The market of performance plastics in the European automotive market, earned revenues of US$4.22 bln in 2013 and is estimated to reach US$7.26 bln in 2019, as per Frost & Sullivan.

The robust properties and significant cost advantage of plastics over metals is accelerating market growth. While the recent economic slowdown has led to diminished car ownership interest in many countries, especially Germany, France, Italy, Spain, Portugal and Greece, the automotive plastics market will be sustained by the shift in focus towards more fuel-efficient, smaller, economy class vehicles. The study covers virgin compounds and polymeric blends. Regulations demanding the reduction of carbon dioxide emissions from passenger and light commercial vehicles by 2020 are compelling automotive component manufacturers and OEMs to substitute metal parts. The improved heat, chemical and impact resistance, enhanced aesthetics, optimum price-performance index in high performance polymers such as polypropylene (PP), acrylonitrile butadiene styrene, polycarbonates and polyurethanes (PU) coupled with new compounding techniques have made plastics the most preferred material in automotive applications.

Plastics also offer significant cost advantages over metals. They are, in fact, the material of choice for the vibrant automotive sector. While plastics is 3 times lighter than aluminum and 7 times lighter than sheet metal, it meets regulatory requirements, functional requirements, environmental requirements, all in one go. Bumper, dashboard, fenders and body trims are already well established with plastics. Intake manifolds, cylinder cover heads, air ducts, oil panes and reinforced tires are areas where plastic is also replacing the traditional sheet metal and aluminum parts. Replacement of metal with plastics to make fuel tank and battery boxes reduces the weight of the components by 40% and 70%, respectively making the vehicle more fuel-efficient. The fuel economy resulting from replacement of metals with plastics has therefore, been a key consideration for the switchover to plastic auto components. While metals are cheaper than plastic materials on a cost-per-unit basis, the latter remain a more feasible alternative due to lower processing, assembling and finishing costs.

The cost of plastics will fall further when standardisation and mass production commence. The rising use of reinforced and composite material in automotive applications, however, poses a threat to virgin plastic compounds. The maturity of certain polymers for specific applications – such as the use of PU polymers for seating applications and PP polymers for interior applications – further limits growth potential. "Market participants should focus on the exterior and UTH application segments rather than the interior application segment, where opportunities are relatively saturated," said Soundarya Shankar, an analyst of materials and food research at Frost & Sullivan Chemicals. "They must also forge close relationships with customers and gain sound technical expertise and backward-integrated resin manufacturing capability to stand out in the European automotive market." The need for light-weight materials among automotive original equipment manufacturers (OEMs) and component manufacturers is accelerating the demand for automotive plastics in Europe. The use of plastics can reduce the number of parts required for a specific application, cut down on processing costs, and facilitate fuel savings between five to seven percent for every 10% drop in vehicle weight. In addition to environmental sustainability, plastics enable enhanced design flexibility and passenger safety features such as shock absorption in bumpers, reduced explosion risks in under-the-hood (UTH) applications and life-saving accessories such as air bags and seat belts.

The automotive industry continues to have a large impact on the economy of the country and is a visible industry for plastics. The importance of the automotive industry is evident as it is one of the largest industries in the world employing around ten million people. India is today, the 7th largest producer of automobiles in the world and with more and more overseas auto majors preferring to set up manufacturing in the country, India has emerged as hub for autos and ancillaries. Plastics have played a pivotal role in this growth and as a material, it is today the industry’s delight. The trend, world over, is to go for smaller, lighter, safer, greener and more fuel efficient cars. The viable solution is plastics. Plastics help produce lightweight, resilient and recyclable car components and parts.

Plastics have enabled auto manufacturers to produce lightweight vehicles at an economical cost, enhancing safety, strength, reliability and comfort, in addition to fuel economy. The fuel economy resulting from replacement of metals with plastics has been a key consideration for the switchover to plastic auto components. While presenting the significance of growing use of plastics in automotive industry, Mr. Ajay Jain, Chairman and Managing Director, Precision Pipes and Profiles Co Ltd, said that plastics was no more an option. To provide a further boost to the use of plastics in auto and packaging industries, Plastindia Foundation is holding the ninth edition of Plastindia 2015 from February 5-10, 2015 at Pragati Maidan, New Delhi. This mega show is supported by the Ministry of Chemicals and Fertilizers and will be one of the third largest shows in the plastics industry globally, with strong international participation. Plastindia 2015, spread over 125,000 sq. meters of area, will have over 2000 exhibitors from over 40 countries and over 150,000 business visitors. The Foundation’s main objective is to promote the development and growth of the Indian Plastics Industry in India and is dedicated to national progress through plastics. Meeting the agenda of sustainability in automobiles is best possible by use of plastics. Light-weighting continues to be the buzz-word for this industry.

Plastics is the answer. It helps in improving the sustainability by reducing overall weight. A well proven fact is that a 10% reduction in weight of the total vehicle, improves the fuel economy by 5 to 7%. Moreover, every kg of vehicle weight reduction has the potential to reduce CO2 emissions by 20 kg. Reducing weight of cars is the key to using less energy and minimizing wear and emission.