For the last few decades PVC-plastisols have been one of the most common process materials in the automotive production used as adhesives, sealants or for various coating processes. A high standard of performance has been reached.But recently raised concerns about chlorine containing substances created in fire and combustion arose search of alternatives to PVC-products.Intensive work led to various possibilities to substitute today's PVC-plastisols by using polymers free of halogens. As a main target, concentration was given to similar technical performance as well as to same easy application as with PVC-plastisols. Although investigations referring to polyurethanes gave excellent technical results the price/performance ratio was rather unacceptable.For some applications plastisols based on pure acrylic ester (co)polymers are very valid substitutes especially for body-in-white purposes. But for paint shop applications the cost for the basic raw material was seen to be too high.A new family of styrene/acrylic copolymers was developed to clear the hurdle of price and to step into plastisol technology. Good technical performance, same simple application as with other plastisols combined with a cost effective polymer seem to characterize the ideal candidate for PVC-free coatings and sealants.With these materials we can contribute considerably to the world's first PVC-free car.