Global Automotive Plastic Fuel Tank Market 2021-2026

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    In an internal combustion engine, a vehicle’s fuel tank is an integral part of the fuel system. A tank is a container used to hold motor fuel such as gasoline, diesel, and gas. Fuel tanks nowadays are built of a variety of sophisticated materials, including ferroalloys, aluminium alloys, and polymers. Stamping of sheet metal and welding of top and lower sections are used to make steel gasoline tanks. Steel gasoline tanks are made of high-viscosity steel with a high ultimate strength. A gasoline tank deforms owing to its viscosity when exposed to external forces, yet it remains leak-proof. Steel gasoline tanks have a significant corrodibility, which is its major drawback.


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    Water entry into a gasoline tank is quite likely since it can enter as condensate or mixed with fuel and sink to the bottom. Stamping and welding are used to make aluminium gasoline tanks. They are less corrosive and weigh less than steel fuel tanks. Aluminium fuel tanks have the following drawbacks over steel tanks: potential gasoline leaks due to weld failure during operation; poor deformation capacity (impact resistance); existence of stress risers in a material after a short-term strain greater than its strength; expensive cost.


    Leading global manufacturers are in the midst of transitioning to plastic fuel tanks. Rotational moulding or extrusion are used to make polyethylene and polypropylene fuel tanks. In comparison to steel and aluminium gasoline tanks, plastic tanks are not corrodible, are resistant to scratches and chipping, are lighter, do not require welding, and are less expensive. Existing plastic fuel tank manufacturing processes allow for the fabrication of components with complicated geometry, efficient use of tank mounting space, and maximum tank volume.



    The following requirements of operational needs should be met by modern plastic fuel tanks which includes vehicles operating temperature range of minus 60 °C to plus 80 °C; local and short duration heating up to 110 °C (high temperature near areas of more intense sunlight, exhaust system, points of contact with the wire bundles); leak proofness at an excessive pressure of up to 0.02 MPa. Although plastic-tank applications have experienced some reversals as a result of the stricter permeation standards, some experts believe their usage will gain momentum by the end of the decade as new plastics technology is converted to commercially feasible operations.


    The major drivers projected to drive market expansion in the future years are rising demand for lightweight cars for fuel economy, increased vehicle manufacturing, and growing urbanization. One of the key reasons driving market expansion is the rising demand for and sales of commercial vehicles as a consequence of the rise in the e-commerce sector, which has resulted in the growth of the logistics and construction industries. However, issues such as increasing electric car adoption and demand, as well as rising base metal costs, such as aluminium, may stymie industry development.


    The tightening of pollution and fuel efficiency standards has turned automobile manufacturers’ attention to alternative fuel vehicles such as compressed natural gas (CNG), liquefied natural gas (LNG), and fuel cell vehicles. According to the 2012 efficiency requirements, the US passenger car fleet must attain an average fuel economy of 49.1 miles per gallon (mpg) by 2025, or 54.5 mpg when CO2 emissions are included in, with different credits for extra climate benefits added in.



    The Global Automotive Plastic Fuel Tank Market can be segmented into following categories for further analysis.


    By Integrated Capacity

    • Less than 45 Litres
    • 45 Litres to 70 Litres
    • Above 70 Litres


    By Vehicle Application

    • Residential Application
    • Commercial Application
    • Industrial Application
    • High-Capacity User Application


    By Connectivity Material Type

    • Specialised Plastics
    • Recyclable Plastics


    By Regional Classification

    • Asia Pacific Region – APAC
    • Middle East and Gulf Region
    • Africa Region
    • North America Region
    • Europe Region
    • Latin America and Caribbean Region



    Plastic fuel tanks and systems are intended to provide the automobile industry with environmentally responsible, cost-effective, lightweight, and safe alternatives. The goal of this work is to design and numerically examine the impact strength and develop a modular prototype using high density polyethylene plastic, which is a strong and lightweight material, allowing manufacturers to significantly reduce the overall weight of their vehicles and make them more fuel efficient.


    Plastic gasoline tanks also provide enhanced safety in the case of a collision. Unlike metal fuel tanks, many may bend and flatten instead of ripping, rupturing, and leaking gasoline, securely eliminating fuel leaks. Plastic fuel tanks are composed of high-density polyethylene (HDPE), a durable and lightweight material that allows manufacturers to significantly lower the total weight of their cars while also increasing fuel efficiency. Plastic gasoline tanks also provide greater safety in the case of a collision.


    In contrast to metal fuel tanks, many may bend and flatten rather of ripping, rupturing, and spilling gasoline, thereby eliminating fuel leakage as a source of a fire or explosion. Plastic may be moulded to fit around certain components. Furthermore, plastic gasoline tanks are corrosion resistant, but steel tanks require stainless steel to offer a comparable level of corrosion resistance, which also increases the cost. Multilayer plastic tanks are now more capable than earlier monolayer tanks of meeting car emissions regulations set by the EPA and CARB. Despite the limits of life cycle design that were shown in this demonstration, the project team learned a lot about the ecological contours of steel and HDPE fuel tank systems. Furthermore, the assessments of feat, cost, and policy concerns pertaining to fuel tank design were beneficial to all team members.




    Plastic tanks can fulfil packing limitations with complicated forms, and design engineers have more wiggle room in automobile design and style without having to worry about fitting the gas tank. The plastic tank could almost be fashioned to suit whatever gaps the design leaves. Other connections to and within the plastic tank need of casket mechanical joints. Plastic, on the other hand, expands when exposed to organic liquids and vapour on a continuous basis. Cadillac, on the other hand, says that while its plastic tanks allow for more design flexibility and enhanced safety, they do not save weight over steel tanks.


    Textron Kautex has been part of the major ecological development of the plastic-based fuel tanks. It has most recently produced the NGFS® technology, also known as “twin sheet ”, technology which helps reduce emissions and weight while potentially increasing volume depending on tank design. It also serves as the basis for our lightweight hybrid fuel tank. NGFS® is produced by lowering two sheets of multi-layered parison through the blow moulder extruders. The “twin sheet” design allows easy access for components to be integrated directly into the plastic shell, thus eliminating the need for cutting and welding and reducing emissions. The two half shells, with their associated components in place, are then moulded together before being removed from the bold moulder. These more complex fuel tank applications require closed fuel systems with a higher internal pressure which causes massive deformations on un-reinforced plastic tanks.


    Fuel Total System is into the product innovation of the latest technology based plastic fuel tanks. The construction technology used by the organisation is of the highest standards wherein, The high-density polyethylene fuel tanks are created through a multi-layered, blow moulding technology to ensure safety and efficiency. Blow moulding is a manufacturing process that allows hollow plastics parts to be joined together seamlessly. They use the mass reduction technology that enables us to construct highly advanced uniformed fuel tanks. It’s an effective process that maintains the integrity of the design for safe and effective driving. The 6-layer, Co-Extrusion Blow Moulding process for the Fuel Tank results in low permeation to minimize fuel hydrocarbons. This produces a Fuel Tank that is environmentally friendly and meets the highest federal government requirements.



    Sl no Topic
    1 Market Segmentation
    2 Scope of the report
    3 Abbreviations
    4 Research Methodology
    5 Executive Summary
    6 Introduction
    7 Insights from Industry stakeholders
    8 Cost breakdown of Product by sub-components and average profit margin
    9 Disruptive innovation in the Industry
    10 Technology trends in the Industry
    11 Consumer trends in the industry
    12 Recent Production Milestones
    13 Component Manufacturing in US, EU and China
    14 COVID-19 impact on overall market
    15 COVID-19 impact on Production of components
    16 COVID-19 impact on Point of sale
    17 Market Segmentation, Dynamics and Forecast by Geography, 2021-2026
    18 Market Segmentation, Dynamics and Forecast by Product Type, 2021-2026
    19 Market Segmentation, Dynamics and Forecast by Application, 2021-2026
    20 Market Segmentation, Dynamics and Forecast by End use, 2021-2026
    21 Product installation rate by OEM, 2021
    22 Incline/Decline in Average B-2-B selling price in past 5 years
    23 Competition from substitute products
    24 Gross margin and average profitability of suppliers
    25 New product development in past 12 months
    26 M&A in past 12 months
    27 Growth strategy of leading players
    28 Market share of vendors, 2021
    29 Company Profiles
    30 Unmet needs and opportunity for new suppliers
    31 Conclusion
    32 Appendix


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