Conventional epoxy coatings emit harmful Volatile Organic Compounds (VOCs), with xylene being a significant contributor to environmental pollution and health risks due to its high volatility and toxicity. This research explored the use of propylene glycol monomethyl ether (PM) as a safer, sustainable substitute for xylene in high-solid epoxy coatings. Five formulations with varying xylene-to-PM ratios (100:0, 0:100, 50:50, 70:30, 30:70) were tested for VOC emissions, viscosity, touch dry time, and corrosion testing. The 0:100 PM formulation achieved an 80% reduction in VOC emissions compared to the xylene control (100:0 xylene). Viscosity measurements showed that the 0:100 PM formulation had a lower viscosity of 41.7 cP compared to 166.6 cP for the xylene-based formulation. Meanwhile, the touch dry time for 0:100 PM coatings was recorded at 80 min, 2.7 times higher than that of the 100:0 xylene formulation’s 30-min drying time. Although the 100:0 PM formulation had a higher corrosion rate (8.71 mpy) compared to the xylene control (2.18 mpy), its inhibition efficiency of 66.67% is within an acceptable range for industrial applications. Notably, formulations with reduced xylene content showed improved environmental performance while maintaining acceptable protection. These findings highlight decreasing xylene concentration can result in a more balanced approach that aligns with sustainability goals.