Lubricants saving the day!

By Staff Report July 1, 2025 5:23 pm IST

The role of lubricants has changed significantly; they now serve more than just reducing friction. Today, they are pivotal for improving energy efficiency and extending the lifespan of machines. Industry experts discuss how advancements in lubrication technologies, ranging from smart lubricants to eco-friendly and synthetic options, enhance industrial efficiency, sustainability, and reliability across various sectors, including manufacturing, automotive, and heavy machinery.

Approximately 50% of all mechanical failures are caused by poor lubrication practices. Lubricant producers aim to address this issue by developing tailored solutions that extend the equipment’s life, even under harsh operational and environmental conditions. Samwar Mavani, the Director of MOSIL Lubricants, explains that their approach is based on performance simulation. They replicate the end-user application using custom-built test rigs to simulate real-world factors, such as load, temperature, speed, and other environmental conditions, before the product is delivered to the customer’s site.

Role of smart lubricants
Smart lubricants enhance equipment reliability and reduce downtime in predictive maintenance. These advanced lubricants are embedded with sensors and additives that monitor temperature, pressure, and wear in real time. By analysing this data, industries can detect early signs of machinery failure and take preventive action before costly breakdowns occur. Smart lubricants also optimise performance by adjusting their properties based on operating conditions, ensuring smooth functioning and energy efficiency. This technology is widely used in manufacturing, automotive, and heavy industries, where unplanned maintenance can lead to significant losses. By integrating smart lubricants into predictive maintenance strategies, businesses can extend the life of their machinery, improve efficiency, and reduce maintenance costs, ultimately leading to long-term operational success.

Good lubrication is key to making machines run smoothly and using less energy. When the right lubricant is used, it reduces friction between moving parts, so machines don’t have to work as hard. This means less power is needed, which helps save energy. High-quality synthetic oils last longer and perform well even in extreme conditions, reducing wear and tear. Regular checks and maintenance ensure that lubrication stays effective and prevents energy loss. Choosing the correct oil thickness and applying it at the right time also helps improve efficiency. By using proper lubrication, manufacturers can lower costs, extend machine life, and run their operations in a more energy-efficient way.

Challenges in selecting the right lubricant
Hitesh Torawane, Consultant, emphasises that selecting the right lubricant for manufacturing processes is a complex and critical decision. Every machine works differently; some run at high speeds, others handle heavy loads, and temperatures vary. A single lubricant cannot suit all needs. Using the wrong one can cause wear, rust, or contamination. Poor-quality lubricants can break down machines and increase costs and downtime. Safety and environmental rules also matter, so choosing eco-friendly options is important. Another challenge is balancing cost and performance, as inexpensive lubricants may initially save money but can damage machines over time. As technology advances, new lubricants are required to match the demands of modern machinery. Picking the right lubricant helps machines run smoothly, last longer, and save money in the long run.

Latest industrial oils and lubricants innovations
Bio-based lubricants, derived from renewable sources, are gaining popularity for their eco-friendly nature and superior performance. Nano-lubricants, infused with microscopic particles, minimise friction and wear, enhancing machinery lifespan. Smart lubricants, equipped with sensors, provide real-time data on lubricant health, reducing downtime and maintenance costs. High-performance synthetic oils offer extended drain intervals and excellent thermal stability, making them ideal for heavy-duty applications. Meanwhile, advancements in additive technology have led to lubricants with superior resistance to oxidation and contamination, ensuring smoother operations. These innovations are revolutionising manufacturing by boosting productivity, sustainability, and cost-effectiveness.

Nano-additives, bio-based base oils, and smart formulation chemistry are reshaping lubricant performance, offering enhanced wear protection and sustainability. Karthik Balu, Partner at Torq Lubrication, shares, “We are integrating these advancements to enhance longevity, minimise environmental impact, and enhance energy efficiency. Our formulations also use sensor-friendly properties for condition monitoring.”

The sustainability aspect has led to the development of eco-friendly alternatives. Traditional lubricants, made from petroleum, can harm the environment. In response, companies are creating biodegradable options using renewable sources like vegetable oils and synthetic esters. For example, Shell’s Naturelle range and Castrol’s BioRange offer biodegradable lubricants that reduce carbon footprints while maintaining high performance. These lubricants break down naturally, preventing soil and water contamination. Additionally, advanced additives enhance efficiency without toxic effects. Industries such as marine, agriculture, and automotive are adopting these solutions to meet stringent environmental regulations. With rising consumer demand and stricter policies, eco-friendly lubricants are making a greener future, proving that sustainability and high performance can go hand in hand.

Synthetic machine lubricants
As a Machinery Lubrication Consultant for Tulco Oils, Trent Richardson highlights the transformative impact of high-performance lubricants in industrial applications. The right lubrication strategy focuses on maximising efficiency, reducing downtime, and extending equipment life, where synthetic machine lubricants stand out. Synthetic lubricants have gained popularity across various industries due to their superior performance compared to conventional mineral oils. They offer improved viscosity stability, enhanced wear protection, and increased oxidation resistance. This reduces friction and component damage, resulting in fewer breakdowns and longer service life for machinery. In high temperatures, synthetic oils resist oxidation and thermal breakdown, preventing sludge buildup to keep systems clean. In cold environments, they maintain fluidity, ensuring smooth startups and minimising wear.

These lubricants also enhance energy efficiency by lowering power consumption and reducing operational costs. Their longer drain intervals lead to fewer oil changes and a decrease in downtime and maintenance expenses. Overall, switching to synthetic lubricants is a smart move to improve equipment reliability, efficiency, and longevity while reducing operational costs.

Impact of regulatory changes

The lubricants industry is undergoing significant changes due to evolving regulations focused on sustainability, emissions control, and environmental safety. Stricter limits on sulfur content, carbon footprints, and hazardous additives are pushing manufacturers to develop eco-friendly formulations. Governments worldwide are encouraging the use of bio-based and synthetic lubricants, reducing reliance on petroleum-based products. Compliance with new standards, such as API SP and ILSAC GF-6, is driving innovation in high-performance lubricants that enhance fuel efficiency and engine protection. Additionally, regulations on waste oil disposal and recycling are reshaping supply chains. While these changes create challenges in terms of cost and reformulation, they also open doors for sustainable growth and technological advancements in the industry.