Driven by over 2.5 billion online shoppers, global ecommerce sales are projected to exceed $7.4 trillion in 2025, an increase of more than 14% from 2024. While online shopping is now ubiquitous, most consumers give little thought to the logistical complexities required to get an item that they see on a computer screen to their front door. Rising demand for international shipping underscores the vital role that containers play at nearly every stage of the supply chain. Their durability and reliability directly influence transport efficiency, product quality and overall logistics costs.
How well a container is constructed and the materials used are important for its structural integrity. But high-performance coatings are also instrumental in keeping goods secure and protected and the containers in good working condition for the long haul. These coatings must endure harsh conditions on a global scale, including UV exposure, heat, moisture and salt, while also withstanding the impacts of loading, stacking and moving tons of freight.
Newer generations of high-performance powder coatings represent the future of finishing for containers, offering superior durability, faster application and a more environmentally friendly footprint.
Solvents, Waterborne, and Powders
For decades, global trade relied on wooden ships and bulk cargo carriers to transport goods. This changed when containerization was introduced in the 1960s, followed by a boom in the 70s and 80s. Initially, containers were owned by the shipping lines themselves. But as leasing companies and private equity organizations entered the market, the focus shifted toward maximizing the return on such assets. Coatings were a significant part of this effort.
Early on, solvent-borne marine coatings were the standard for containers, driven by the essential role of ocean freight in global logistics. But these solutions released volatile organic compounds (VOCs), were inefficient to apply and required expensive pollution-control equipment. For that reason, the container industry has almost entirely transitioned to waterborne coatings to eliminate the use of solvents that emit VOCs within the last 10 years. This shift meant less harmful air pollutants in factories and greater regulatory compliance, while offering comparable protective performance.
But waterborne coatings present their own challenges; they dry slowly, and their efficacy is highly weather-dependent. While sunny days allow for proper curing, cold or rainy conditions can lead to inconsistent coverage and quality issues in the finish.
Powder coatings address many of these challenges. When applied under proper conditions on a production line, they are more durable, less sensitive to weather for adhesion and curing and are typically formulated without solvents, so no VOCs are produced.
However, since the large-scale shift to waterborne systems is still relatively new, many manufacturers are reluctant to overhaul their operations once again. Changing coating technologies requires retooling production lines, retraining workers and making significant capital investments. This makes container manufacturers cautious, even when newer solutions like powders offer clear advantages.
Despite the challenges, the industry is beginning to acknowledge the significant and well-documented benefits of transitioning to powder coatings.
The Early Adopters
The initial transition to powder coatings for container companies began in the mid-2010s. However, many manufacturers, especially those in China, are still loyal to waterborne systems.
Intermodal coatings applications extend beyond containers alone. They are also critical for trailer chassis, a segment that largely converted to powder around 2012. Companies that own both containers and chassis have seen the performance and cost advantages firsthand, and many are now applying that experience to their container coating lines.
Early adopters in the container segment value powder coatings for their precision and more stable application process. Unlike waterborne systems, which must be force-dried and may not reveal issues until months or years later, powder coatings fully cure at once. The ability for workers to conduct an immediate quality check helps to ensure good adhesion, finish quality and long-term performance. Powder coatings also outperform waterborne systems in top-coat quality, color and gloss retention and impact protection, and they meet the Institute of International Container Lessors (IICL) specifications for corrosion.
Powder Coating Advantages
Powder coatings deliver significant cost savings for a number of reasons, but primarily because they achieve up to 95% transfer efficiency with the ability for overspray to be reclaimed and reused. This inherent need for less material also decreases the amount of powder that must be shipped to manufacturers, saving on transportation costs.
Traditional liquid systems transfer only about 60% of the paint to the part, meaning that roughly $4 is wasted for every $10 spent. Liquid sludge, a hazardous byproduct of waterborne paint lines, is another downside, requiring expensive transport and disposal.
Alternatively, powder coatings are shipped in reusable gaylord containers and require up to 40% less material to coat a part. Unlike waterborne systems, powders do not produce hazardous sludge or wastewater, and overspray can simply be collected and reused. In essence, powders have a smaller environmental impact due to the absence of solvents, wastewater and coating waste.
Powder coated parts also provide higher performance due to how it is applied and cured. Automated powder lines allow precise control of film thickness, reducing variation and allowing applicators to achieve levels that meet industry standard recommendations. Film thickness is important for the longevity of the finish, as the right amount improves durability, color and gloss retention, corrosion resistance and impact performance.
The Cure + Getting Set Up
While transitioning from liquid to powder lines requires a capital investment, the energy savings from powder use can help to offset the costs of new equipment. On average, standard powder coatings require about 30 minutes in a thermal oven to cure. But low-bake formulations cure at lower oven temperatures and in less time (around 15-20 minutes). Both can result in significant energy cost savings.
Beyond curing efficiency, powders also extend the lifecycle of containers. Their superior durability reduces the need for frequent recoating or repair, which means fewer interruptions, lower maintenance costs and longer service lives for individual units. This is a significant benefit for leasing companies, shipping lines, investors and other stakeholders. Over time, powder’s advantages make the transition from waterborne solutions worthy of consideration.
Organizations like PPG, through programs like Secure Launch Excellence™, offer comprehensive, step-by-step support for manufacturers transitioning from liquid to powder coatings and implementing new equipment into their manufacturing processes. PPG has a large network within the industry and can work with container manufacturers to ensure that new powder coating lines are implemented efficiently to minimize production downtime and ensure success.
The Future of Container Protection
Global trade is bound to continue on its growth trajectory and with it comes an increasing demand for durable shipping containers built to last. In fact, UNCTAD projects that total seaborn trade will grow by 2.4% and containerized trade by 2.7% from 2025 to 2029.
For these industries, powder coatings have proven to be a solution that delivers longevity, sustainability and cost efficiency.
While adoption is gradual, early successes and the growing emphasis on sustainability, particularly around VOCs, suggest that powder coatings will emerge as the standard for modern container finishing in the near future. Investing in these advanced finishing technologies equates to longer lifecycles and a competitive edge for all shipping and transportation stakeholders.