FUSION Issue 1 2026 DIGITAL SINGLE PAGES - Flipbook - Page 7
The real culprit: shop floor habits,
not invoice prices
Across paint and composite environments, the most significant sources of consumable waste
hide in plain sight. Over-application is one of the most common contributors, often driven by
a belief that using more material improves finish quality or durability. In practice, excessive use
frequently leads to rework, longer cure times and inconsistent results, sometimes increasing
material use by twenty to thirty per cent with no performance benefit.
Poor or inconsistent training also plays a role. When operators are not aligned on correct
usage rates, application techniques or product purpose, variation increases.
This is compounded when standards are undocumented, unclear or interpreted differently across
shifts or teams. The result is waste driven by habit rather than necessity.
Inefficient sequencing can further inflate consumption. Using the wrong abrasive grade at the
wrong stage, applying protection materials too early, or opening consumables long before they
are needed all increase unnecessary waste and disposal costs.
“ manufacturers can
reduce environmental
impact, control
costs, and maintain
the high standards
expected in
paintshop and
marine
environment ”
Waste is rarely a cost problem. It is usually a process problem.
The hidden cost of
disposal and rework
Reducing waste without
sacrificing results
A performance led approach to
waste reduction
Consumable waste has
consequences beyond the price of
the material itself. Disposal costs,
particularly for contaminated or
hazardous waste, continue to rise.
Environmental compliance adds
further pressure, with increasing
scrutiny on how materials are used,
stored and discarded.
The good news is that manufacturers that successfully
reduce consumable waste do not rely on sweeping
policy changes. They focus on a small number of
practical, operational improvements.
Reducing consumable waste does not require cutting
corners, lowering specifications or
risking finish quality. In fact, the most effective waste
reduction strategies are often those that improve
performance consistency and operator confidence.
Quality impact is another
overlooked factor. Inconsistent
consumable usage can lead to
surface defects, adhesion failures
and finish variability. These issues
often trigger rework, which can
double the consumable cost of
a job, along with lost production
time and increased disposal costs.
The original waste problem is
amplified rather than solved.
Clear standards are the starting point. Defining
approved products, correct usage rates and
application methods removes ambiguity and reduces
variation. When these standards are supported by
practical training rather than assumptions, operators
are better equipped to work efficiently without
compromising quality.
Process alignment is equally important. Ensuring
consumables are introduced at the correct stage, in
the correct quantity and for the correct task prevents
overuse driven by habit or guesswork.
By reframing waste as an operational issue rather than
a purchasing one, manufacturers
can reduce environmental impact, control costs, and
maintain the high standards expected in paintshop
and marine environments.
Waste reduction, done properly, is not about using less.
It is about using materials with precision, purpose and
zero compromise on quality.
Visibility also plays a role. When teams understand what is
being used, where and why, waste becomes measurable
rather than assumed. This allows organisations to address
root causes rather than symptoms.
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