Efficient operations depend on proper cooling of both the workpiece and tools to eliminate the negative effects of heat. Coolants and lubricants play a crucial role in the performance and longevity of industrial machinery. As such, cooling is a crucial parameter that cannot be overlooked in various processes. They are essential components in the manufacturing industry, providing thermal stability, corrosion protection and friction reduction to the machinery. Both coolants and lubricants offer protection to a cutting tool. Coolants take away the heat generated during the machining process, which increases the life of the cutting tool. Lubricants, on the other hand, reduce friction between two mobile parts during machining, which prevents raw tears.
In recent years, the market for coolants and lubricants has seen significant changes in terms of trends and technologies. What’s new and next for metalworking fluids? What are the regulations and localized needs governing MWFs when they are being used? And, what innovations in tooling and in manufacturing overall will take root that might change the very nature of cooling?
The Market:
From a market perspective, the metalworking fluids market is expected to grow globally to $15 billion by 2025, according to Global Market Insights, a research firm and consultancy. In 2020, the Indian automotive coolant market had a value of approximately USD 63 million, but it is projected to increase to over USD 140 million with a compound annual growth rate of about 8% during the forecast period.
The COVID-19 pandemic negatively impacted the market due to a sharp decline in demand for automobiles and suspension of vehicle production during the lockdown period to maintain social distancing guidelines and prevent the spread of the virus. However, as the economy gradually reopens, demand is gradually increasing, and the market is expected to recover in the latter half of 2021.
The demand for vehicles is growing, and the Indian government is incentivizing Original Equipment Manufacturers (OEMs) to invest in local production under the Make in India initiative. As a result, several OEMs from around the world are heavily investing in the country to establish production facilities to meet both domestic and global demand. Another market driver is the increasing average age of vehicles on the road.
“The pursuit of higher performance, higher efficiency and more durability has led to the development of a wide range of newer alloys. While automotive sector prefers lighter aluminum alloys, aerospace industry uses stronger titanium alloys for their operations. In addition to this, machine shops are increasingly producing components of different metallurgy for their set of customers. This has led to an increase in the use of different coolants on a single shop floor resulting in rising operational complexity, risk of cross-contamination, and higher costs for manufacturers,” explains Sagar Vira, Vice President – Industrial Sales, Castrol India Limited. The automotive coolant market share is anticipated to experience significant growth due to such technological advancements.
Impact of crude oil prices on the lubricants business:
According to Munish Garg, Managing Director of See Lube Technologies Pvt. Ltd., Group I and Group II are integral components of the crude oil refining process, and fluctuations in crude oil prices have a significant impact on the lubricant industry. The cost of finished goods is largely affected by changes in base oil prices, as base oil typically comprises 80%-90% of any lubricant. When crude oil prices rose sharply in the past, there was a corresponding exponential increase in base oil prices and the cost of ready-to-use lubricants.
Sagar also noted that in 2022, high forex and inflationary pressures resulted from volatile crude oil prices, causing additives and base oil costs to increase. To minimize the impact on their customers’ businesses, Castrol has always prioritized working closely with them. Through rigorous cost management across the value chain and their close relationships with customers, Castrol has been able to provide effective solutions and optimize the impact of lubricant costs on their overall operations.
Trends in Coolant and Lubricant Technologies
Fluid manufacturers are constantly tweaking their formulations and chemical compositions to optimize performance and reduce waste, as the use of metalworking fluids (MWFs) always raises health and safety concerns. Customers are looking to recycle coolants to save costs and want used coolants to remain in the sump for as long as possible without posing any health risks.
Innovation is happening by balancing part-making performance needs with desired healthy outcomes. The trend is shifting towards minimum quantity lubrication, which involves using the smallest amount of lubricant with minimal additives, chemicals, and emulsifiers. Due to concerns about the health effects of chemical-based lubricants, regulators and entire regions are frequently banning the use of certain chemicals.
There are some murmurs in the distant future about the possibility of fluids becoming obsolete, but there is still a significant amount of time before that happens. Following are few trends that are changing the coolant and lubrication landscape:
- Environmentally friendly solutions: In recent years, there has been a growing demand for environmentally friendly coolants and lubricants. Many industries are shifting towards using bio-based and biodegradable products to reduce their carbon footprint. These products are made from renewable resources and are safer for the environment. Furthermore, they are increasingly being used in industries such as food, pharmaceutical, and medical, where traditional petroleum-based products are not allowed due to regulatory concerns.
- Increase in synthetic lubricants: Synthetic lubricants are becoming increasingly popular in the industrial sector due to their superior performance characteristics. They offer longer life and better wear protection than traditional mineral oil-based lubricants. They also have better high-temperature stability, which is essential in high-speed, high-temperature applications.
- Smart Lubrication Systems:
Smart lubrication systems are becoming more popular in industrial machinery. These systems use sensors and other technologies to monitor the performance of lubricants and automatically adjust lubrication levels to optimize machine performance. They can also detect issues such as leaks, contamination, and wear, allowing maintenance personnel to take action before damage occurs.
“Manufacturing processes are evolving rapidly, with advanced input materials, and increasing use of sensors and connected technologies. Sensors allow for collection of data in real time, which enables real time decision making and compliance to optimal operating conditions. This data, which accurately maintains the optimum level of the critical parameters while allowing for timely top-ups, reduces the variability of critical parameters like concentration and pH significantly and optimizes the coolant consumption,” says Sagar Vira. He shares how Castrol is adapting this change. “Castrol’s Smart Control, a cutting-edge fluid monitoring system, monitors six critical parameters in real time and offers automatic top-up aiding the effective use of the coolant and enhanced consistency in their sump parameters. Castrol also offers the XBB range of water-soluble coolants, which have a more stable pH with pH control technology. They require less fluid top up, reduced use of biocide and offer improved tool life and surface finish. This range of coolants is compatible with the Castrol XBC technology used in our cleaners range, Techniclean, which enables it’s use in topping up the machining sump while running with our XBB coolant and reducing water consumption and wastage.”
“Automation in coolant management systems are key performance Indicators. The evolution of IoT has facilitated the shop floor manager to look into the machine for its performance parameters at any given real-time. Lubrication, the blood of any system, can be tested online for its critical parameters & precautionary measures can be adopted for the extended life of the lubricant, lubrication system & finally of main equipment,” said Munish Garg. - 3D printing lubricants: 3D printing is a growing technology that is revolutionizing the manufacturing industry. Lubricants are used in 3D printing to reduce friction and improve print quality. Manufacturers are developing specialized lubricants for 3D printing that are designed to work with specific materials and printer types.
Conclusion
The coolant and lubricant industry is experiencing significant changes in trends and technologies. The demand for environmentally friendly products, synthetic lubricants, smart lubrication systems, and 3D printing lubricants are some major trends shaping the industry. Nanotechnology, artificial intelligence, additive manufacturing, and predictive maintenance are key technologies driving innovation in the industry. As these technologies evolve, we can expect further improvements in machine performance, efficiency, and sustainability.