especially construction products, infrastructure parts, transport components, and industrial equipment. In other words, corrosion protection decisions do not stay inside the coatings function, they shape how reliably products perform, how long assets last, and how efficiently manufacturers compete in demanding markets.

The Interpon Cost of Corrosion report shows that 96% of Indian manufacturers view corrosion protection in their choice of coating as either essential or very important. This suggests corrosion protection is not a niche coatings concern, but rather a high-priority manufacturing issue, and the real shift is not simply toward robust protection, but toward protection that works commercially and operationally.

The true cost of corrosion

Indian respondents also see corrosion’s impact across several fronts. Environmental concerns lead, with 37% citing poor product performance and early equipment replacement as the main cost of corrosion, followed by financial impact at 33% and lost reputation at 20%. Part of the reason environmental concerns lead may be rising regulatory pressure, including measures such as India’s Carbon Credit Trading Scheme.

This broader perspective is helping to drive a shift toward smarter protection. Durability and corrosion resistance remain central, with 49% citing them as a key driver of coating choice. But Indian manufacturers also need protection that helps optimize production and support sustainability goals. Some 51% cite manufacturing efficiency as a reason for current coating choice, 43% say sustainable attributes are key, and 42% choose coatings to ensure innovation in manufacturing processes. The results indicate that this is a pragmatic market that values technologies that can improve protection while also supporting operational and environmental efficiency.

Why Indian manufacturers are choosing advanced coating technologies

This helps explain why advanced coating technologies are gaining attention. India’s current coating mix is broad and not dominated by a single option: liquid coatings are used by 52% of respondents, powder coatings by 46%, and hot dip galvanizing by 21%. While liquid remains dominant, support for powder coating is strong. Some 78% say powder coatings provide longer-term, more durable finishes, while 76% say they deliver superior edge coverage, which is important in corrosion protection. Powder coatings are also seen to support environmental and production goals: 85% say they produce less waste, 70% say they are better for the environment, 76% say they are very easy to apply, and 72% say they provide the best production efficiencies.

The appeal of advanced powder coating technologies lies in their ability to combine protection with production and sustainability benefits. For example, single-coat systems provide high-protection with lower operational output, low-cure technologies reduce energy use, and the ability to reclaim overspray means they produce minimal waste. As powder coatings are free from VOCs, they also help manufacturers balance performance with practical plant demands.

The opportunity lies not simply in higher levels of protection, but smarter protection: solutions that improve durability, work efficiently within plant realities, and respond to rising environmental expectations. Corrosion protection is becoming a competitive manufacturing decision, tied as closely to cost control and resilience as it is to long-term reputation and environmental safeguarding.