Biobased Lubricants and Hydraulic Fluids from Vegetable Oils

How They Are Made from Vegetable Oils

Key Steps:

1. Oil Extraction & Preprocessing
• Vegetable oils (e.g., castor, palm, soybean, sunflower) are mechanically or solvent-extracted and filtered to remove impurities.
2. Chemical Modification
• To improve oxidation stability and cold-flow properties, oils undergo processes like:
• Esterification (forming fatty acid esters)
• Epoxidation
• Transesterification (e.g., with trimethylolpropane)
• Hydrogenation to reduce unsaturation
3. Additive Blending
• Additives such as antioxidants, anti-wear agents, and corrosion inhibitors are added to meet industrial standards.
4. Formulation and Testing
• Final blends are tested for viscosity, flash point, pour point, biodegradability, and wear resistance.

Feedstocks: Canola oil, soybean oil, castor oil, palm oil, rice bran oil, and used cooking oils

Case Study: FUCHS Group – PLANTO Biolubricants Line

Highlights:

• Germany-based FUCHS Petrolub SE developed the PLANTO range of biodegradable lubricants.
• Applications include hydraulic systems, chainsaws, gears, marine, and railroad switch lubrication.
• Uses canola and esterified vegetable oils with high oxidation and thermal stability.

Timeline & Outcome:

• 2000–2005: Introduced PLANTO hydraulic fluids meeting ISO 15380 and OECD 301B biodegradability.
• 2010: Expanded into construction and forestry equipment.
• 2020: PLANTO product line enters railways and marine compliance segments in the EU.
• 2023: New generation PLANTO oils launched with improved low-temp flow and longer drain intervals.

Global Startups and Companies in Bio-lubricants

• Renewable Lubricants Inc. (USA) – Pioneers in soy-based lubricants and greases.
• FUCHS Group (Germany) – PLANTO line is a global benchmark.
• Panolin AG (Switzerland) – Produces fully synthetic biodegradable hydraulic fluids from estolides.
• BASF – Developed Synative® base oils for biolubricants.
• Green Earth Technologies (USA) – Offers G-Oil™ motor oils from natural fats.
• BTG Bioliquids (Netherlands) – Converts pyrolysis oil into bio-oil base fluids.

India’s Position

• India has abundant feedstocks: castor, mustard, palm, rice bran, and used cooking oils.
• Indian Oil Corporation (IOCL) and CSIR-IIP have developed biolubricants for railways and defense.
• Godrej Agrovet and Ruchi Soya produce vegetable oils with potential for biolubricants.
• Startups like Varaha Bio and Nivshakti Bioenergy explore castor/Neem-based lubricants.
• Adoption is still limited to pilot and defense use, but growing environmental regulations could spur demand.

Commercialization Outlook

Market & Demand

• Global bio-lubricant market: ~$3.1 billion (2024), CAGR ~5.8%
• Applications:
• Hydraulic systems
• Engine oils and gear oils
• Chainsaw and marine lubricants
• Metalworking fluids
• Railways and agricultural machinery

Key Drivers

• Environmental safety and biodegradability mandates, especially in forestry, marine, and agriculture.
• Government procurement for defense and railways favoring green alternatives.
• Extended drain intervals and better lubricity than mineral oils.
• Supportive regulations in Europe, USA, and select Asian markets (e.g., ISO 15380, EU EcoLabel)

Challenges to Address

• Oxidative instability of unmodified oils.
• Higher production cost (~20–50% above mineral oils).
• Limited performance at low temperatures and high loads.
• Need for engineer and OEM acceptance and long-term field validation.
• Limited domestic certification and standardization protocols in India.

Progress Indicators

• 2000–2005: EU mandates for biodegradable lubricants in sensitive areas.
• 2010–2015: Launch of field-validated products by FUCHS and Panolin.
• 2016–2022: Bio-based hydraulic fluids penetrate construction, forestry, and defense.
• 2023–2024: IOCL and Indian Railways collaborate on bio-lubricant trials in harsh conditions.
• 2024 onward: Indian ministries issue procurement tenders favoring bio-based oils.

Vegetable oil-based lubricants are at TRL 9 globally (fully commercial). In India, TRL ranges from 6 to 8, with deployment in select sectors (railways, defense) and growing private-sector R&D.

Conclusion

Biobased lubricants and hydraulic fluids derived from vegetable oils are emerging as sustainable, non-toxic alternatives to petroleum-based fluids — especially in environmentally sensitive and safety-critical industries. Global leaders like FUCHS and Panolin have proven their performance across sectors. India’s strength lies in indigenous oil crops and growing environmental policy focus, making it well-positioned to scale. To accelerate adoption, India must address cost competitiveness, certification frameworks, and localized performance testing. With proper ecosystem support, biolubricants can play a vital role in greening industrial maintenance, mobility, and precision agriculture.

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