Plastic repair: improving the bottom line

The growing costs of plastic parts coupled with improved repair methods and equipment mean repairing rather than replacing plastic is the profitable way. NRMA Insurance recently introduced an initiative to help repairers benefit.
NRMA Insurance has moved to reduce the amount of plastic car parts that end up in dwindling state landfill, as research reveals plastic parts discarded in NSW alone last year would stretch from Sydney to Brisbane.
NRMA Insurance and NSW TAFE recently launched a Plastic Repair Index and information hotline to provide smash repairers with a step-by-step guide on how to repair gashes, scratches and dents from bumper bars, grilles and headlamps which generate about 750 tonnes of landfill annually in NSW and the ACT.
Claims and assessing manager, Paul Pemberton, said NRMA Insurance is looking at new ways to improve collision repairs to enhance the skills of smash repairers, pass on the benefits to customers and help the community.
"Traditionally, most cars involved in collisions have been repaired by replacing damaged parts and fitting new ones. Now with developments in plastics technology, parts can be easily and more efficiently repaired to the same level of quality before the accident," he said.
Almost all cars on the Australian market have plastic front and rear bumper bars, radiator grilles, headlamps with clear plastic lenses, plastic wheel covers, external mirrors and body protection strips. Some vehicles, such as the Volkswagen Beetle, have all four mudguards made from plastic.
Thirty years ago, the average car contained less than 50kg of plastic materials. Now, it is more that 150kg.
"More than 320,000 plastic parts, costing around $65 million each year are being thrown away and replaced. If these parts were lined-up, this represents landfill that would stretch from Sydney to Brisbane," Pemberton said.
"Because most plastic parts are not biodegradable, repairing plastic parts instead of throwing them away reduces landfill and helps the environment.
"Many smash repairers agree that with a little know-how and the right equipment such as hot air guns, welding guns, glues, solvents and adhesives, quality repairs to plastic parts can be achieved quite simply. The results will be real cost savings and efficiencies for the smash repair industry."
Head teacher of panel beating at Southern Sydney Institute of TAFE, Gary Thomas, said plastic repair workshops are now part of smash repair apprenticeship courses.
"Plastic parts were originally designed to be cheap throwaways," said Thomas. "Because technology has improved and materials are more expensive, it makes good sense to use skills to repair plastics instead of replacing them. Repairers need to tackle plastic repair jobs as if they are repairing a metal part. Instead of throwing away plastic parts that can be worth hundreds of dollars, they can be easily moulded back into shape for the single cost of labour.
"Bumper bars alone can cost anywhere from $130 to $3000 to be replaced, depending on the make and model of the vehicle. Often parts may have to be imported which can increase the time it takes to get motorists back on the road. Savings can be also be passed onto motorists through fast, quality repairs that restore the look of the vehicle to pre-accident condition," Thomas said.
Not only do repairers stand to gain increased profits from repair over replace, the workforce benefits too. "Technicians feel that they are doing their job better if they have the opportunity to actually repair these parts," said Theo Pittas, NRMA Competitive Partnering & assessing manager, Metro South Region. "Many panel beaters these days complain that they have been reduced almost to robots because all they are doing is replacing parts. Panel beaters already have the skills to repair plastic and allowing them to do so not only improves profitability, it improves staff morale and allows technicians to properly utilise their skills," he added.
Special 'Plastic Repair Indexes' have been distributed to NRMA Insurance Preferred Smash Repairers in NSW and the ACT as well as to NRMA repairers in Queensland, RACV shops in Victoria, SGIO shops in WA and SGIC facilities in South Australia, according to Pittas.
The Plastic Repair Indexes include all the information repairers need to successfully and profitably repair plastic parts, including headlamps, bumper bars, grilles and headlamp moulds. Tips on how to identify different types of plastic are also included along with a list of all plastic types used in vehicle manufacture.
Each section consists of step-by-step guides to specific repairs, accompanied by colour photos. The Index is printed on laminated card and comes ring-bound for ease of use and durability.
NRMA has donated a mobile phone to Thomas and repairers can access his advice using the Plastic Repair Helpline by calling 0411 013 352 during business hours, Monday to Friday.