How lubricants can offer ethical and economical benefits
January 1st 2007

In 2007, one thing is clear: environmental control is no longer a peripheral issue but something that concerns us all. If 2006 was credited as the year that the world finally acknowledged the problems of climate change, 2007 is the year for action

If ever a problem called for a holistic response involving every effective measure and every person and business on this planet, it is climate change. Tony Blair recently called climate change "the most serious issue facing mankind" and in just 12 months, the issue has become something at the very heart of public debate and personal concern, involving not just those sympathetic to sustainability but every individual living under the sheltering, shifting skies of climate change.

The responsibility of industry has been a central factor in this debate and whilst many "green" solutions have been presented during the last few years, they have generally been viewed as cost disadvantageous, and whilst socially ethical, the steadily increasing demand for improved profitability and lower costs proved too much of a barrier to change.

Lubricants based on renewable resources, such as rapeseed oil, synthetic esters and sunflowers, have been available for many years, and whilst their additional benefit of biodegradability has made them widely accepted in areas such as forestry and construction plant equipment, manufacturing industries have been slow to understand that these products offer significant economical as well as ecological benefits.

"Convincing manufacturing companies that 'green' is not a pseudonym for 'poor quality' has been one of the most difficult tasks," explains Richard Rogers, Industrial Product Manager at Fuchs Lubricants (UK).

"However as companies and individuals become more ecologically aware, and take the time to understand the technology behind lubricants from renewable resources, more manufacturers are becoming switched on to the economic benefits that these products actually offer." Fuchs Lubricants (UK) is the UK subsidiary of Fuchs Petrolub, the world's largest independent lubricant company.

Fuchs has been pioneering the development into lubricants from renewable resources since the late 1970's and are well respected as world leaders in this field, working with some of world's most prominent manufacturers.

"Our Planto range of lubricants, based on harvestable raw materials, is probably the most comprehensive available, offering solutions for all applications, including hydraulic oil, gear oil, engine and compressor oils, greases, metalworking fluids, mould release agents and chain lubricants. "We have the products and we can prove that they are technically superior to conventional products and offer significant economic benefits," Mr. Rogers added.

One of the most high profile users of Planto products is a leading German Automobile manufacturer, where the economic and ecological benefits are both of primary importance. After some initial development, the manufacturer's entire engine production plant was designed around the concept of using only Planto lubricants. It was opened in 1995, and since then, no conventional mineral oil based fluids have been used. All metalworking fluids, machine oils, hydraulic fluids, gear lubricants, greases and associated fluids are made from renewable resources and the benefits have been quite remarkable.

The most notable include:

• Fluid reduction: Reduction in the total number of fluids in use, from over 30 (as in a conventional plant) down to 6, with cost savings from this rationalisation
• Rationalisation: One type of Planto metalworking fluid is used for all operations on steel, cast iron and aluminium. Normally 6 different metalworking fluids are needed in engine plants, but one Planto fluid can now perform all operations
• No separate cleaners required: The same metalworking fluid also serves as the inter-operational cleaning fluid, reducing use of water based cleaners and potential corrosion issues
• Reduced water use: The amount of water used per engine produced has been reduced from typically 4 litres per engine to 1 litre per engine, with massive costs savings in both water use and waste water disposal, another major ecological concern
• Safety: Planto fluids have very low emissions, greatly reducing the mist and smog levels in machine shops, which helps with worker safety as well atmospheric pollution
• Extended cutting tool life: This has brought extra cost reduction

Final calculations on the implementation of Planto lubricants calculated cost savings of 60% per engine unit relating to lubricant and tooling costs. For the manufacturer this is a significant cost saving, but ecologically this is thousands of litres of products previously based on refined crude oil converted to a renewable source. If it is so advantageous why aren't others following suit? In the UK, Mr. Rogers admitted little success with UK Automotive Manufacturers regarding Planto lubricants but remained optimistic. "I have recently written to leading executives at certain Auto makers asking them to review the volumes of lubricant used and to question whether they think their company has a "green" lubricant policy. As yet, I have no reply but it's early days!" One extensive UK user is the Eden Project, the UK's leading environmental centre and tourist attraction. During the construction of their educational centre, the Eden Project converted a range of equipment to the Fuchs Plantosyn HVI 46 hydraulic fluid, which is based on renewable resources. It therefore has an extremely high level of biodegradability when exposed to the ground, a critical concern for companies working in the field of quarrying, forestry or agriculture.

Over a two year period, the wear of components was analysed by measuring levels of metals in the hydraulic fluid and changes in viscosity, as well as monitoring contamination from dust, dirt and water.

The Plantosyn fluid used had not been changed since the tests began, despite working in the extremely dusty and dirty china clay environment, where the Eden Project is based.

The results highlight the fact that wear rates of components working on Fuchs Plantosyn HVI 46 were 10 times lower than equipment working on conventional mineral hydraulic oil, offering tangible benefits to users in terms of efficiency and cost savings.

Roger Powell, director of Highway Plant, the main contractor to McAlpine and Eden Project commented that, "These results are amazing. China clay is known in the quarry and extractive industries as the most invasive, abrasive and destructive of all quarry dusts." Cliff Lea, Planto product manager at Fuchs UK, confirmed these figures and highlighted that this was not the first accolade for the Plantosyn product. "The product is approved by both Mannesmann and Sauer Sunstrand, following tests conducted in Germany." The implementation of lubricants from renewable resources at many manufacturers is only a small step to ecological improvement, but is one route open to manufacturers that can actually bring economic benefit as well.

The growth in public awareness of climate change over the past year has seen a shift from the sceptical to the sympathetic. The manufacturer that embraces this change in public feeling could be the one that gains significant advantage over their competitors.

In our personal lives we are always being asked to look at areas where we can be more energy efficient to control climate change; taking shorter showers, switching off lights when leaving a room or leaving the car at home and taking the bus. Individuals that employ this personal energy efficiency philosophy to their business could see significant savings, as well as improving their brand image.

As well as the influence on climate control, energy efficiency for business is a serious matter. Escalating energy costs have accounted for the closure of many businesses during 2006 and continue to be a major headache for companies.

Lubricants based on renewable esters are also well documented to reduce energy consumption. Areas such as gear and compressor lubrication are high energy users and again the implementation of lubricants based on renewable resources offers companies a simple and effective answer.

The principal reason for energy savings from renewable resource lubricants is simple; these products have a lower coefficient of friction than mineral based lubricants. For any machine to move, energy has to be provided to overcome friction. Lubricants are used to reduce this friction but lubricants with a lower coefficient of friction require less energy and hence cost the manufacturer less.

To a problem where "every conceivable effort" must be made in the words of Mr.

Blair, lubricants from renewable resources are a simple first step forward.

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