19 May, 2025
Why are many industries moving away from metal to engineering plastics?
In an industry driven by sustainability, efficiency and competitiveness, an increasing number of companies are reconsidering the materials used in their processes. One of the most strategic — and cost-effective — changes is replacing metal with engineering plastics in components and functional parts.
But why now? What has changed? The answer lies, in part, in REPowerEU, the European plan that is setting the pace for a more sustainable, decarbonised and less externally dependent industrial transition.
Although its focus is on heat and power generation systems, it is generating a ripple effect in other key areas, such as equipment redesign. Reducing the weight of components, optimising processes and choosing lighter and more energy-efficient materials not only allows progress towards a more sustainable industry, but can also translate into significant economic savings in the medium term.
But, before you read on
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A new policy context: REPowerEU
Launched by the European Commission in the wake of the 2022 energy crisis, the REPowerEU strategy has a clear objective: to reduce dependence on fossil fuels and accelerate the transition to renewable energy and a more efficient industry. This means:
- Reducing energy consumption in all industrial sectors.
- Promoting the use of lighter, recyclable materials with a lower carbon footprint.
- Supporting technological transformation through European funds and incentives.
Although this may appear to be a measure designed for the energy sector, its implications extend to any industry that manufactures, transforms or consumes energy, particularly those that use heavy materials or energy-intensive processes, such as the metal industry.
This framework is not just a voluntary roadmap; it is linked to legal obligations and concrete deadlines that already affect thousands of industries.
So how does it affect you if you use metal?
If you work in sectors such as automotive, industrial construction, HVAC, machinery or capital goods, REPowerEU and other European regulations are already influencing – directly or indirectly – your operations.
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The weight of energy efficiency in industrial processes
- The Energy Efficiency Directive (EED), which imposes energy audits and improvement plans.
- The use of engineering plastics allows for less intensive transformation processes and lighter materials, which reduces energy consumption and improves efficiency ratios.
- Binding targets such as a 43% improvement in energy efficiency by 2030 in Spain (according to the National Integrated Energy and Climate Plan –PNIEC-).
- Indirect penalties, such as those derived from the use of heavy or difficult-to-transform materials.
“Manufacturing and processing metal requires much more energy than moulding a technical polymer”.
Emissions, penalties and limits: The EU ETS case
Energy-intensive industries (such as metallurgy or metal processing) are subject to the EU Emissions Trading Scheme (EU ETS), which requires them to reduce CO₂ emissions by 62% by 2030 compared to 2005 levels. This involves:
- Acquiring emission allowances if you exceed your quota.
- Assuming penalties of up to €100/tonne of excess CO₂.
- Evaluating lower environmental impact alternatives to remain competitive.
Strategic raw materials and sustainable design: new requirements for 2030
The European Commission is already working on regulations to promote the use of recyclable, critical or strategic raw materials, reducing external dependence and environmental footprint.
“Many advanced technical plastics are recyclable, lighter, and can be custom-designed to replace metallic functions… without relying on volatile markets”.
“FROM METAL TO PLASTIC: A practical guide to saving costs, complying with regulations and making your products lighter”
Key Raw Materials Act (CRMA)
In particular, the European Commission is pushing for a regulatory framework that accelerates the transition towards the use of more sustainable and circular raw materials, with a major impact on industries working with metals. One of the key pillars is Regulation (EU) 2024/1252, also known as the Critical Raw Materials Act (CRMA), which aims to secure strategic supply and reduce external dependence.
By 2030, it imposes concrete targets: to source at least 10% of annual raw material needs on European territory, process 40% within the EU, cover 25% of consumption with recycled materials, and limit dependence on a single country to 65% for any critical raw material.
Ecodesign Regulation for Sustainable Products (ESPR)
In parallel, the new Ecodesign Regulation for Sustainable Products (ESPR) establishes mandatory requirements to improve the recyclability, durability, efficiency and traceability of industrial products. This includes the obligation to use recyclable materials, reduce hazardous substances and design with circular economy criteria. Industries that still rely on heavy or difficult-to-recycle materials, such as certain metals, will be forced to justify their use or look for alternatives.
«In this context, engineering plastics are positioned as an effective, lighter solution that is aligned with European legislative goals».
Technical plastics: an alternative that is already a competitive advantage
- Weight reduction → less energy consumption in operation (automotive, air conditioning, machinery).
- More efficient processes → less energy use in moulding/injection moulding than in machining.
- Better thermal or chemical behaviour, depending on material design.
- Compatibility with recycling and circular economy.
- Regulatory compliance and emissions reduction.
| Property | Metal | Engineering Plastic |
|---|---|---|
| Weight | High | Up to 70% lighter |
| Manufacturing energy | High | Medium or low (injection moulding) |
| Production emissions | High | Up to 80% reduction |
| Recyclability | Medium | High (depending on the polymer) |
| Chemical resistance | Limited | High in many grades |
| Design flexibility | Limited | High (moulding, 3D geometries) |
“FROM METAL TO PLASTIC: A practical guide to saving costs, complying with regulations and making your products lighter”
Case studies: From metal to plastic without loss of performance
Automotive, air-conditioning and electronics companies have already replaced metal parts with technical plastics:
- Withstand temperatures of up to 280°C.
- Have high dimensional stability.
- They reduce weight by up to 70%, improving the energy consumption of the final product.
- Are recyclable or derived from organic sources.
Is it viable for your company to replace metal with plastic?
Many companies consider this transition as something complex. That is why Guztec Polymers offers real technical support, based on success stories and experience in demanding sectors such as automotive, industrial construction, electronics or air conditioning.
In addition, our materials are already aligned with the sustainability criteria required by the EU, which will allow you to anticipate future regulatory obligations without sacrificing performance.
Do you want to explore whether you can substitute metal for plastic in any of your product applications?
We help you analyse whether it is feasible, which polymer is best suited and what the real benefit would be in your case.