Each year, over 4 million tonnes of lubricants are produced and consumed in the European Union, with most still derived from fossil raw materials. In response, a consortium of research institutes and industrial companies has launched the "GearOil-Loop" project to develop advanced recycling technologies for lubricants, particularly focusing on gear oils. The goal is to establish a circular economy where fossil-based raw materials are used for as long as possible, reducing dependence on non-renewable resources.
Recycling lubricants remains a challenge, as current processes only allow about 40 percent of waste oil from industrial use to be reprocessed into base oils. Existing technologies do not effectively recover the high-quality base materials required for high-performance lubricants, limiting their reuse in producing new, long-lasting products. The "GearOil-Loop" project is addressing this issue by developing a recycling process alongside a gear oil specifically designed for recyclability, with at least 50 percent of its composition coming from recycled base oil.
Research efforts focus on testing the behaviour of the new lubricants in gearboxes and bearings, alongside fundamental studies on friction and wear to ensure performance and durability match those of conventional, non-recycled gear oils. Sustainability is a key consideration, with an evaluation of the entire closed-loop concept, including raw materials, manufacturing, recycling processes, and overall lubricant performance.
The project brings together partners from various sectors, including lubricant manufacturing, mechanical engineering, and environmental research. Companies such as Klüber Lubrication, Schaeffler, Starke & Sohn, BASF, and SEW-Eurodrive, along with research institutions like the Fraunhofer Institute and ifeu, are collaborating to advance lubricant recycling. By improving both recycling processes and lubricant formulations, the "GearOil-Loop" project aims to support a more sustainable and resource-efficient industry.
