In this, the fifth edition, we review the key market drivers for fuel tank systems, and update our market analysis. At over 1,500 words longer than the previous edition, just-auto's latest global market review of fuel tanks offers excellent value for money.

just-auto has completely revised its estimates and forecasts of fuel tank system market volumes and values. This report therefore sets out our revised forecasts for such systems for passenger car vehicle assembly in North America, Western Europe and Japan from 2005 through to 2016. In addition, and given the sheer volatility of the global economy at present, we have set out an ‘expected’, ‘best case’ and ‘worst case’ scenario applied to fuel tank systems.

For some time, fuel tank manufacturers have come under increasing pressure from legislation, particularly in the US, to design and build tanks that can withstand higher and higher impacts without leaking. The main factors driving fuel tank innovation are legislation, weight, packaging, safety and cost. In addition to continued demand for fuel tank range and fuel economy, we are seeing more complex shapes and geometries, particularly driven by the all/rear-wheel drive increase in smaller car segments. This creates a unique packaging environment that influences the design selection and requirement for those programmes.

Against this backdrop and given the continuing popularity of plastic tanks, can steel tanks really make a comeback? There are always opportunities available for steel tanks for low-volume production. Although multi-layered plastic seems to have become the material of choice, there are some concerns that it might not be able to meet the forthcoming emissions regulations or that it meets the spirit of the ELV Directive. Some vehiclemakers are said to be re-evaluating plastic tanks in favour of steel, and for some higher value models, even systems made of stainless steel.

Following our market overview in Chapter 1, just-auto’s product fitment forecasts in Chapter 2 predict the market (by volume and value) in North America, Western Europe, Japan and China for plastic and steel fuel tanks. This chapter begins with reviewing the key suppliers, including a lengthy interview with TI Automotive.

Extract:

j-a: Biodiesel is already popular in Europe and is reported to be spreading to the North American market. And yet are there still issues concerning the vehicle manufacturers using plastic fuel tanks to store biodiesel? Can steel do a better job? What do you see as the issues there?

TI Automotive: For plastic tanks, the issue is polymer compatibility as biodiesel fuel ages and eventually breaks down into more chemically reactive constituents. For steel tanks, TI Automotive has studied the effects of biodiesel, at different concentration levels, on various grades of steel. In summary, for steel tanks to withstand the aggressive nature of biodiesel it is necessary to move up to higher grades of stainless steel or use a surface coating. Both options will add cost to the product, making it less competitive and you still have the weight problem.

Also in chapter 2 is an interview with the Plastic Fuel System Manufacturers Association.

We review the latest developments to the sector in emerging markets. The chapter goes on to provide world, Western European, North American, Asia-Pacific and Japan & Korea market shares for the OE supply of fuel tanks for passenger cars and light trucks in 2008.

Chapter 2 concludes with the report's market analysis and data. The numbers provided comprise of percentage fitment rates by region for plastic fuel tanks and then steel tanks from 2005 to 2016. Plus, we provide market volume and value by region for the two sectors over the same timeline. The volumes and values include our actual/estimated data plus our best- and worst-case scenario forecasts.

Chapter 3 Technical review
In addition to basically storing fuel, there are a number of technical requirements that a fuel tank must fulfil. This chapter sets out a review of recent innovations and fuel-type considerations and looks at the implications of the latest emmission standards.

The chapter takes a look at the latest information on urea tanks: From 1 January 2010, urea tanks will be standard equipment for most new diesel trucks, buses, cars and SUVs manufactured in the US. An automotive grade of urea [known as diesel exhaust fluid (DEF)] will be injected into the vehicle's exhaust stream to ‘scrub’ nitrogen oxide (NOx) from the diesel exhaust.

The innovations section looks at other key developments such as new materials and how manufacturers are combating mis-fuelling errors.

The chapter also reviews biofuels' impact on fuel tank design and concludes with a lengthy interview with Ray Sheffield, director of fuel tanks, Martinrea International, and Peter Mould, programme manager, Strategic Alliance for Steel Fuel Tanks (SASFT).

Chapter 4 Manufacturers
Profiles of the major manufacturers, namely Inergy Automotive Systems, Kautex Textron, TI Automotive and Visteon.

This report includes exclusive Q&As with the Plastic Fuel System Manufacturers Association and the Strategic Alliance for Steel Fuel Tanks providing both sides of the plastic versus steel fuel tanks debate.